AFB Manual Station AS/RS
This document consists of 4 parts, divided into: • Part A contains the manual of the system or station. • Part B, as far as present, contains a collection of exercises together with relevant solutions or additional information. • Part C contains the circuit diagram of the system or station. • Part D contains the data sheets of the system or station.
Order no.: Name:
Manual AS/RS
Designation:
AFB_Manual_AS_RS_S7_A003
Date:
11.12.2007
Author:
Schober
Graphics:
Schober
Layout:
Schober
© Festo Didactic GmbH & Co., D-73770 Denkendorf, 2007 Internet: www.festo.com/didactic e-mail:
[email protected] 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. Parts of this manual may be copied by the authorized 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.
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© Festo Didactic GmbH & CoKG. • AFB
Intended use
Intended use This installation was developed and manufactured 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.
© Festo Didactic GmbH & Co.KG. • AFB
3
Intended use
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© Festo Didactic GmbH & CoKG. • AFB
Content
Content 1
Introduction ______________________________________________________ 9 1.1
General Information AFB ________________________________________ 9
1.2
AS/RS station _______________________________________________ 10
1.2.1
2
1.3
Duty of the operating authority _________________________________ 13
1.4
Duty of trainees ______________________________________________ 13
1.5
Warranty and liability _________________________________________ 14
1.6
Intended use ________________________________________________ 15
1.7
Important notes ______________________________________________ 15
General safety instructions _________________________________________ 17 2.1
Handling the system __________________________________________ 17
2.1.1
Dangers in handling the machine ____________________________ 17
2.1.2
Safety precautions in standard operation _____________________ 18
2.1.3
Dangers due to electric current _____________________________ 18
2.1.4
Dangers due to pneumatic energy ___________________________ 19
2.1.5
Maintenance – Servicing – Malfunction removal ________________ 19
2.1.6
Organizational measures __________________________________ 19
2.2
© Festo Didactic GmbH & Co.KG. • AFB
Topics for project work ____________________________________ 12
Personnel ___________________________________________________ 20
2.2.1
Notes on personnel _______________________________________ 20
2.2.2
Training operations _______________________________________ 20
5
Content
2.2.3 2.3
Emergency stop system _______________________________________ 20
2.3.1 3
Transport ___________________________________________________ 23
3.1.1
Unpacking ______________________________________________ 23
3.1.2
Scope of delivery _________________________________________ 23
3.2
Set up ______________________________________________________ 24
3.2.1 3.3
General information ______________________________________ 24
Commissioning ______________________________________________ 27
3.3.1
Pneumatical commissioning ________________________________ 27
3.3.2
Electrical commissioning __________________________________ 27
3.3.3
Communication cables ____________________________________ 28
3.3.4
EMERGENCY-STOP system _________________________________ 29
3.4
Start-up process _____________________________________________ 33
Operation _______________________________________________________ 35 4.1
General notes on operation ____________________________________ 35
4.1.1
Handling regulations ______________________________________ 35
4.1.2
Operating regulations _____________________________________ 35
4.2
Touch panel AS/RS station _____________________________________ 36
4.2.1 4.3
6
Safety symbols __________________________________________ 21
Commissioning __________________________________________________ 23 3.1
4
Outside training operations ________________________________ 20
Menu Touch Panel ________________________________________ 37
Reset ______________________________________________________ 43
© Festo Didactic GmbH & CoKG. • AFB
Content
4.3.1
Requirements ___________________________________________ 43
4.3.2
Adjustment process_______________________________________ 43
4.4
5
6
7
Automatic mode _____________________________________________ 43
4.4.1
Requirements and start automatic mode______________________ 43
4.4.2
Stop automatic __________________________________________ 43
4.5
Process description ___________________________________________ 44
4.6
Material flow ________________________________________________ 45
Technology _____________________________________________________ 47 5.1
drawings ___________________________________________________ 47
5.2
Technical datas ______________________________________________ 48
Pneumatic ______________________________________________________ 49 6.1
The valve ___________________________________________________ 49
6.2
Pneumatic cylinder ___________________________________________ 50
6.3
Pneumatic supply ____________________________________________ 51
Electrical system _________________________________________________ 53 7.1
Power supply ________________________________________________ 53
7.2
Controller ___________________________________________________ 54
7.2.1 7.3
Wiring ______________________________________________________ 55
7.3.1 7.4
I/O-Components _________________________________________ 55
Axis with CAN-BUS ___________________________________________ 57
7.4.1
© Festo Didactic GmbH & Co.KG. • AFB
Controller design S7 ______________________________________ 54
Function CAN-BUS ________________________________________ 58
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Content
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© Festo Didactic GmbH & CoKG. • AFB
1
1.1
Introduction
General Information AFB
The Festo Didactic Learning System for Automation and Technology is designed to meet a number of different training and vocational requirements. The systems and stations of the AFB facilitate industry-orientated vocational and further training. The hardware consists of didactically suitable industrial components. The stations provides an appropriate system for practice-orientated tuition of the following key qualifications • Social competence, • Technical competence and • Methodological competence Moreover, training can be provided to instill team spirit, willingness to cooperate and organizational skills. Actual project phases can be taught by means of training projects, such as: • • • • • • •
Planning, Assembly, Programming, Commissioning, Operation, Maintenance and Fault finding.
This manual describes the handling of the AFB system. It contains explanations and descriptions of all the processes required for operation. Facts are partly described with the help of graphics or images sub serving an easier understanding. Complete operating instructions which explain the processes of the system are available for working with the system. Additionally to technical and social competence, the comprehension of the process and the interaction of the respective components appear in clear presentation. Festo Didactic succeeded in using the most updated industrial hard- and software for this model production. The AFB system is a successively expandable system consisting of individual stations. However, the central unit is always the transport system. For this reason, this manual is not only a general manual, but also a station manual for the transport system. Each one of the other stations has its own manual. Operation is not dependant on the operating position the material flow is being started from. Still, the sequential order of the stations requires adherence, as it is pre-defined in the PLC-program.
© Festo Didactic GmbH & Co.KG. • AFB
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Introduction
The AFB system is designed in such a way, that the amount and kind of attached stations guaranteed is not important. A complete processing cycle of the work-piece is always warranted. Only the transport system is required under any circumstances. If the automatic mode is started, the filling station is starting to work. Bottles are filled with liquid and a cover is placed and turned on the bottle to close it. The filled bottles are transported to the packing station. Here 6 bottles are grouped. As soon as these are 6 bottles, an empty six pack is ordered and equipped with the waiting bottles. First one line with 3 bottles and then the second line with 3 bottles. The filled tray is transported to the In/Out station for handing out of the system. If the handing out slide at the In/Out station is occupied, the trays are carried into the AS/RS station for intern storage. As soon as the handing out slide at In/Out station is free, the six packs are restored from the AS/RS and are carried on the slides of the In/Out station. In case the In/Out station is not available or not active all filled six packs are stored in the AS/RS.
1.2
AS/RS station
The AS/RS is responsible to store and restore the trays. The carrier arriving on the transport system, stops in front of the AS/RS station. The tray on the carrier is gripped from the AS/RS handling and moved to one of the free shelve. The status of the tray (full or empty) is transmitted to the controller. Afterwards the carrier is released. If an empty tray is requested from another station, a carrier is ordered to the AS/RS. If the carrier is ready, an empty tray is picked out from one of the shelve and is placed on the waiting carrier. Afterwards the carrier is released and transported to the waiting station.
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© Festo Didactic GmbH & CoKG. • AFB
Introduction
Overview In/Out station
© Festo Didactic GmbH & Co.KG. • AFB
Position
Description
Position
Description
1
CAN-Motor x-axis
6
Reception for workpiece trays
2
Axis for x-motion
7
Tray to pick up 6 workpieces
3
CAN-Motor z-axis
8
Touch panel for operation
4
Axis for z-motion
9
Shelf to pick up one tray
5
Pneumatic axis for y-motion
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Introduction
Training contents covering the following subjects can be taught: • Mechanics – Mechanical construction of a station • Pneumatics – Piping connections of pneumatic components – Pneumatic linear drives • Electrical – Correct wiring of electrical components – Use of electric axes • Sensors – Correct use of limit switches • PLC – Programming and use of a PLC – Structure of a PLC program • Commissioning – Commissioning of a production system • Fault finding – Systematic fault finding on a production system • CAN-Bus technology – Programming and use of CAN-Bus 1.2.1
Topics for project work
• Replacing a relay control system with a PLC • Selecting pneumatic components – Linear drives • PLC programming – Programming of an operational section – Programming of a RESET sequence – Programming of an EMERGENCY-STOP function • Optimising cycle time
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© Festo Didactic GmbH & CoKG. • AFB
Introduction
1.3
Duty of the operating The operating authority undertakes to ensure that the AFB is used only by persons authority who: • are familiar with the basic regulations regarding operational safety and accident prevention and who have received instructions in the handling of the AFB, • have read and understood the chapter on safety and the cautionary notes in this manual. • Safety-conscious working of the persons should be regularly vetted.
1.4
Duty of trainees
Prior to commencing work, all persons assigned to working on the MPS® have a duty to: • read the chapter on safety and the cautionary notes in this manual and, • observe the basic regulations regarding operational safety and the prevention of accidents.
© Festo Didactic GmbH & Co.KG. • AFB
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Introduction
1.5
Warranty and liability
In principle all our „Terms and Conditions of Sale“ apply. These are available to the operating authority upon conclusion of the contract at the latest. Warranty and liability claims for persons or material damage are excluded if these can be traced back to one or several of the following causes: • Use of the AFB not in accordance with its intended purpose • Incorrect assembly, commissioning, operation and maintenance of the AFB • Operation of the AFB using faulty safety equipment or incorrectly fitted or non operational safety or protective devices • Non observance of notes in the manual regarding transport, storage, assembly, commissioning, operation, maintenance and setting up of the AFB • Unlawful constructional modifications on the AFB • Inadequate monitoring of components subject to wear • Incorrectly carried out repairs • Catastrophes as a result of foreign bodies and vis major.
Festo Didactic herewith rules out any liability for damage or injury to trainees, the training company and/or other third parties which may occur during the use/operation of the system other than purely in a training situation, unless such damage has been caused intentionally or due to gross negligence by Festo Didactic.
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© Festo Didactic GmbH & CoKG. • AFB
Introduction
1.6
Intended use
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 use of the system for its intended purpose also includes: • Following all advice in the manual and • Carrying out inspection and maintenance work.
1.7
Important notes
The basic requirement for safe use and trouble-free operation of the AFB is to observe the fundamental safety recommendations and regulations. This manual contains important notes concerning the safe operation of the AFB. The safety recommendations in particular must be observed by anyone working on the AFB. Furthermore, the rules and regulations for the prevention of accidents applicable to the place of use must be observed.
© Festo Didactic GmbH & Co.KG. • AFB
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Introduction
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© Festo Didactic GmbH & CoKG. • AFB
2
2.1
General safety instructions
Handling the system 2.1.1
Dangers in handling the machine
The installation has been constructed technologically up to date and in conformance with the recognized rules of safety engineering. Nevertheless, during operation it is possible that harm might be caused to the user or third parties or that the installation or other property might get damaged. Therefore, the installation has to be handled according to specified operational use in perfect technical condition only. Safety endangering malfunctions cannot be tolerated during training and have to be removed immediately. The AFB is to be used only: • for its intended purpose and • in absolutely safe conditions.
Faults impairing safety must be rectified immediately!
© Festo Didactic GmbH & Co.KG. • AFB
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General safety instructions
2.1.2
Safety precautions in standard operation
Put the installation into operation only, once all of the protection settings are completely functional. At least, before starting operation, check the installation for externally visible damages and for the reliability of the safety devices. Do not grip into the installation while in operation. Before circuit construction, circuit disassembly and circuit modification: switch off air pressure and power supply. General safety regulations are to be observed: DIN 58126 and VDE 0100.
2.1.3
Dangers due to electric current
As soon as maintenance is completed, check the function reliability of the safety devices. Only trained experts in electric or electronic engineering are permitted to carry out work on the electric supply system. The terminal boxes are to be kept closed at all times. Access must be permitted only under supervision of a member of the training staff. Do not activate electric limit switches manually during fault search. Tools are to be used. Only low voltage 24VDC is to be used.
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© Festo Didactic GmbH & CoKG. • AFB
General safety instructions
2.1.4
Dangers due to pneumatic energy
Accidents might occur due to bouncing off tubes, caused by air pressure. Interrupt air pressure supply immediately. Caution! When the air pressure supply is activated, cylinders may move in or out. Do not uncouple any tubes under air pressure supply. Exception: Fault finding. In this case, keep on holding the end of the tube. Do not exceed the permitted operating pressure. See data sheets. 2.1.5
Maintenance – Servicing – Malfunction removal
Carry out adjustments and inspections as instructed, in accordance with the specified intervals. Secure the compressed air and electricity supplies to prevent unintentional start-up. During inspections, maintenance and repair work, the machine must be deenergized, de-pressurized and secured against unexpected restart. All screw connections released during maintenance, inspection or repair work must be checked to ensure correct re-tightening. 2.1.6
Organizational measures
All existing safety devices must be checked at regular intervals.
© Festo Didactic GmbH & Co.KG. • AFB
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General safety instructions
2.2
Personnel
2.2.1
Notes on personnel
Basically two situations have to be considered, concerning matters on personnel. • Activities during training operations • Activities outside training operations
2.2.2
Training operations
Trainees are permitted to work with the machine only under strict supervision of an experienced person or an instructor. Activities of trouble-shooting and fault correction are to be checked by the instructor. Special care should be taken regarding safety aspects. 2.2.3
Outside training operations
Activities in the areas of maintenance, service and repair are to be carried out by only persons with appropriate technical qualifications.
2.3
20
Emergency stop system
The emergency stop system is controlled by a higher safety control unit. The description is noted in the manual of the transport system.
© Festo Didactic GmbH & CoKG. • AFB
General safety instructions
2.3.1
Safety symbols
In this manual the following danger designations and signs are being used:
This symbol indicates an immediate threat to a person’s health or life. DANGER ! Failure to pay attention to this symbol may result in serious health damage, which may even lead to life-threatening injuries.
This symbol emphasizes important information for correct machine handling. IMPORTANT Failure to pay attention to this symbol may result in damages to the machine or to its surroundings.
This symbol indicates operational tips and especially useful directions.
i
INFORMATION This symbol assists you to make optimal use of all of your machine’s functions.
© Festo Didactic GmbH & Co.KG. • AFB
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General safety instructions
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© Festo Didactic GmbH & CoKG. • AFB
3
Commissioning
3.1
Transport
Care is to be taken that the transport of the stations is to be executed only by a suitable transport vehicle. The weight amounts up to 500 kg, depending on the station. The route of transport is to be cleared in advance, to be accessible to the transport vehicle. Installation of warning signs or barriers may be required. The transport boxes are to be opened with care, as additional components, such as computers may be contained in the delivery, which are to be protected from falling out.
i
Once the transport box has been opened and the possibly contained additional components removed, the station can be taken out to be transported to its destination by means of two fork-lifts or one fork-lift truck. Please check the stability of all of the profile connectors by means of an Allen key size 6. The connectors may have come loose during transport, due to inevitable vibration. Pay special attention to all overhanging components. Sensors and similar small parts are very easily damaged in case of improper transport. The stations are not to be picked up by or even under the mounted feet – increased risk of becoming trapped or contused. Check the station for any possible damaged once unpacked. The carrier and Festo Didactic are to be notified immediately of any damage. 3.1.1
Unpacking
Carefully remove the padding material in the container box when unpacking the station. When unpacking the station, make sure that none of the station assemblies have been damaged. Check the station for any possible damaged once unpacked. The carrier and Festo Didactic are to be notified immediately of any damage. 3.1.2
Scope of delivery
Check the scope of delivery against the delivery note and the order. Festo Didactic must be notified immediately of any discrepancies.
© Festo Didactic GmbH & Co.KG. • AFB
23
Commissioning
3.2
Set up
3.2.1
General information
The installation is to be set up in a frost-free room with maximum relative air humidity of 70%. In countries with an atmospheric humidity over 70% and temperatures above 25 degrees Celsius are the premises to provide an air-conditioning system for constant surroundings conditions. To comply with the regulatory guidelines, sources of electrical interference such as welding plants, large motors and contactors are to be checked for electromagnetic compatibility in advance and screened where necessary. To ensure fault-free operation a load-bearing floor is required to avoid settling. Allow sufficient distance between the installation and the wall of the room. Any dust originating from construction work has to be kept off the installation (by covering). First, the room has to be measured, if not done so previously. The measures of all stations have to be marked roughly onto the floor space (i.e. with adhesive tape) to avoid shifting at a later stage.
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© Festo Didactic GmbH & CoKG. • AFB
Commissioning
The following picture shows a complete set-up situation adapted to a more basic area design. The stations are to be adjusted as shown, to ensure faultless workpiece transfer flow.
Set-up situation AFB system – the MPS-PA-Stations serves as an example
© Festo Didactic GmbH & Co.KG. • AFB
25
Commissioning
Dimensional drawing of set-up AFB system
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© Festo Didactic GmbH & CoKG. • AFB
Commissioning
3.3
Commissioning
Commissioning of the system can ensue only, once all of the stations are connected to their definite position. The AS/RS station has to be mounted at the transport system, utilising the included profiles. Align the station by means of a spirit-level and tighten the connector profiles afterwards. 3.3.1
Pneumatical commissioning
The mechanical construction must be finished. At the beginning the stations have to be attached to the pneumatic system of the room. In most cases the maintenance unit is on the profile plate of the station. The coupling has a 5 mm nominal diameter. If the available system is equipped with 7.9 mm nominal diameter, it is possible to change the coupling of the maintenance unit with a greater one. (reducer 1/8 on 1/4 necessary). If this has been carried out, the stations can be provided with 6 bar and the pneumatic commissioning is realized. 3.3.2
Electrical commissioning
First place the electrical board and the 24V powers supply unit into the station. The station must be provided with electrical voltage now. The basic rack is provided with a power supply unit, provided with a voltage of 110/230 V. The delivered cable has a completely protected norm plug, this must be plugged into an electrical socket protected sufficiently. Distribution strips are, enclosed to this also for the connection of other stations. If an extension for the cable is necessary for the distribution strip, this can to be executed only by a trained expert. The electrical socket must be protected, corresponding to the customer. The power supply (24 VDC) of the sensoric and the actuators of the station is provided in each case by means of a 2-pin cable. The voltage supply is a 24 V power supply unit, contained in the control cabinet or somewhere in the station. To avoid problems during the operational process, individual protection (16A) of the installation is recommended.
© Festo Didactic GmbH & Co.KG. • AFB
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Commissioning
3.3.3
Communication cables
The internal communication lines of the station are hard-wired and do not require connection or plugging in. Connect the touch panel and the electrical board with a MPI cable. The communication connections to the transport system are to be set up according to the following example.
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© Festo Didactic GmbH & CoKG. • AFB
Commissioning
3.3.4
EMERGENCY-STOP system
The emergency-stop system is to be de-activated for transport. The connector possibilities are listed below and are to be re-activated during start-up. The complete emergency-stop system is described in the chapter “EMERGENCY-STOP”.
EMERGENCY-STOP connectors in control cabinet / conveyor belt
Example EMERGENCY-STOP connector on board
© Festo Didactic GmbH & Co.KG. • AFB
29
Commissioning
All of the required EMERGENCY-STOP connectors can be established according to this example.
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Plugs with links are to be inserted into the unoccupied operating positions, as shown in the picture above. Plug
Type
2-pin Phönix XNA11
2 Contacts for EMERGENCYSTOP switch
Device
Example
External EMERGENCY-STOP switch
from XNA11 to external EMERGENGY-STOP
4-pin Phönix 2 Contacts for XNA01
EMERGENCYSTOP,
e.g. Testing station
2 Contacts for feedback
from XNA01 at the conveyor belt to SPS-board
See also chapter EMERGENCY-STOP.
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© Festo Didactic GmbH & CoKG. • AFB
Commissioning
The EMERGENCY-STOP system is controlled centrally by the transport system station. In the control cabinet of the station an EMERGENCY-STOP switch device is located, which is connected to all of the operating positions and all external EMERGENCY-STOP devices.
Example: external EMERGENCY-STOP Transport system
The external EMERGENCY-STOP devices are controlled by a 2-pin cable. The devices are connected to the 2-pin Phönix plug-in contact. In case no device is plugged in, the contact is to be established with a strapped plug. EMERGENCY-STOP at the PLC-board
The PLC-boards are connected to the 4-pin plug-in contacts. In this case 2 lines are for the feedback (station available) and 2 lines for the EMERGENCY-STOP of the PLCboard.
© Festo Didactic GmbH & Co.KG. • AFB
31
Commissioning
External Emergency-Stop Emergency-Stop push button
Emergency-Stop push button
e.G. Testing station
e.G. Transportsystem
Phönix plug -in 2pin -XNA11 -XN11
1
2
1
2
Phönix plug-in 2pin -XNA12 -XN12
1
2
1
2 XNA13 ==> XNA18 Other external emergency-stop devices
SIEMENS
CP 342-2 Asi Master
SM323 DI8/DO8 xDC24V SF RUN APF CER AUP CM
RUN-P RUN
0 1 2 3 4 5 6 7
30+ 20+ 10+
STOP MRES
SET
7 2 6 1
3
3
3
8
2
4
2
0 1 2 3 4 5 6 7
9
1
Simatic S7-300 5
1
Phönix plug-in 4 pin
-XN1
-XNA1
X 2 3 4
X1MPI
4
4
0 1 2 3 4 5 6 7 X 2 3 4
Operatingposition 1 S11 S12 S12 S21 S22 A1
B1
13
23
33
43
Y1
Y2
S52 S11
13
23
33
53
73
81
91
A1
Y1
Y2
63
13 23 33 43 53 63 73 81 91
Pilz
CH. 1
Y1
S37
64
74
82
/B2 A2
43
55
A2
14
24
34
4
54
4
Y30 Y31 Y32 Y35
44
3
34
3
24
2
14 24 34 44
14
2
14 24 34 44 54 64 74 82 92
13 23 33 43
1
CH. 2
CH. 1 OUT CH. 2 OUT
1
CH. 2 IN START
Phönix plug-in 4 pin
PNOZ X9
-XN2
Power CH. 1 IN
S33 S34
-XNA2
Emergency-stop switch device Transportsystem
CPU 314 SF BAF DC 5V FRCE RUN STOP
If no station exists in an operating position, a plug with a strap is to be inserted for the feedback.
Operatingposition 2 SIEMENS
CPU 314 SF BAF DC 5V FRCE RUN STOP
CP 342-2 Asi Master
SM323 DI8/DO8 xDC24V SF RUN APF CER AUP CM
0 1 2 3 4 5 6 7
30+ 20+ 10+
STOP MRES
SET
7 2 6 1
3
3
3
8
2
4
2
0 1 2 3 4 5 6 7
9
1
Simatic S7-300 5
1
Phönix plug-in 4 pin
-XN3
-XNA3
RUN-P RUN
4
4
X 2 3 4
X1MPI
0 1 2 3 4 5 6 7 X 2 3 4
Operatingposition 3
Line for feedback
32
XNA4 ==> XNA10 other stations
Line for SPS emergency-stop
Other operating positions
Line for external Emergency-stop
© Festo Didactic GmbH & CoKG. • AFB
Commissioning
3.4
Start-up process
For the AFB installation the first start-up has been executed in the factory already. For the installation to be ready for operation execute the following directions: 1. Mains supply 230 V AC for power supply unit, connect control cabinet of transport system. 2. Power supply unit 24V DC with connections +24V/0V/earth are connected correctly to the stations and activated. 3. Each station is supplied with ca. 6 bar compressed air. 4. I/O-communication connectors (laboratory plugs) are connected according to communication plan. 5. All of the PLC-programs are loaded into the respective controls. The controls are switched to RUN and the red error indicators of the controls are not on. 6. All of the EMERGENCY-STOP signal generators (push-buttons, door contact, light barriers, a.s.o.) are not to be switched on, i.e. activated. 7. Activate the main switch of the transport system station. 8. Acknowledge the EMERGENCY-STOP of the control cabinet of the transport system. 9. Remove all of the work-pieces from the installation, i.e. stations: - Remove work-pieces from the palettes on the transport system - Clear the storage shelves of the AS/RS station - Clear the slides of the In/Out station. - Fill up conveyor at In/Out station - clear conveyor at buffer station - PCS System – see manual PCS 10. The magazines of all of the stations are to be stocked up: - Fill magazine of the distribution station with covers 11. Now adjust the stations and the transport system (see chapter – Operation).
© Festo Didactic GmbH & Co.KG. • AFB
33
Commissioning
34
© Festo Didactic GmbH & CoKG. • AFB
4
Operation
The chapter Operation describes the control units required for the operation, as well as start-up and close-down 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 can not 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.
© Festo Didactic GmbH & Co.KG. • AFB
35
Operation
4.2
Touch panel AS/RS station
To provide the station with 24V and to start the station, the power supply must be switched on. If the control is ready with booting, the station can be controlled with the touch panel.
Touch panel example
Name
Element
Quit emergency
H5
Stop Emergency stop
Function flashing
Request to quit emergency stop
Lights up
Emergency stop is active
S5
Quit emergency stop
S6
Switch off controller / emergency stop function
The table assists in operating the station. All of the push-buttons and lamps are described within.
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© Festo Didactic GmbH & CoKG. • AFB
Operation
4.2.1
Menu Touch Panel
The menus of the touch panel are explained in the following.
Screen 1 Main menu automatic off
Screen 2 Main menu automatic on
© Festo Didactic GmbH & Co.KG. • AFB
37
Operation
Screen 3 inventory of stock
Screen 4 system adjustments
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© Festo Didactic GmbH & CoKG. • AFB
Operation
Screen 5 In/Outputs
This screen is just for visualization
Screen 6 manual mode screen 1
Here you can the axes from one position to the other.
© Festo Didactic GmbH & Co.KG. • AFB
39
Operation
Screen 7 manual mode screen 2
Screen 8 manual mode screen 3
40
© Festo Didactic GmbH & CoKG. • AFB
Operation
Screen 9 teach mode
Screen 10 teach mode screen 2
© Festo Didactic GmbH & Co.KG. • AFB
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Operation
Screen 11 teach mode screen 3 How to store a position: 1. Teach the position you want to store by moving the axis manually (screen9) 2. If the position is okay, click on “store position” 3. Choose the shelve number in the following screen 4. The position is stored automatically
Screen 12 diagnostic
Here you can see the actual status of the x/z axis. 42
© Festo Didactic GmbH & CoKG. • AFB
Operation
4.3
Reset
4.3.1
Requirements
The adjustment process (is also to be executed after STOP- or EMERGENCY-STOP activation) is independent from the switch position of the key actuator AUTO/MANU. 4.3.2 1. 2. 3. 4. 4.4
Automatic mode
Adjustment process
Press button referencing axis at teach panel. Station moves to basic position The START-automatic button indicates the arrival in basic position. Station is ready for Automatic mode
4.4.1
Requirements and start automatic mode
1. After adjustment process the station is ready for automatic mode. 2. Press START- button → the button changes his color and the station is in automatic mode
The automatic discharge of empty trays is starting if there are 6 bottles at the packaging station available. Only when this situation is reached, an empty tray is coming to the transport system. 4.4.2
Stop automatic
If the Stop button is pressed, the automatic mode is stopped at interval end. If the packaging station is stopped, all trays on the conveyor system are stored into the AS/RS if available.
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Operation
4.5
Process description
The following process description is just for the AS/RS station. 1. The carrier, coming on the transport system, stops in front of the AS/RS station. 2. The tray on the carrier is gripped from the AS/RS handling and moved to one of the free shelfs. 3. The status of the tray (full or empty) is transmitted to the controller. 4. Afterwards the carrier is released. 5. If an empty tray is ordered from another station, a carrier is ordered to the AS/RS. 6. If the carrier is ready, a empty tray is picked out from one of the shelve and handed over to the waiting carrier. 7. Afterwards the carrier is released and transported to the waiting station.
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© Festo Didactic GmbH & CoKG. • AFB
Operation
4.6
Material flow
The AFB installation reacts flexible to the changes during the production process and controls the material flow according to circumstances.
Example: Layout of material flow of the AFB System
© Festo Didactic GmbH & Co.KG. • AFB
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Operation
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© Festo Didactic GmbH & CoKG. • AFB
5
Technology
This chapter refers to the technology of the AS/RS station. For better construction understanding of the station, the technical drawings should be a very helpful data. The rooms must be checked for their technical datas before built up the station/system. The size of the door openings and the entrance must be big enough for the measurements of the system. Even the load-capacity of the floor must be high enough for the system. 5.1
drawings
Technical drawing AS/RS station
© Festo Didactic GmbH & Co.KG. • AFB
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Technology
5.2
48
Technical datas
Pos.
Designation / Criterion
Measurements / Feature
1
Width:
700 mm
2
Max. width with touch panel
776 mm
3
Length
1 100 mm
4
Max. length with handling
1 234 mm
5
height
1 787 mm
6
Max. height
1 790 mm
7
Weight
approx. 200 kg
8
Max. trays in handling
1 piece
9
Max. trays in store
20 pieces
© Festo Didactic GmbH & CoKG. • AFB
6
Pneumatic
With the help of a pneumatic cylinders the handling extracts into the shelfs. This valve is necessary for the control. The valve is described in the following. 6.1
The valve
Example CPE 10 valve
© Festo Didactic GmbH & Co.KG. • AFB
Pos.
Name
1
Order number
161 868
2
Order name
CPE10-M1H-5L-Mt
3
Order number cable
MZB9-2E..AZ
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Pneumatic
6.2
Pneumatic cylinder
Cylinder for y-motion of handling
50
Pos.
Name
1
Order number
171133
2
Order name
DGPL 18-190-PPV-A-B-KF-GK-SH
© Festo Didactic GmbH & CoKG. • AFB
Pneumatic
6.3
Pneumatic supply
The pressure in the supply line must not exceed 10 bar. A fine filter has to be installed, to prevent contamination by rust or similar. A stop cock is required for the supply of the installation. The pressure regulators should be set in between 5 and 6 bar. The filter and water separators require maintenance according to the instructions of the documentation of these components. The exact allocation of the valve terminal can be found in the pneumatic plan.
Service unit
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Pneumatic
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7
Electrical system
To operate the station it is required to connect all of the supply cables and communication lines included. The cables used to program the system are explained additionally. To give you a better survey of the being lines used in the plant, these are explained in the following. 7.1
Power supply
The devices are delivered together with the respective power supply plugs, protectively contact covered, in case they require power supply. The customer must ensure that the power supply is earthed correctly and is equipped with a fault current monitor. If it is required for several devices to be in operation at the same time, it is possible to connect these to a switchboard containing distribution board, provided that the permissible maximum rating is not exceeded.
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Electrical system
7.2
Controller
7.2.1
Controller design S7
Card location
Module
Name
Comment
2
Controller
CPU-313C
3
Analog card
For analog In/Outputs of station
4
Digital Card
For digital In/Outputs of station
5
Can Bus card
CAN 300
For can bus motors
6
Ethernet Card
CP 343-1 IT
(Option) For Ethernet communication
S7 controller AS/RS station
Two possibilities are available to program the Siemens controls. A MPI cable is sufficient for programming, if a special programming unit is available. If a common PC is used for programming, a MPI card needs to be installed into the PC. If such a card containing PC is available, a common MPI cable may be used. A MPI cable inclusive adapter box is required, if a PC without MPI card is used for programming. The interface for programming is on the CPU–Card.
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© Festo Didactic GmbH & CoKG. • AFB
Electrical system
7.3
Wiring
The wiring within the station and the wiring to the other stations are explained in the following. 7.3.1
I/O-Components
The operation panel, the modules from station are pluggable connected via I/O-terminals to the I/O-cards from the control. So that a perfect communication can be ensured, the I/O interface is standardised. The I/O terminal is at all work positions at the disposal.
I/O-Terminal
Technical data
© Festo Didactic GmbH & Co.KG. • AFB
Plug type
IEEE 488 24 pins
Inputs
8
Outputs
8
Current consumption
Max. 1A/PIN
Power supply
24 VDC
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Electrical system
OUT BIT 0 OUT BIT 1 OUT BIT 2 OUT BIT 3 OUT BIT 4 OUT BIT 5 OUT BIT 6 OUT BIT 7 POWER 24 VDC POWER 24 VDC POWER 0 VDC POWER 0 VDC
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
IN BIT 0 IN BIT 1 IN BIT 2 IN BIT 3 IN BIT 4 IN BIT 5 IN BIT 6 IN BIT 7 POWER 24 VDC POWER 24 VDC POWER 0 VDC POWER 0 VDC
syslink pin assignment 01 02 03 04 05 06 07 08 09 10 11 12
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 24 V
Output word Output word Output word Output word Output word Output word Output word Output word Power supply
white brown green yellow grey pink blue red black
0 V Power supply pink-brown 0 V Power supply purple
13 14 15 16 17 18 19 20 21 22 23 24
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 24 V
Input word Input word Input word Input word Input word Input word Input word Input word Power supply
0 V Power supply
grey-pink red-blue white-green brown-green white-yellow yellow-brown white-grey grey-brown white-pink white-blue
Allocation I/O- Terminal
Clamp
Bit
Function
Color
Clamp
Bit
Function
Colour
01
0
Output
White
13
0
Input
Grey-pink
02
1
Output
Brown
14
1
Input
Red-blue
03
2
Output
Green
15
2
Input
White-green
04
3
Output
Yellow
16
3
Input
Brown-green
05
4
Output
Grey
17
4
Input
White-yellow
06
5
Output
Pink
18
5
Input
Yellow-brown
07
6
Output
Blue
19
6
Input
White-grey
08
7
Output
Red
20
7
Input
Grey-brown
24V
Power supply
Black
21
24V
Power supply
White-pink
0V
Power supply
White-blue
09
10 11
12
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22 0V
Power supply
Pink-brown
23
0V
Power supply
purple
24
© Festo Didactic GmbH & CoKG. • AFB
Electrical system
7.4
Axis with CAN-BUS
Example axis for handling x-motion
For x-motion Pos.
Name
1
Order number
534391
2
Order name
DGE 25-750-ZR-RF-LK-RB-KG
For z-motion
© Festo Didactic GmbH & Co.KG. • AFB
Pos.
Name
1
Order number
534391
2
Order name
DGE 25-400-ZR-RF-LK-RB-KG
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Electrical system
7.4.1
Function CAN-BUS
Overview CAN-BUS
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© Festo Didactic GmbH & CoKG. • AFB
Electrical system
The device profile for drives and motion control (CiA DSP 402) defines the functional CiA 402: CANopen device profile for drives and motion behavior of controllers for servo drives, frequency inverters and stepper motors. The specification includes a state machine description of the drive. A single state control represents a special internal or external behavior. The state of the drive also determines which commands are accepted. E.g. it is only possible to start a point-topoint move if the drive is in the state ‘Operation Enabled’. States may be changed using the control-word and/or according to internal events. The current state can be read using the status-word. The device profile describes several modes of operation functions such as: Homing Mode, which describes the various methods to find a home position, reference point, datum, or zero point. Profile Position Mode, which defines the positioning of the drive. Speed, position and acceleration can be limited, and profiled moves using a trajectory generator are also possible. Interpolated Position Mode, which describes the time interpolation of single axles and the spatial interpolation of coordinated axles. Synchronization mechanisms and interpolation data buffers are covered as well Profile Velocity Mode is used to control velocity of the drive with no special regard of the position. It supplies limit functions and trajectory generation. Profile Torque Mode, which defines the torque control with all related parameter. Velocity Mode is a simple mode used by many frequency converters. It provides limit and ramp functions.
© Festo Didactic GmbH & Co.KG. • AFB
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Electrical system
With the exception of the Homing Mode, these listed modes of operation can all be put under the heading of „set point setting“. In parallel to this, manufacturerspecific modes of operation may also be implemented. These are not limited to set point settings. It is possible to implement different device modes. It is not possible to operate the modes in parallel. An example of exclusive functions is position and torque control, which can only control one variable at any one time. The variables can perform at most a limited function. Such hybrids are regarded as the particular characteristics of a mode of operation. Position control operation and encoder profile support can be active at the very same time, for example. Consequently encoder profile support is not regarded as a mode of operation (see CANopen device profile for encoders). The user can switch between various modes of operation as long this is supported by the device. It is possible for the manufacturer to allow dynamic switching from different modes of operation at any time to the state „local control“; which is not possible via the CAN network. The device profile specifies the default mapping of the used Process Data Objects. All Receive-PDOs contain the „control-word“ and, depending on the device functionalities, so do the parameters for the supported modes of operation. The described PDO distribution should be used for every axle of a multi-device module with an offset of 64, e.g. the first PDO of the second axle gets the number 65. In this way a system with a maximum of eight axles is supported. It is up to the manufacturer to specify additional entries in the mapping table or define absolutely new PDO mappings and it is also up to a user to change these default settings by changing the mapping structure, if the module supports variable PDO mapping. The Transmit-PDOs, which contain the status-word, and different actual values, which depend on the mode of operation, monitor the drives behavior. Transmit-PDO 1, 2 and 7 are event-driven; the others can be implemented as synchronous or remotely requested (RTR) Process Data Objects.
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