OMRON _DeviceNet_ (2)

TECHNICAL DESCRIPTION

FMS-200

FLEXIBLE AUTOMATED CELL TRAINER

1

10 REASONS FOR CHOOSING THE FMS-200
SYSTEM

1. The FMS-200 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 includes a 4- metre line transfer system which integrates the various stations.

4. The process stations or layouts can work independently or integrated in the transfer in
cell mode, and can change position within the transfer.

5. The automatons 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 stations incorporates a key-protected Fault Generation System which
makes it possible to work on diagnostic and repair capabilities, using the “Switches”
methodology and “Virtual Repair”.

7. The FMS-200 cell has been designed for assembly of a turning mechanism with a
total of 24 variants.

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

9. The Practical Activities drawn up from the modular concept of 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, Electrical Actuators,

Robotics/Manipulation, Industrial Communications, Control Systems, Electric

Automatisms, Safety Devices, Basic Mechanical Systems, and so on.

10. It has been conceived and designed using the pooled knowledge of two leading
companies: SMC (world leader in pneumatics and electro-pneumatics) and ALECOP
(leader in the world of training).

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INDEX

1. TECHNICAL AND FUNCTIONAL DESCRIPTION……………………..……………..1
1.1 Programmable automaton with network communications system…………………..…3
1.2 Automaton programming software…………………………………………………….3

2. PROCESS STATIONS………………………………………………………….………...4
2.1 Body feed- positioning…………………………………………………………………….4

2.1.1. Station function……………………………………………………………………..4
2.1.2. Integral parts………………………………………………………………………..4
2.1.3. Technical data………………………………………………………………………5

2.2. BEARING HANDLING-FITTING LAYOUT…………………………………………..7
2.2.1. Station function……………………………………………………………………..7
2.2.2. Integral parts………………………………………………………………………..7
2.2.3. Technical data………………………………………………………………………9

2.3. HYDRAULIC BEARING PRESSING LAYOUT……………………………………...11
2.3.1. Station function……………………………………………………………………11
2.3.2. Integral parts……………………………………………………………………...12
2.3.3. Technical data……………………………………………………………………..13

2.4. SHAFT HANDLING-FITTING-MEASUREMENT-SELECTION……………………15
2.4.1. Station function……………………………………………………………………15
2.4.2. Integral parts………………………………………………………………………15
2.4.3. Technical data……………………………………………………………………..18

2.5. COVER HANDLING-FITTING-SELECTION LAYOUT………………………….…21
2.5.1. Station function…………………………………………………………………...21
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2.5.2. Integral parts………………………………………………………………………21
2.5.3. Technical data……………………………………………………………………..24

2.6. SCREW HANDLING-FITTING…………………………………………………….….27
2.6.1. Station function……………………………………………………………………27
2.6.2. Integral parts……………………………………………………………………...28
2.6.3. Technical data…………………………………………………………………….29

2.7. ROBOT SCREWDRIVER……………………………………………………………..31
2.7.1. Station function……………………………………………………………………31
2.7.2. Integral parts………………………………………………………………………31
2.7.3. Technical data……………………………………………………………………..32

2.8. UNLOADING-STORAGE-PALLETIZATION OF COMPLETED ASSEMBLY….…33
2.8.1. Station function……….……………………………………………..………….…33
2.8.2. Integral parts………….…………………………………………….….………….33
2.8.3. Technical data…………………………………………………...…..……………35

3. 4-METRE TRANSFER LINE WITH AUTOMATON AND PALLET ASSEMBLY.…..37
3.1. Transfer function and composition…………………………………..…………...……..37
3.2. Technical details of transfer………………………….…….…….…..…………….……38
4. INSTALLATION AND START- UP…………………………………………………….40
4.1. Prerequisites………………………………………………………………………….40

4.1.1. Spatial requirements …………………………………………………………40
4.1.2. Electrical requirements ………………………………………………………41
4.1.3. Air requirements ……………………………………………………………..41

4.2. Handling and packaging ……………………………………………………………..43

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4.3. Installation …………………………………………………………………………...44
4.3.1. Individual station …………………………………………………………….44
4.3.2. Cell …………………………………………………………………………..45

4.4. Start- Up ……………………………………………………………………………..46
4.4.1. Individual Station ……………………………………………………………46
4.4.2. Cell …………………………………………………………………………..48

4.5. PROCEDURE FOR USE ……………………………………………………………49
4.5.1. Individual Station ……………………………………………………………49
4.5.2. Cell …………………………………………………………………………..50

5. LOCATING AND CORRECTING FAULTS ………………………………………51

6. MAINTENANCE AND INSPECTION …………………………………………….67
6.1. Introduction ………………………………………………………………………….67
6.2. Inspection points …………………………………………………………………….67

6.2.1. Daily inspection ……………………………………………………………...67
6.2.2. Periodic inspection …………………………………………………………..67
6.3. Maintenance procedures ……………………………………………………………..68
6.3.1. Pneumatic components ………………………………………………………68
6.3.2. Electrical shafts ……………………………………………………………...68
6.3.3. Cleaning ……………...……………………………………………………...68

7. SAFETY ……………………………………………………………………………..69
7.1. General safety precautions …………………………………………………………..69
7.2. Protection and safety devices ………………………………………………………..69

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8. FAULT SIMULATION SYSTEM………………………………………………………..70
9. SETS OF PARTS FOR ASSEMBLY………………………………………………...…..71
10. EC SELF- CERTIFICATION……………………………………………………….…..72
11. SUPPORT MATERIAL………………………………………………………………....73
ANNEX A: FAULT GENERATION
ANNEX B: ELECTRIC DIAGRAMS
ANNEX C: PNEUMATIC DIAGRAMS
ANNEX D: GRAFCET AND CONTROL PROGRAMS
ANNEX E: MECHANICAL DIAGRAMS
ANNEX F: MANUALS

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1.- TECHNICAL AND FUNCTIONAL
DESCRIPTION

From SMC, a world leader in Pneumatics, we introduce SMC International Training. Our
clear and wholehearted international vocation defines the objectives of this company: the
conception and marketing of training systems in the automation field to satisfy the training
needs of educative centres and companies all over the world.
An example of a Comprehensive Training System developed within the framework of this
project, constitutes the Flexible Assembly System FMS-200.

Figure 1: Flexible Automated Cell Trainer FMS-200

The flexible automation cell 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.

1

It enables the development of various skills associated with pneumatic, electro-pneumatic,
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.
- Hall detectors.
- Photoelectric detectors.
- Reed detectors.
- Photochromatic detectors.
- Capacitive detectors.
- Linear encoders.
- Etc.

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 2: Turning mechanism Figure 3: Turning mechanism components

Parts are transported between the different stations or layouts by an automated 4-metre
transfer line with corresponding stoppers and precision lifters-positioners. Parts are mounted
on pallets with a magnetic coding system.

The process stations or layouts function either independently of the transport system, or
integrated into it. The stations are situated around the transfer, and may be withdrawn for re-
positioning in a different order, moved for future extensions or work in a completely
independent and self-sufficient mode.

Each station has its own electrical panel, where the wiring system and automaton are fully
visible for study, while new elements may be fitted to the panel if desired. This electrical
control panel may be made entirely independent at each station for use in programmable
automaton training. In addition, students may design and build their own controls with
different automatons 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.

2

The front of each station incorporates the start, stop, and single and continuous cycle
pushbuttons.

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

The stations are mounted on aluminium 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:

Layout A: Feed body to which the other parts are assembled.
Layout B: Pick and Place bearing.
Layout C: Press bearing in hydraulically.
Layout D: Pick and Place shaft, and verify.
Layout E: Pick and Place cover.
Layout F: Fit screws.
Layout G: Robot screw driving.
Layout H: Unloading, storage and palletization of final assembly.

1.1. PROGRAMMABLE AUTOMATON WITH NETWORK
COMMUNICATIONS SYSTEM.

The standard layout includes a programmable automaton, Omron model CPM2C, panel-
mounted via a DIN track.

The CPM2C automaton has 6 inputs and 4 outputs, timed and programmed interrupts,
internal PID, high-speed counter and 0.08us instruction time. It incorporates an RS-232 port
for programming, and an DeviceNet port for communication with other automatons or PCs.

The automatons which govern the cell stations communicate with each other via a network,
so that each station comes ready with the necessary adapter and communications module.

1.2. AUTOMATON PROGRAMMING SOFTWARE

This software enables programming of instructions and contact diagrams for all standard
OMRON automatons in any desired layout. It allows ON LINE contact diagram monitoring
and modification. There are options to generate listings with comments, data reports and
memory listings. It incorporates help advice in all functions. The software includes an
operating manual and works under the Windows environment.

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2. PROCESS STATIONS
2.1. BODY FEED-POSITIONING

2.1.1. STATION FUNCTION

This first station feeds in the body which is the support for the turning mechanism, and
moves it to the pallet located in the transfer system.

This operation begins when the pallet is opposite the station, held in a determined location by
a stop on the transfer. Confirmation that the pallet is in the correct position is provided by a
microswitch which sends the appropriate signal to the automaton.

2.1.2. INTEGRAL PARTS

Station A, like the others, may be divided into a series of modules. Each sub-division has
been made by considering it as a set of components which performs a specific operation
within the process completed at the station. Starting out from this consideration, a description
is given below of the ordered sequence of actions performed for assembly of the body,
indicating the components involved in each operation.

- Body feed: Figure 4: Body-feed positioning
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.
The body is extracted by a pneumatic
cylinder which pushes against a pusher
shaped to match the profile of the
body.

- Position verification:
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.
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.

- Movement to transfer point:
A cylinder with a pusher at its end is used to situate the body at the point from
which it is loaded onto the pallet.

4

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

- Rejection of incorrect body:
If the verification process shows the position of the body to be incorrect, a
single-acting cylinder moves it towards a ramp, leaving the space clear for a
new body.

- Placing body on pallet:
A two-axis manipulator is used to place the
body on the pallet lying on the belt
conveyor. Each axis carries a parallel rod
cylinder.
The terminal element is a vacuum holding
platform with four suction cups to absorb
possible lack of alignment in height.

Figure 5: Placing body on pallet

Suction is created 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 6: Vacuum Ejector

2.1.3. TECHNICAL DATA

Dimensions:
Table of slotted aluminium section, 900 x 540 mm.
Height 900 mm.

Air treatment unit:
Filter to 5 µm, pressure regulator and pressure gauge.

Pushbutton control:
Start, stop, reset pushbuttons. Emergency button and error pilot indicator.

Composition of station modules:
Body feed module.
Magazine capacity: 12 bodies.
Actuators:
- Double-acting pusher cylinder Ø16, Stroke:100mm (CD85N16-100B), with flow

regulators and initial-end position detector. Controlled by 5/2 way monostable solenoid
valve.
Sensors:
- Reed type magnetic detectors (D-C73L).

5

Position verification module
Actuators:
- Double-acting cylinders Ø12, Stroke:50mm (CD85N12-50B), with flow regulators and

end position detector. Controlled by 5/2 way monostable solenoid valve.
Sensors:
- Reed type magnetic detector (D-A73CL)

Movement module
Actuators:
- Rectangular section pusher cylinder Ø25, Stroke:200mm (MDUB25-200DM), with flow

regulators and end position detector. Controlled by 5/2 way monostable solenoid valve.
Sensors:
- Reed type magnetic detector (D-A73CL).

Inverted body rejection module
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 rod cylinder Ø20, Stroke:150mm (CXSWM20-150-XB11), with

flow regulators and initial-end position detector. Controlled by 5/2 way monostable
solenoid valve.
- Vertical axis: Parallel rod cylinder Ø15, Stroke:50mm (CXSM15-50), with flow
regulators and initial-end positio n detector. Controlled by 5/2 way monostable solenoid
valve.
- Holding plate: 4 telescopic suction cups Ø16 (ZPT16CNK10-B5-A10), with ejector to
generate vacuum (ZU07S). Controlled by 3/2 way monostable solenoid valve.
Sensors:
- Reed type magnetic detectors (D-Z73L)
- Vacuum switch PNP output (PS1100-R06L)
Input/ Output Module:
- DevideNet module 8 inputs/ 8 outputs

Electrical control panel:
- Mounted on perforated mesh 550 x 400 mm.
- Accessible terminal plate with supply connections and coded I/Os.
- Thermal overload switch incorporated.
- I/O station: 13 inputs, 10 outputs.
- Supply module: 24V/2.1A
- PLC control:

- Omron model CPM2C-S110C-DRT
- Digital Card 8 inputs CPM2C- 8EDC
- Digital Card 8 outputs CPM2C- 8ER

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2.2. BEARING HANDLING-FITTING LAYOUT

2.2.1. STATION FUNCTION

The operation carried out by the second station consists of picking the bearing and placing it
inside the housing formed in the body.

Figure 7: Bearing Handling-fitting layout

The task of placing the bearing is performed on the pallet brought by the belt conveyor and
carrying the body located at the previous station. The bearing fitting operation requires the
pallet carrying the body to be precisely situated in a predetermined place. To achieve this
precision, once the pallet has been retained by a stop, it is lifted by a cylinder and centred at
the same time by four pins which fit inside housings formed for this purpose in the bottom of
the pallet.

2.2.2. INTEGRAL PARTS

Bearing insertion requires a series of operations which are carried out by the following
modules:

- Bearing feed:
The bearings are held in a gravity feed
magazine. This consists of a column
magazine with a pusher cylinder at the
bottom which extracts the bearing at the
moment the cycle is to start.

Figure 8: Bearing feed

7

In this case, there is a bearing proximity 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 9: Proximity sensor

- Transfer to measuring station:
A manipulator is used to move the bearing from the feed point to the place
where the following operation is to be performed. The manipulator uses a rack
and pinion type rotary actuator which describes an angle of 180º.
An arm is attached to the rotary actuator to move a two- finger parallel-opening
gripper which grips the inner part of the bearing. This arm houses a mechanism
consisting of a toothed belt and two pinions, the purpose of which is to change
gripper orientation throughout the turning moveme nt, so that when the bearing
reaches the point at which it is deposited, it has no angle of inclination
whatsoever.

Figure 10: Transfer to measuring station

- Height measurement:
As the station caters for the
possibility of feeding bearings
of differing heights, a measuring
module is included to
differentiate between them.
The bearing is deposited on a
platform, on a centring device
operated by a pneumatic
cylinder which locates it at a
very precise initial point.

Figure 11: Height measurement

8

This platform is lifted by a rodless pneumatic cylinder such that the bearing
contacts with a touch trigger and gives a height reading. The touch trigger
consists of a linear potentiometer with an output processed via an analogue
module included in the PLC.
After measurement, the lifter returns to its original position, at which time the
ejector cylinder pushes the bearing towards a collection bin if it is not of the
desired height.

- Bearing insertion:
The final operation is performed by a manipulator comprising a rotary-linear
unit with an arm to which a two-finger gripper has been fitted. After picking up
the bearing, the arm is lifted, turns through 180º then drops down again to insert
the bearing in the housing formed in the body.

Figure 12: Bearing insertion

2.2.3. TECHNICAL DATA

Dimensions:
Table of slotted aluminium section, 900 x 540 mm.
Height 900 mm.

Air treatment unit:
Filter to 5 µm, pressure regulator and pressure gauge.

Pushbutton control:
Start, stop, reset pushbuttons. Emergency button and error pilot indicator.

Composition of station modules:
Bearing feed module
Magazine capacity: 38 bearings
Actuators:
- Double-acting pusher cylinder Ø16, Stroke:100mm (CD85N16-100B), with flow

regulators and initial position detector. Controlled by 5/2 way monostable solenoid valve.
Sensors:

- Reed type magnetic detector (D-C73L).
- Proximity detector: Microswitch OMRON V-166-1C5.

Measuring station transfer module
Actuators:

9

- Rotary actuator: Double rack and pinion Ø50, ? max:180º ( MSQB50A), with flow
regulators and 0º, 90º and 180º position detector. Controlled by 5/3 way solenoid valve,
mid position closed.

- Holding arm: Two- finger parallel-opening grippers (MHK2-16D). Controlled by 5/2 way
monostable solenoid valve.

Sensors:
- PNP type magnetic detectors (D-A93L).

Height measuring module
Actuators:

- Compact single-acting centring cylinder Ø12, Stroke:5mm (CQ2B12-5S). Controlled
by 3/2 way monostable solenoid valve.

- Vertical axis: Rodless cylinder Ø16, Stroke:250mm (MY1B16G-250), with flow
regulators and initial position detector. Controlled by 5/2 way bistable solenoid valve.

- Incorrect part ejection: Double-acting cylinder Ø10, Stroke:40mm (CD85N10-40),
with flow regulators. Controlled by 5/2 way monostable solenoid valve.

Sensors:
- Reed type magnetic detector (D-A93L).
- Linear potentiometer NOVOTECHNIK TR25.

Bearing insertion module
Actuators:

- Compact linear and rotary movement cylinder Ø32, Stroke:25mm (EMRQBS32-
25CB), with flow regulators and initial-end of travel detection for linear movement,
and 0º and 180º detection for rotary movement. Controlled by two 5/2 way monostable
solenoid valves.

- Holding arm: Two- finger parallel-opening grippers (MHK2-16D). Controlled by 5/2
way monostable solenoid valve.

Sensors:
- Reed type magnetic detectors (D-A73CL).

Input/ Output module:
- DeviceNet module 8 inputs/ 8outputs

Electrical control panel:
- Mounted on perforated mesh 550 x 400 mm.
- Accessible terminal plate with supply connections and coded I/Os.
- Thermal overload switch incorporated.
- I/O station: 15 inputs, 13 outputs.
- Supply module: 24V/2.1A.
- PLC control:
- Omron Model CPM2C-S110C-DRT
- Analogic Card 2 inputs/ 1 output CPM2C-MAD11.
- Digital Card 16 inputs CPM2C- 16EDC
- Digital Card 8 outputs CPM2C- 8ER

10

2.3. HYDRAULIC BEARING PRESSING
LAYOUT

2.3.1. STATION FUNCTION

Following the bearing insertion operation performed by the preceding station, this third
station carries out the task of pressing the bearing firmly into the body to fix it securely. In
actual fact, this pressing operation is not actually carried out; instead, it is only simulated so
that the finished assembly may be dismantled easily and the component parts reused.
In spite of this, the components included are all industrial grade and similar to those used in
numerous hydraulic applications. They allow the study of systems based on hydraulic
technology which incorporate real components integrated in an authentic application.
A complete hydraulic unit as required to supply the press cylinder with high pressure oil is
installed under the table, avoiding the need for any additional hydraulic installation other
than the electrical and pneumatic take-offs from the central transfer.

Figure 13: Hydraulic Bearing Pressing Lay-out

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2.3.2. INTEGRAL PARTS

The pressing stage requires a number of operations to be performed, as detailed below.

- Insertion / extraction of assembly:

The first operation consists of moving

the body with the bearing inside it

from the pallet retained at the transfer

to an unloading point inside the station.

This handling, and the reverse process

of unloading following pressing, are

performed by a pneumatic rotary

actuator. Figure 14: Insertion/extraction of assembly

This actuator incorporates an arm with a set of four suction cups at its end,
whose job is to hold the part by means of an internal vacuum generated by
an ejector. To keep the body permanently horizontal throughout the turning
movement, this arm incorporates a pinion and toothed belt mechanism
similar to that used at the bearing insertion station.

- Feed in to press:
The body to be fed in to the press is deposited on a platform fitted with two
double-acting pneumatic cylinders. The first effects the transfer from the
loading/unloading point to the press, while the second carries out the
reverse operation following the pressing operation.

- Pressing the bearing:
When the body with the bearing inside has been positioned under the
hydraulic cylinder, a protective screen operated by a pneumatic cylinder
drops down. This protects the user against any risk of accident, and also
demonstrates a safety device widely used in this type of application.
By means of a hydraulic 4/3 way directional control valve, the pressing
cylinder now exerts a force which may be regulated using the pressure
limiting valve incorporated in the hydraulic unit. After pressing, the
cylinder returns to its original position, the screen is lifted and the assembly
is pushed to the unloading position.

Figure 15: Pressing the bearing

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2.3.3. TECHNICAL DATA

Dimensions:
Table of slotted aluminium section, 900 x 540 mm.
Height 900 mm.

Air treatment unit:
Filter to 5 µm, pressure regulator and pressure gauge.

Pushbutton control:
Start, stop, reset pushbuttons. Emergency button and error pilot indicator.

Composition of station modules:
Assembly insertion/extraction module
Actuators:
- Rotary actuator: Double rack and pinion type Ø50, ? max:180º (MSQB50A), with flow

regulators and 0º, 90º and 180º position detector. Controlled by 5/3 way solenoid valve,
mid position closed.
- Holding arm: 4 Suction cups Ø16 (ZPT16UN-B5), with ejector to generate vacuum
(ZU07S). Controlled by 3/2 way monostable solenoid valve.
Sensors:
- PNP type magnetic detectors (D-A93L).
- Vacuum switch PNP output (PS-1100-R06L).

Press feed module
Actuators:

- 2 Double-acting pusher cylinders Ø12, Stroke:125mm (CD85N12-125A), with flow
regulators and initial-end of stroke position detector. Controlled by 5/2 way
monostable solenoid valves.

Sensors:
- Reed type magnetic detectors (D-A73CL).

Bearing pressing module
Actuators:

- Protector: Do uble-acting parallel rod cylinder Ø15, Stroke:100mm (CXSM15-100),
with flow regulators and initial-end position detector. Controlled by 5/2 way
monostable solenoid valve.

- Pressing: Compact double-acting hydraulic cylinder Ø40, Stroke:50mm (CHDQH340-
50), with ATOS HQ012 flow regulators and initial-end position detector. Controlled
by ATOS DHI-0714 4/3 way solenoid valve, mid position closed.

Sensors:
- Reed type magnetic detector (D-Z73L and two D-A73CL).

Input/ Output module:
- DevideNet module 8 inputs/ 8 outputs.

13

Electrical control panel:
- Mounted on perforated mesh 550 x 400 mm.
- Accessible terminal plate with supply connections and coded I/Os.
- Thermal overload switch incorporated.
- I/O station: 18 inputs, 11 outputs.
- Supply source: 24V/2.1A.
- Net filter.
- Frequency converter
- PLC control:
- Omron model CPM2C-S110C-DRT
- Digital Card 16 inputs CPM2C- 16EDC
- Digital Card 8 outputs CPM2C- 8ER
- Three-phase contactor for hydraulic unit operation.

Hydraulic unit:
- Three-phase motor 380V/1.4A 0.37kW 1400rpm.
- Pressure gauge.
- Pressure limiter.

14

2.4. SHAFT HANDLING-FITTING-
MEASUREMENT-SELECTION

2.4.1. STATION FUNCTION

The fourth station follows the process needed to insert a
shaft into the bearing fitted at a previous station.

This station represents an increase in flexibility in that it
allows variety in the assemblies put together, in the form of
being able to fit shafts of different materials; aluminium or
nylon.

Figure 16: Shaft station

The existence of these variants means that the extra operations of checking the type of
material and extracting ones which are not of the desired material are added to the normal
operations of feeding, handling and insertion.

2.4.2. INTEGRAL PARTS

The extra operations to be carried out involve an increase in the complexity of the station,
which means that its structure is noticeably different from previous stations. In this case, the
components are arranged on an 8-station index plate.

Successive operations are performed at these stations, a description of which is given below:

- Index plate:
This element is used as a system of
alternating rotary movement, in the sense
that each turning movement moves the
plate round by a number of degrees equal
to the circumference divided by the
number of defined positions.
To achieve this effect, the system
incorporates a pneumatic pusher cylinder
with back and forth movement giving the
required angular advance.

Figure 17: Index plate

There are a further two stop cylinders which function alternately, one moving
which holds the plate during the turn, and another fixed cylinder which locks
the plate in position when movement has ceased. In this way, the plate is held
firmly and the pusher cylinder can return to its initial position to await a new
cycle.

15

- Shaft feed:
The shafts stored in a gravity type feeder are
deposited on the first plate station via a step-by-step
feed system involving two pneumatic cylinders.
These cylinders are in a permanent counterpoise
position, so that while the lower one releases the next
shaft from the feeder, the upper one holds the rest in
place.

F
Figure 18: Shaft feed

- Shaft height measurement:
The shaft is not symmetrical and must therefore be
mounted on the assembly in a particular position.
The shaft is measured to check whether it has been
correctly inserted. A pneumatic cylinder fitted with
magnetic detector registers whether contact is made
with the shaft during outstroking, or whether the
cylinder is able to reach the end of its travel if the
shaft is not in its proper place.

Figure 19: Height measurement

- Placing shaft in correct position:
If the second station on the index plate determines that the shaft has been placed
upside down, a manipulator has the job of turning it round. This is achieved by
holding the shaft between a two- finger gripper, lifting it by a parallel rod
cylinder, then turning it over using a 180º rotary actuator and replacing it in the
correct position in the housing.

Figure 20: Placing shaft in correct position

16

- Shaft material detection:
The next operation at this station is carried out using two consecutive index
plate stations. The aim is to determine the material of which the shaft is made, it
being necessary to distinguish between aluminium and nylon. This is achieved
by inductive and capacitive detectors fitted to the third and fourth stations
which enable the two types of materials to be differentiated.

Figure 21: Shaft material detection

- Removal of incorrect shaft:
As mentioned earlier, this station fulfils the potential to work at a higher level
of cell management by making a choice of shaft material to be used for the
various assemblies. This means a need for some element to reject the shaft if it
is not of the type indicated, an operation carried out at the fifth index plate
station and involving a manipulator which removes the shaft from the plate on
receiving the corresponding command.

This element takes the form of a two-axis
manipulator, at the extreme end of which is a
suction cup to hold the top part of the shaft.
Each axis comprise a parallel rod pneumatic
cylinder used to lift the shaft and carry it to a
removal ramp. The shaft is held by the
vacuum technique consisting of a suction cup,
ejector to create the necessary vacuum and a
vacuum switch which sends a signal to the
PLC to indicate that the shaft is securely held.

Figure 22: Removal of incorrect shaft

- Shaft insertion in assembly:
Shaft insertion, carried out at the last of the index plate stations, is performed by
a rotary- linear type manipulator. This rotary- linear cylinder makes it possible
for a single component to pick up the shaft, take it to the unloading point and
insert it. The cylinder offers the possibility of independently commanding rod
instroking and outstroking as well as turns to left or right.
It is this cylinder which turns an arm fitted with a suction cup used to holds the
shaft throughout the movement. As in the case of the other manipulators using
the vacuum technique, an ejector and vacuum switch are provided for the
cylinder.

17

Figure 23: Shaft insertion in assembly

Given that the operation of inserting the shaft in the bearing calls for a certain
precision, the pallet supporting the components and lying on the belt is, after
being retained by a stop cylinder, lifted by a further cylinder which incorporates
centring pins for correct positioning.

2.4.3. TECHNICAL DATA

Dimensions:
Table of slotted aluminium section, 900 x 540 mm.
Height 900 mm.

Air treatment unit:
Filter to 5 µm, pressure regulator and pressure gauge.

Pushbutton control:
Start, stop, reset pushbuttons. Emergency button and error pilot indicator.

Composition of station modules:
Index plate module
Actuators:
- Compact double-acting pusher cylinder Ø25, Stroke:40mm (CDQ2B25-40D), with flow

regulators and initial position detector. Controlled by 5/2 way monostable solenoid valve.
- Stops: 2 Compact cylinders Ø16, Stroke:10mm (CQ2B16-10D). Controlled by 5/2 way

monostable solenoid valve.
Sensors:
- Reed type magnetic detector (D-A73L).

18

Shaft feed module
Magazine capacity: 17 shafts.
Actuators:
- 2 Double-acting cylinders Ø10, Stroke:10mm (CD85N10-10B). Controlled by 5/2 way

monostable solenoid valve.

Shaft height measuring module
Actuators:
- Double-acting cylinder Ø12, Stroke:50mm (CD85N12-50A), with flow regulators and

end position detector. Controlled by 5/2 way monostable solenoid valve.
Sensors:
- Reed type magnetic detector (D-A73CL).

Place shaft in correct position module
Actuators:
- Double-acting parallel opening two-finger gripper (MHK2-16D). Controlled by 5/2 way

monostable solenoid valve.
- Vertical axis: Double-acting parallel rod cylinder Ø15, Stroke:50mm (CXSM15-50), with

flow regulators and initial-end position detector. Controlled by 5/2 way monostable
solenoid valve.
- Rotary actuator: Double acting ? max=180º (MSUB3-180S), with flow regulators.
Controlled by 5/2 way monostable solenoid valve.
Sensors:
- Reed type magnetic detectors (D-Z73L).

Shaft material detection module
Sensors:

- Inductive detector: OMRON E2EG-X5B1.
- Capacitive detector: OMRON E2K-C25MF1.

Incorrect shaft ejection module
Actuators:

- Horizontal axis: Double-acting parallel rod cylinder Ø15, Stroke:100mm (CXSM15-
100), with flow regulators and initial-end position detector. Controlled by 5/2 way
bistable solenoid valve.

- Vertical axis: Double-acting parallel rod cylinder Ø10, Stroke:50mm (CXSM10-50),
with flow regula tors and initial-end position detector. Controlled by 5/2 way
monostable solenoid valve.

- Holding arm: Suction cup Ø8 (ZPT08UN-B5), with vacuum generating ejector
(ZU05S). Controlled by 3/2 way monostable solenoid valve.

Sensors:
- Reed type magnetic detectors (D-Z73L).
- Vacuum switch PNP output (PS-1100-R06L).

Shaft insertion in assembly module
Actuators:

- Compact linear and rotary movement cylinder Ø32, Stroke:25mm (EMRQBS32-
25CB), with flow regulators and initial-end of travel detection for linear movement,
and 0º and 180º detection for rotary movement. Controlled by two 5/2 way monostable
solenoid valves.

- Holding arm: Suction cup Ø10 (ZPT10CNK10-B5-A10), with vacuum generating
ejector (ZU05S). Controlled by two 3/2 way monostable solenoid valve.

Sensors:

19

- Reed type magnetic detectors (D-A73CL).
- Vacuum switch PNP output (PS-1100-R06L).
Input/ Output module:
- DeviceNet module 8 inputs/ 8 outputs.
Electrical control panel:
- Mounted on perforated mesh 550 x 400 mm.
- Accessible terminal plate with supply connections and coded I/Os.
- Thermal overload switch incorporated.
- I/O station: 20 inputs, 16 outputs.
- Supply source: 24V/2.1A.
- PLC control:
- Omron model CPM2C-S110C-DRT
- Digital Card 16 inputs CPM2C- 16EDC
- Digital Card 8 outputs CPM2C- 8ER

20

2.5. COVER HANDLING-FITTING-SELECTION
LAYOUT

2.5.1. STATION FUNCTION

The fourth of the components to be assembled is a cover which is fitted into a housing
formed on the body for this purpose. The cover serves to retain the turning mechanism shaft
mounted at the previous station.

While the preceding station saw the introduction of a variant in the form of different
materials for the shaft, this station increases the number of variants by offering the choice of
three different materials for the cover: aluminium, white nylon and black nylon, in addition
to a choice of two different cover heights, giving a total of six possible combinations for this
particular assembly task.

The need for appropriate checks to determine which type of cover is to be mounted at each
station cycle means that this station is the most comp lex in terms of the operations to be
carried out. It is also essential that the station control coordinates part selection operations in
accordance with the commands supplied by the master responsible for production
management in the FMS-200.

2.5.2. INTEGRAL PARTS

The structure adopted for the cover assembly process is
similar to that of the previous station. It is based on an 8-
station index plate to improve the method of working at
the station, as it saves space compared with other spatial
arrangements of work stations, and also means that all
handling operations may be carried out simultaneously to
optimize the process in question.

Figure 24: Cover station

The operations to be performed and the components involved are described below:

- Index plate:
The 8-station index plate which moves round to effect the interchange of parts
between the different stations is of similar structure to that used at the
preceding station.
It is operated by two cylinders, one fixed stop and one moving, together with a
pusher cylinder which produces the turning movement as previously
described.

21

- Feed module:
A gravity feeder is used to store and feed the covers. It is operated by a pusher
actuated by a pneumatic cylinder and which carries out the part extraction
process.

Figure 25: Feed module

- Loading station: Figure 26: Loading station
The material feed described above supplies
the covers which will later be mounted on
the assembly lying ready on the pallet.
First, however, the cover must be loaded
on the index plate.
This is performed by ma nipulator
comprising a rotary-linear cylinder which
lifts and then turns an arm fitted with a
two- finger parallel opening gripper.

The 180º turn effected by the manipulator leaves the gripper at the exact point
of unloading the cover at the first index plate station.

- Material detection stations:
As described above, this station offers the possibility of working with
aluminium, white nylon and black nylon respectively.

Figure 27:Inductive sensor Figure 28: Capacitive sensor Figure 29:Photoelectric cell

To differentiate the first of these types, the second index plate station is fitted
with an inductive pick-up which supplies a signal to the PLC only if the cover
presented by the plate, as it turns, is of aluminium.
Detection of the nylon covers necessitates the use of a different type of sensor,
in this case capacitive, which supplies a signal when the part detected is not
made of metal.

22

The final cover differentiation process is that between black and white nylo n,
and for this purpose a photoelectric cell as in figure 31 is fitted. This component
only detects white-coloured nylon covers.

- Cover measuring station: Figure 30: Measuring station
The fact that covers of two different heights may
be used necessitates a height measuring device.
Owing to the teaching and training objective for
which the cell has been designed, various solutions
have been used to perform similar operations, so
that while components such as pneumatic
cylinders with correct height detectors or analogue
output touch probes have been employed at other
stations, this particular station uses a digital
transducer which provides a pulse output, as it is a
linear encoder.

The component used consists of a pneumatic cylinder which moves the probe
until it touches the cover. An integral linear encoder in the cylinder sends pulses
which are counted by a quick counter input at the PLC, making it possible to
determine the distance the cylinder advances until it makes contact with the
cover. This information allows direct determination of the height of the cover.

- Rejection of incorrect cover: Figure 31: Rejection of incorrect cover
If the cover reaches the last-but-one
index plate station, and the various
material or height sensors have
indicated that it is not of the material or
height indicated by the central controller
in charge of production, then it must be
rejected. This operation is effected at
this station by a two-axis manipulator,
which picks the cover off the index
plate and deposits it on a removal ramp
if the corresponding signal is received.

The manipulator comprises two pneumatic parallel rod cylinders, at the end of
which is a suction plate with three vacuum- holding cups.

23

- Cover insertion:
As at the previous station, the final index plate station is where the cover is
fitted onto the assembly at a stop on the belt conveyor.
The manipulator used for this task is of identical characteristics to the one
which deposits the cover on the index plate. It has a parallel opening gripper to
hold the cover, which is lifted and turned towards the unloading point by a
rotary- linear pneumatic actuator.

Figure 32: Cover insertion

2.5.3. TECHNICAL DATA

Dimensions:
Table of slotted aluminium section, 900 x 540 mm.
Height 900 mm.
Air treatment unit:
Filter to 5 µm, pressure regulator and pressure gauge.
Pushbutton control:
Start, stop, reset pushbuttons. Emergency button and error pilot indicator.
Composition of station modules:
Index plate module
Actuators:
- Compact double-acting pusher cylinder Ø25, Stroke:40mm (CDQ2B25-40D), with flow

regulators and initial position detector. Controlled by 5/2 way monostable solenoid valve.
- Stops: 2 Compact cylinders Ø16, Stroke:10mm (CQ2B16-10D). Controlled by 5/2 way

monostable solenoid valve.
Sensors:

- Reed type magnetic detector (D-A73CL).

24

Cover feed module
Magazine capacity: 19 covers.
Actuators:

- Double-acting pusher cylinder Ø16, Stroke:100mm (CD85N16-100B), with flow
regulators and final position detector. Controlled by 5/2 way monostable solenoid
valve.

Sensors:
- Reed type magnetic detector (D-C73L).
- Microswitch OMRON V-166-1C5.

Loading station module
Actuators:

- Compact linear and rotary movement cylinder Ø32, Stroke:25mm (EMRQBS32-
25CB), with flow regulators and initial-end of travel detection fo r linear movement,
and 0º and 180º detection for rotary movement. Controlled by two 5/2 way monostable
solenoid valves.

- Holding arm: Two- finger parallel opening pneumatic gripper (MHKL2-16D).
Controlled by 5/2 way monostable solenoid valve.

Sensors:
- Reed type magnetic detectors (D-A73CL).

Material detection stations module
Sensors:

- Inductive detector: OMRON E2EG-X5C1.
- Capacitive detector: OMRON E2K-C25ME1.
- Photoelectric detector: OMRON E3F2-DS30C4.

Cover measuring module
Actuators:

- Double-acting cylinder with stroke reading Ø20, Stroke:50mm (CE1B20-50), with
flow regulators. Controlled by 5/2 way monostable solenoid valve.

Sensors:
- Linear encoder integrated in cylinder.

Incorrect cover rejection module
Actuators:

- Horizontal axis: Double-acting parallel rod cylinder Ø15, Stroke:100mm (CXSM15-
100), with flow regulators and initial-end position detector. Controlled by 5/2 way
bistable solenoid valve.

- Vertical axis: Double-acting parallel rod cylinder Ø10, Stroke:50mm (CXSM10-50),
with flow regulators and initial position detector. Controlled by 5/2 way monostable
solenoid valve.

- Holding arm: 3 suction cups Ø8 (ZPT08UN-B5), with vacuum-generating ejector
(ZU07S). Controlled by 3/2 way monostable solenoid valve.

Sensors:
- Reed type magnetic detectors (D-Z73L).
- Vacuum switch PNP output (PS-1100-R06L).

25

Cover insertion module
Actuators:

- Compact linear and rotary movement cylinder Ø32, Stroke:25mm (EMRQBS32-
25CB), with flow regulators and initial-end of travel detection for linear movement,
and 0º and 180º detection for rotary movement. Controlled by two 5/2 way monostable
solenoid valves.

- Holding arm: Two- finger parallel opening gripper (MHKL2-16D). Controlled by 5/2
way monostable solenoid valve.

Sensors:
- Reed type magnetic detectors (D-A73CL).

Input/ Output module:
- DeviceNet module 8 inputs/ 8 outputs

Electrical control panel:
- Mounted on perforated mesh 550 x 400 mm.
- Accessible terminal plate with supply connections and coded I/Os.
- Thermal overload switch incorporated.
- I/O station: 24 inputs, 16 outputs.
- Supply source: 24V/2.1A.
- PLC control:
- Omron model CPM2C-S110C-DRT
- Digital Card 16 inputs CPM2C- 16EDC
- Digital Card 8 outputs CPM2C- 8ER

26

2.6. SCREW HANDLING-FITTING

2.6.1. STATION FUNCTION

This station carries out the final operation to fit components to the assembly under
construction, and involves the insertion of four screws in four threaded holes in the base body
of the turning mechanism.
The technology used to effect the movements at this station, based on different pneumatic
cylinders, means it is only possible to unload the screws at a single point. In consequence, an
additional component is needed for the transfer to give it successive turns, so that four
insertion cycles at this station will result in the four screws being fitted.
The components used for this particular operation are a pne umatic lifting cylinder on which a
similarly operated rotary actuator is fitted.
In contrast with preceding stations, where communication between the stations and the
transfer was limited to sending start messages and end of cycle indications, here there is a
greater need for coordination between the units. As a result, more use is made of the
possibilities offered by the automaton network for information exchange between the
different stations.

Figure 33: Screw handling-fitting station

27

2.6.2. INTEGRAL PARTS

The screw insertion function involves a series of operations which are described below.

- Screw feed:
The screws to be inserted are stored in a
vertical gravity feeder, from where they are
unloaded onto a housing via a step-by-step feed
system involving two pneumatic cylinders
working in a permanent counterpoise position,
so that while the lower one instrokes to let the
next screw fall from the feeder, the upper one
outstrokes to hold the rest in place. Both
cylinders return to their original posit ion once
the screw has dropped down.

Figure 34: Screw feed

- Transfer module:
The housing which receives the screws is situated on a double-acting parallel
rod pneumatic cylinder whose construction allows it to be fixed by plates at
each end so that it is the cylinder body which slides like a carriage.
This cylinder is used to transfer the screws from point at which they are fed in
to the point where the following module picks them up for fitting to the
assembly.

- Screw insertion manipulator:
Once the items mentioned above have deposited a screw and transferred it to
the pick- up point, the pneumatic manipulator fits the screw into one of the holes
in the turning mechanism body retained on the transfer.
Constructed using two parallel rod cylinders, this manipulator has two degrees
of freedom corresponding to the horizontal and vertical axes. Its end effector is
a parallel opening two-finger gripper, used to hold the screws.

Figure 35: Screw insertion manipulator

28

2.6.3. TECHNICAL DATA

Dimensions:
Table of slotted aluminium section, 900 x 540 mm.
Height 900 mm.

Air treatment unit:
Filter to 5 µm, pressure regulator and pressure gauge.

Pushbutton control:
Start, stop, reset pushbuttons. Emergency button and error pilot indicator.

Composition of station modules:
Screw feed module
Magazine capacity: 38 screws.
Actuators:
- 2 Double-acting cylinders Ø10, Stroke:10mm (CD85N10-10-B). Controlled by 5/2 way

monostable solenoid valve.

Transfer module
Actuators:
- Double-acting parallel rod cylinder Ø20, Stroke:100mm (CXSWM20-100), with flow

regulators and initial-end position detector. Controlled by 5/2 way bistable solenoid
valve.
Sensors:
- Reed type magnetic detectors (D-Z73L).
- Photoelectric cell OMRON E3X-A41.
- Fibre optic OMRON E32-TC200.

Screw insertion manipulator module
Actuators:

- Horizontal axis: Double-acting parallel rod cylinder Ø25, Stroke:200mm
(CXSWM25-200-XB11), with flow regulators and initial-end position detector.
Controlled by 5/2 way bistable solenoid valve.

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

- Holding: Two-finger parallel opening pneumatic gripper (MHK2-16D) and open-
closed position detector. Controlled by 5/2 way monostable solenoid valve.

Sensors:
- Reed type magnetic detectors (D-Z73L).
- PNP type magnetic detectors (D-A93L).

Input/ Output module:
- DeviceNet module 8 inputs/ 8 outputs.

29

Electrical control panel:
- Mounted on perforated mesh 550 x 400 mm.
- Accessible terminal plate with supply connections and coded I/Os.
- Thermal overload switch incorporated.
- I/O station: 13 inputs, 9 outputs.
- Supply source: 24V/2.1A.
- PLC control:

- Omron model CPM2C-S110C-DRT
- Digital Card 8 inputs CPM2C- 8EDC
- Digital Card 8 outputs CPM2C- 8ER

30

2.7. ROBOT SCREWDRIVER

2.7.1. STATION FUNCTION

All the preceding stations were of a design in which actuators based on fluid technology
predominated. These were primarily pneumatic components, although the study of hydraulic
technology was facilitated at the bearing pressing station.
With a view to matching the cell to all the most widely used techniques in industrial
automation, this station introduces a new though widespread technology, that of robotics.
The operation carried out by the robot consists of tightening the four screws fitted to the body
of the turning mechanism at the preceding station.

Figure 36: Robot screwdriver

2.7.2. INTEGRAL PARTS

Given the flexibility and numerous possibilities offered by the use of robots in automating
operations, at this station it is regarded as enough to use the element for the operations
needed to drive in the screws.
Control of the robot’s movements between the different points it has to reach is carried out
by a controller which has been specially designed for use with the particular robot used. It
performs the function of controlling all the movements of all of the motors incorporated in
the robot, so that the latter moves to the defined positions with great accuracy.

31

It is also possible to program the robot’s movements into the controller and thereby specify
what sequence of movements has to be followed for a particular process. Programming is by
means of specific software to be run on PC, which communicates the transfer of information
to the controller via a serial line.
There is also a programming console on which it is possible to enter a series of commands, or
to define the points to which the robot has to move.
The positional accuracy enables the tip of the electric screwdriver to be located on each of
the screws fitted in the body, before slowly screwing in the appropriate distance for the screw
to be properly fixed.
To avoid the possibility of uncontrolled movements during the programming phase causing
any type of accident, the station is protected by screening of aluminium section with
methacrylate see-through panels. This practically eliminates the risks involved in handling
components of this type.

2.7.3. TECHNICAL DATA

Dimensions:
Table of slotted aluminium section, 900 x 540 mm.
Height 900 mm.

Pushbutton control:
Start, stop, reset pushbuttons. Emergency button and error pilot indicator.

Station elements:
- MOVEMASTER EX MELFA RV-M1 MITSUBISHI 5-axis robot. Speed 2.1 m/s, 2500

storable positions, 0.02 mm accuracy, 10 speeds, 2 kg payload, 19 kg arm weight, parallel
(centronics) and series (RS-232) interfaces, 16 inputs (3 switches) and 16 outputs, 1
emergency stop input.
- Electric screwdriver 3.6 V.
- Methacrylate screening for user protection.

Input/ Output module:
- DeviceNet module 8 inputs/ 8 outputs.

Electrical control panel:
- Mounted on perforated mesh 550 x 400 mm.
- Accessible terminal plate with supply connections and coded I/Os.
- Thermal overload switch incorporated.
- I/O station: 7 inputs/ 7 outputs.
- Relay for screwdriver supply.
- Supply source: 24V/ 0.6A.
- Supply source: 5V/ 2.5A
- MITSUBISHI robot driver.
- MITSUBISHI robot programming console.
- PLC Control:

- Omron model CPM2C-S110C-DRT
- Digital Card 8 inputs CPM2C- 8EDC
- Digital Card 8 outputs CPM2C- 8ER

32

2.8. UNLOADING-STORAGE-PALLETIZATION
OF COMPLETED ASSEMBLY

2.8.1. STATION FUNCTION

One operation which is always present in flexible assembly systems, and to which all
operations lead, is that of storage. Once the turning mechanism put together by the cell has
been completed, at the final station it must be removed from the transport system, leaving the
now empty pallet to move towards the first belt to begin work on a new assembly.
This particular finished product store uses a system based on two coordinate axes, so that
assemblies picked off the transporting belt may be distributed at any point on the surface of
the table which constitutes the station.

Figure 37: Storage station

2.8.2. INTEGRAL PARTS

As mentioned, the storage system consists of two position-controlled axes which distribute
the assemblies along the surface of the table. Over these is supported a third vertical axis
with which to pick up the parts.

33

§ Vertical axis:
The system of holding the finished assemblies incorporates four suction cups
which use an ejector-produced vacuum to hold the assembly until it is
positioned at its storage point.
The vertical axis takes the form of a parallel rod cylinder on which the suction
cups are fitted.

Figure 38: Vertical axis Figure 39: Pressure sensor

As at all the stations which make use of vacuum components, a pressure-
sensing element cons isting of a vacuum switch is fitted. This supplies a digital
signal indicating that the ejector has produced the level of vacuum needed to
hold the assembly firmly enough to ensure that it will not drop off when moved
by the other axes. In this case, however, a digital vacuum switch has been
incorporated which provides additional features such as displaying the
instantaneous value of pressure and vacuum, and the possibility of greater
accuracy than conventional units when programming the pressure value at
which the output signal is generated.

§ Positioning axes:
The first task in storing the finished assemblies is to situate the vertical axis
mentioned above over a fixed pick- up point over the place where the pallet is
retained facing the station.
The finished assembly is then picked and lifted by the pneumatic cylinder
forming the vertical axis. The assemblies to be stored must now be positioned at
various points over the surface of the station table before being unloaded at
these points.
The assemblies are moved and their position controlled by two linear motorized
axes, each of which consists of a motor-driven leadscrew-nut which translates
the rotary motion of the motor into linear displacement of the axis carriage.
The vertical pneumatic axis is attached to the first of these axes, this whole
assembly being mounted on the other motorized linear axis. The result is a
three-axis system, two of them being capable of positioning.
From the mechanical point of view, these components incorporate a precision
leadscrew with a recirculating ball system, together with two lateral linear
guides of high rigidity and precision, able to withstand the forces arising out of
the loads acting on the carriage.

34

Axis movement and movement regulation is effected by alternating current
servomotors, with an absolute encoder to provide instantaneous reading of
motor rotation. Control is via two drivers which set up a closed loop position
regulation system. This involves encoder feedback and the position setpoint
required at any particular moment supplied by the automaton governing the
station.
These components allow the study of electric motors used in applications which
call for position control, increasing further the number of technologies
associated with automation which are dealt with by this flexible cell.

2.8.3. TECHNICAL DATA

Dimensions:
Table of slotted aluminium section, 900 x 650 mm.
Height 990 mm.
Methacrylate screening for user protection.

Air treatment unit:
Filter to 5 µm, pressure regulator and pressure gauge.

Pushbutton control:
Start, stop, reset pushbuttons. Emergency button and error pilot indicator.

Composition of station modules:
Vertical axis module
Actuators:

- Double-acting parallel rod cylinder Ø20, Stroke:75mm (CXSWM20-75), with flow
regulators and initial-end position detector. Controlled by 5/2 way monostable
solenoid valve.

- Holding: 4 suction cups Ø16 (ZPT16CNK10-B5-A10), with vacuum generating
ejector (ZH10BS-06-06). Controlled by 3/2 way monostable solenoid valve.

Sensors:
- Reed type magnetic detectors (D-Z73L).
- Digital vacuum switch PNP output (ZSE4B-01-65).

Positioning axes module
Actuators:

- Linear actuators (LJ1H20Y20SC-500-F-X1).
- Linear actuators (LJ1H10Y10SC-500-F-X1).
- Motors OMRON R88M-UE10030VS1 and R88M-U05030VAS1

Sensors:
- Reed type magnetic detectors (D-Z73L).

Input/ Output module:
- DeviceNet module 8 inputs/ 8 outputs.

35

Electrical control panel:
- Mounted on perforated mesh 550 x 400 mm.
- Accessible terminal plate with supply connections and coded I/Os.
- Thermal overload switch incorporated.
- I/O station: 15 inputs, 7 outputs.
- Linear actuator drivers R88D-UEP04V y R88D-UEP03V Omron.
- Driver programation console R88A-PRO3U Omron..
- PLC control (Omron):

- CPU Module: CQM1H-CPU51-NL.
- 16 input module CQM1-OC222
- Supply module CQM1-PA216
- Pulse generating card CQM1H-PLB21.
- DeviceNet slave Card for automaton network connection CQM1-DRT21.

36

3. 4-METRE TRANSFER LINE WITH
AUTOMATON AND PALLET ASSEMBLY

3.1.TRANSFER FUNCTION AND COMPOSITION.

The transport system is a line 4 metres long which links the layouts to facilitate the envisaged
assembly process.
The various layouts are linked up with the line by a quick assembly mechanical system.
The transfer follows a rectangular path, and is fitted with a control cabinet with integrated
automaton to organise and control the whole production sequence. This master automaton
controls the rest of the automatons connected into the RS-485 network.

Figure 40: Transfer

There is a longitudinal channel in the central area of the transfer to facilitate electrical
connections, air supply and connection between the transfer and the various handling
stations.
The transfer incorporates a pallet assembly to transport parts and assemblies between the
handling stations.
A safety button is fitted to the transfer to stop the whole system in case of emergency.
The central panel includes the master automaton which controls the entire process.

37

Figure 41: Transport system

All the transport system actuators, stoppers, lifters, positioners and pallet transfers are
operated by a system of solenoid valves connected to the central station.
Pneumatically-operated pushers unload the pallets from one section to another.
The stations are assembled using screwed joints incorporated for this purpose on both station
and transfer, enabling quick and precise assembly. In front of the station, there is a
mechanical stop to stop the pallets, an identification code reading system and, depending on
the particular process, a further series of elements for lifting, centring, turning, etc.
Both the pallet retention point and the relative position of the station may be varied, making
it simple to modify the distribution of the component bases of the cell.

3.2. TECHNICAL DETAILS OF TRANSFER

Dimensions:
2 sections 3900 x 130 mm. Height 970 mm.
Air treatment unit:
Filter to 5 µm, pressure regulator and pressure gauge with incorporated pressure switch.
Drive:
2 Three-phase motors 230V/1.8A 0.37kW.

38

Composition:
Actuators:

- 8 Compact double-acting cylinders Ø32, Stroke:25mm (ECQ2B32-25D-XSE040).
Controlled by 5/2 way monostable solenoid valves.

- 3 Compact double-acting cylinders with guide Ø16, Stroke:30mm (EMGQM16-30),
with flow regulators and initial-end position detector. Controlled by 5/2 way
monostable solenoid valves.

- Two-direction rotary actuator αmax:90º (MSUB3-90S), with flow regulators.
Controlled by 5/2 way monostable solenoid valve.

- 2 Rodless double-acting cylinders Ø20, Stroke:200mm (MY1B20G-200), with flow
regulators and initial-end position detector. Controlled by 5/2 way bistable solenoid
valves.

Sensors:
- Magnetic reed type detectors (D-Z73L and D-A93L).
- 24 capacitive detectors OMRON E2EG-X5MC1-M1.
- 2 capacitive detectors OMRON E2K-X8ME1.
- 8 microswitches OMRON V-166-1C5.

Electrical control panel:
- Cabinet- mounted 700 x 500mm. Depth 230mm.
- Accessible terminal plate with supply connections and coded I/Os.
- Thermal overload switch incorporated.
- I/O station: 5 inputs, 6 outputs.
- DeviceNet inputs supply source.
- DeviceNet outputs supply source.
- Start, stop, reset pushbuttons. 2 emergency buttons, and error indicator pilot, on line
and emergency.
- 2 Three-phase motor supply contactors.
- Net filter.
- Frequency converter.
- PLC control (Omron):
- CPU CS1G-CPU42-EV1
- Digital inputs module (16) C200H-ID212.
- Digital outputs module (16) C200H-OC226-NNL.
- Supply source C200HW-PA204-JPN.
- DeviceNet Master Card CS1W-DRM21.

39

4. INSTALLATION AND START-UP
4.1 PREREQUISITES

4.1.1 SPATIAL REQUIREMENTS

The FMS200 cell is designed for working with a maximum of eight stations
plus the transfer unit. In figure 44 we are shown the dimensions of the complete cell
and the working space necessary in order to be able to use it. In addition, the figure
provides us with the dimensions of each statio n for cases where a different
configuration is used.

Figure 42

To get the best performance from the system, the following recommendations
should be followed:
- The floor should be level and have no ridging.
- In the vicinity there must be no heavy machinery producing noise or vibration.
- The working environment must be dust free, with no splashing of liquids.
- Humidity normal with no condensation.
- As far as is possible, keep EMI (Electromagnetic Incompatibility) sources at a

distance.
- Check out the quality of the earth connection.
- Atmospheric temperature must be moderate and extremes of temperature avoided.

40

4.1.2 ELECTRICAL REQUIREMENTS

FMS200 electrical supply must be in line with these requirements:
- Full cell voltage: 220 V.
- Minimum power necessary:

Statio n 1, 2 , 4 , 5 y 6 = 71 VA
Station 3 = 633 VA
Station 7 = 67 VA
Station 8 = 671 VA
Transfer = 1082 VA
Complete cell total = 2810 VA

4.1.3 AIR REQUIREMENTS

Details are given below of the air requirements for each station and for the
whole cell:

Station 1:

Element Cycles Diameter Stroke Consum.l/cycle

CD85N16-100B 2 16 100 0.16
CD85N12-50B 2 12 50 0.0144
MDUB25 -200DM 2 25 200 0.7852
CJPB10-15H6 1 10 15 0.0044
CXSWM20-150-XB11 2 20 150 0.3768
CXSM15-50 4 15 50 0.1412
ZU07S 19 l/min
CYCLE TIME 10 sec
STATION 1 TOTAL 28.l/min

Station 2:

Element Cycles Diameter Stroke Consum.l/cycle

CD85N16-100B 2 16 100 0.16
MSQB50A 2 - - 0.32
MHK2-16D 4 16 0.056
CQ2B12 - 5S 1 12 10 0.0022
MY1B16G-250 2 16 5 0.4018
CD85N10-40 2 10 250 0.0125
EMRQBS32 -25CB 4 32 0.3214
2 - 40 0.084
CYCLE TIME 20 sec 25
STATION 2 TOTAL 4.1 l/min -

Station 3:

Element Cycles Diameter Stroke Consum.l/cycle

MSQB50A 2 - - 0.32
CD85N12-125A 4 12 125 0.226
CXSM15-100 2 15 100 0.1413
ZU07S 19 l/min
CYCLE TIME 22 sec
STATION 3 TOTAL 20.8 l/min

41

Station 4:

Element Cycles Diameter Stroke Consum.l/cycle

CDQ2B25-40D 16 25 40 1.256
10 0.2572
CQ2B16 - 10D 32 16 10 0.0125
50 0.0452
CD85N10-10B 4 10 10 0.028
50 0.0706
CD85N12-50A 2 12 - 0.0248
100 0.1413
MHK2-16D 2 16 50 0.0628
25
CXSM15-50 2 15 - 0.3214
0.084
MSUB3 - 180S 2 -

CXSM15-100 2 15

CXSM10-50 4 10

EMRQBS32 -25CB 4 32

2-

ZU05S 19 l/min

CYCLE TIME 4 sec

STATION 4 TOTAL 53.5 l/min

Station 5:

Element Cycles Diameter Stroke Consum.l/cycle

CDQ2B25-40D 16 25 40 1.256
10 0.2572
CQ2B16 - 10D 32 16 100 0.1607
25 0.6428
CD85N16-100B 2 16 - 0.168
10 0.056
EMRQBS32 -25CB 8 32 50 0.1256
100 0.1413
4- 50 0.0628

MHK2-16D 4 16

CE1B20-50 2 20

CXSM15-100 2 15

CXSM10-50 4 10

ZU07S 19 l/min

CYCLE TIME 6 sec

STATION 5 TOTAL 47.7 l/min

Station 6:

Element Cycles Diameter Stroke Consum.l/cycle

CD85N10-10B 4 10 10 0.0125
100 0.2512
CXSWM20-100 2 20 200 0.785
50 0.1413
CXSWM25-200-XB11 2 25 10 0.028

CXSM15-50 4 15

MHK2-16D 2 16

CYCLE TIME 30 sec

STATION 6 TOTAL 2.4 l/min

Station 8:

Element Cycles Diameter Stroke Consum.l/cycle

CXSWM20-75 4 20 75 0.3768

ZH10BS - 06 -0 6 34 l/min

CYCLE TIME 17 sec

STATION 8 TOTAL 35.3 l/min

42

Transfer:

Element Cycles Diameter Stroke Consum.l/cycle

ECQ2B32-25D-XSE040 16 32 25 1.2861
30 0.1447
EMGQM16 - 30 6 16 - 0.0496
200 1.005
MSUB3 - 90S 4 -

MY1B20G-200 4 20

CYCLE TIME 40 sec

TRANSFER TOTAL 3.7 l/min

COMPLETE CELL = 28 + 4.1 + 20.8 + 53.5 + 47.7 + 2.4 + 35.3 + 3.7 = 195.5 l/min

Considering that 100 l/min is equivalent to 1CV, a 1.95 CV or 1.43 kW
(which is the same) compressor is required.

4.2 HANDLING AND PACKAGING

The packaging is designed to protect the modules from physical, chemical or
mechanical attack that might be produced during handling and transportation.

For transoceanic transportation, the packaging is treated with waterproofing
and dehydrating elements so as to provide protection against the effects of steam, salt
spray, dust and other external agents that might damage module components.

Details are given below of the packaging characteristics for each module:

Station 1 Base Height Volume
Station 2 1000 x 700 1450 mm
Station 3 1000 x 700 1450 mm 1.015 m3
Station 4 1000 x 700 1450 mm 1.015 m3
Station 5 1000 x 700 1870 mm 1.015 m3
Station 6 1000 x 700 1450 mm 1.309 m3
Station 7 1000 x 700 2010 mm 1.015 m3
Station 8 1000 x 700 2010 mm 1.407 m3
Transfer 1000 x 700 1920 mm 1.407 m3
4200 x 1400 1120 mm
1.344 m3

6.586 m3

When handling, loading and unloading the packaging, it is advisable to
employ appropriate equipment such as lift trucks. Once unloaded the stations can be
transported by a minimum of two people, while the transfer requires a minimum of
four. The boxes must be kept vertical at all times and must, under no circumstances,
be piled one on top of another or have other objects placed on top.

43

When proceeding to unpacking, it is advisable to observe the following procedure:
1) In the first place, make sure there is enough room to carry out the unpacking

process. We recommend, as a minimum, that there be a free surface area more
than three times the space occupied by each packaging.
2) Next, it is necessary to cut the straps that fasten the four seals at the bottom of the
box. These are then raised so as to be able to lift the lid.
3) Two or more people must raise the lid that covers the station and store it where it
will not get in the way of the following phases.
4) The next move is to loosen the wood pieces that secure the station to the bottom
of the packaging. The best idea is to loosen only the top pieces, as the station can
be extracted without freeing all the others: it can also prove useful to keep them
for possible transportation in the future. In this operation suitable tools will be
required for taking out the coach screws or nails that hold the wood in place.
5) When this operation is complete, the station must be transferred from the base of
the packaging on to the floor of the space where the unpacking operation is taking
place: at least two people are required to do this. It is advisable to check that all
the components listed on the station delivery note are included.
6) The station has wheels, which means that it can be transported easily and
effortlessly to the place where it will be used.

4.3 INSTALLATION

4.3.1 INDIVIDUAL STATION

If there are any individual stations, they come with a tray with a pallet for
placing the pieces. In order to avoid problems in the transportation process, the tray
with the supporting pallet for the piece to be assembled has been placed in the
position indicated in figure 45.

Figure 43

When installing the station, the tray has to be disassembled so that it can then
be placed with the pallet facing upwards, as shown in figure 46.

44