Tallinna Tehnikaülikool

Energeetikateaduskond

Elektriajamite ja jõuelektroonika instituut

Elmo Pettai

Tootmise automatiseerimise erikursus Desciption of Multi-FMS system

Projekt 1.0101-0278

„Interdistsiplinaarse ja rahvusvahelise meeskonna- ja projektipõhise õppe rakendamine elektriajamite ja jõuelektroonika, automaatika ja

mehhatroonika valdkonna magistriõppes”

Metoodiline materjal üliõpilastele

Tallinn 2006

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Contents 1 Training system of the laboratory of Industrial Automation ………………….. 3 1.1 General ………………………………………………………………………… 3 1.2 Organisation of equipmet ……………………………………………………… 3 1.3 Combinations of equipment …………………………………………………… 3 1.4 FMS system overview ………………………………………………………… 4 2 Control system …………………………………………………………………. 5 2.1 Control concept ………………………………………………………………… 5 2,2 System interfaces ………………………………………………………………. 5 3 Multi-FMS stations ……………………………………………………………. 6 3.1 Closed loop conveyor system …………………………………………………. 6 3.2 Material Testing Station ……………………………………………………….. 6 3.3 Material Distributing Station …………………………………………………… 7 3.4 CNC feeding robot …………………………………………………………….. 7 3.5 Milling machining center EMCO Mill 105 ……………………………………. 8 3.6 Robot station and Assembly Station for assembly work cell ………………….. 9 3.7 Two axis handling station ……………………………………………………… 9 3.8 Sorting station ………………………………………………………………….. 10 3.9 Processing Station ……………………………………………………………… 11 3.10 Buffering conveyors …………………………………………………………… 11 4 Software ……………………………………………………………………....... 11 4.1 The FMS installation software …………………………………………………. 11 4.2 Virtual PLC-Learning Environment …………………………………………… 12 4.3 SCADA software for operating, visualization and supervisory of the system … 12 4.4 CAD/CAM software …………………………………………………………… 12 4.5 Teach ware …………………………………………………………………….. 12

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1 Training system of the laboratory of Industrial Automation 1.1 General

In November 2005 department of Elecreical Drives and Power Electronics got modular equipment, including modern factory simulation system named MultiFMS (Flexible Manufacturing System) for laboratory of industry automation. The system can cover the following technologies:

- Electrical drives - Mechatronics - Electro - pneumatic - PLC programming - Fieldbus system - Robot programming simulation - Robot assembly - CNC-machine feeding with robot - CNC programming and simulation - Closed loop material flow system - Sensor technologies - Frequency converter - I/O communication - Conveyors - AC motors - Positioning systems - Analogue Measuring system - Handling technology - Real-time data communication

between machines

Pneumatics

Mechanics

PLC

Networking

Sensorics

El Drives

Safety

Software Basics

Mechatronics

Quality

Robotics

Controller

CAD CAM CNC

Factory Automation

CIM / FMS

VR

WEB ERP / MES

Simulation

Electronic

Microcontroller

CNC

C++

Electric

Education in the scope of Industrial Automation and Mechatronics

Dig Factory

Fig. 1 Field of supported technologies

1.2 Organisation of equipment The system is built by Festo Didactic GmbH & Co. Festo Multi FMS system consists of two separate manufacturing systems Festo Micro FMS and Festo FMS50. This system itself subdivides to the following stations shown on fig. 2.

1 - Conveyor system 2 - Testing station 3- Distribution station 4 - 6 axis robot with slide for CNC

feeding 5 - CNC milling machine Mill 105 6 - Place for CNC programming station 7 - Assembly with 5 axis robot station 8 - Handling station 2 9 - Sorting station 10 - Buffering conveyors 11 - Handling station 1 12 - Processing station 13 - Place for SCADA workstation

Fig. 2. Micro FMS and FMS 50 are put together

1.3 Combinations of equipment The stations are able to operate independently and in the system. The stations itself have a flexible built up, like an LEGO constructor system. The central element in FMS 50 system is transport conveyor. All of the other stations can be in connection with this station. It is possible to combine the stations in at least 5 different configurations. (See fig. 3). This means that student can explore exercises with different hardware configuration. For studying purposes different types of sensors, pneumatic and electrical drives are used in the system. Until now (because the financial problems) there exists three empty places for new machines. This means, that some stations are missing in our system setup, but they are planned to be added.

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- Single stations 2, 3, 4, 5 and 6, 7, 8, 9, 4 and

10, 11, 12, 13, - Combination 1, 2, 3, - Combination 2, 3, 11, 12 - Combination 4, 10, 5, 6 - Combination 3, 2, 1, 7, 8, 9 - All stations linked with the conveyor system

(3).

Fig. 3. FMS 50 stations build up in a row

1.4

FMS system overview CIM/FMS training system is made with industrial components. (See fig. 4) The work-piece processed in these stations has 3 different variants and have been designed to be assembled by robot. At least 4 different components can be assembled to form the final work-piece. A multimedia-training environment is being available for the system components. A SCADA solution in development environment InTouch (from firm Wonderware) is available for FMS stations. Virtual, model based learning environment for integrated CIM/FMS system is being available (Cosimir Educational and Cosimir Professional). All FMS stations except the conveyor system are mounted on mobile trolleys. The bidder guarantees the compatibility of all the subsystems in terms of electrical, mechanical and software interfaces. The FMS system include 6 Siemens S7 300 type controllers, 2 Allen Bradley CompactLogix 1769 L35E type controllers and 1 (Festo) Industrial type controller. CNC machine uses for control system a PC. Each robot has its control system.

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Fig. 4. Multi FMS System overview

2 Control system 2.1 Control concept

The system consists of multiple work cells and separate control units (PLC or robot control unit) for each machine. They are designed to put it underneath the profile plates of the stations. The control architecture has decentralized control structure and provide at least 4 different levels according the industrial standards: - Machine level - Field level - SCADA level - Remote access supervisory level. 1) I/O communication between the stations and conveyor for educational purposes. - This - I/O-Interface must guarantee the basic operation of the system even if the other communication (Profibus/Ethernet) is not active. - The I/O Interface work with standard connectors IEEE488 on 24 VDC level - The I/O Interface is realized using a simulation box for faultfinding and PLC simulation.

2) AS-I communication operates in the field level of Actuators and Sensors 3) Ethernet communication is used in the field level of PLC controllers

and SCADA workstations. (Additionally Profibus-DP communication for Siemens PLC-s)

- The different firm PLC-s of the System is able to communicate with each other via Ethernet 10/100.

- Each PLC is be able to communicate to the SCADA station via Ethernet (or Profibus-DP using RS232 interface in SCADA PC) 4) Ethernet TCP/IP communication on the level of remote supervisory (See fig. 5).

SWITCHCONVEYER

CONTROLLER

WORK-CELL 1

WORK-CELL 2

WORK-CELL 3

WORK-CELL 4

WORK-CELL 5

WORK-CELL 7

WORK-CELL 6

MULTIMASTER

Fig. 5 Control system stations use Ethernet

TCP/IP connections

2.2 System Interfaces All subsystems are equipped with standardized Interfaces. The digital I/O signals are concentrated at each station on I/O terminal blocks with LED indicators for easy diagnosis and fault finding. I/O terminal blocks are equipped with IEEE488/24 pin connector.

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The connections between controllers and stations have take place via a standardized cabling system with IEEE488/24 pin Connectors. A test equipment to check all I/O signals are available for simulation of inputs and outputs. It must be possible to strobe the simulated output signals simultaneously by the means of a strobe switch.

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Multi-FMS stations

3.1 Closed loop conveyor system It is a pallet transfer system designed to transport the work-pieces from one work-cell to the next (See fig. 6). It is built of stable and rigid, anodized aluminum profile. The following features are fulfilled: - Length 3000 mm and width 500 mm - It is modular with 4 segments, each with one AC drive - Two conveyor segments in the length, each 3000 mm - Two conveyor segments in the width, each 500 mm - Sensors and actuators networked via AS-Interface bus system - 6 working positions - Pallet identification at each working position - Speed variation of the conveyor - The pallets must keep front side in moving direction - Three accusable emergency stop buttons The PLC control cabinet include: - One Industrial type PLC from Siemens - Ethernet interface (and additionally Profibus-DP interface for

Siemens controllers) - AS-I master interface and power supply - Frequency converter for speed variation - Central emergency system - Control panel

Fig. 6 Closed loop conveyor system

3.2 Material Testing Station

The testing station (See fig. 7) is designed to recognize the material and the color of the work-pieces (red, black, moralized) and to measure the height of the work-pieces by the means of a linear analog sensor. Additionally the following features are fulfilled: - Station mounted on a grooved aluminum profile plate - Dimensions 350 x 700 mm, distance of grooves 50 mm - Sensors and actuators connected to a terminal block with

LED indicators for status of sensors and actuators. - Standardized terminal block connector IEEE488/24 pin - Standard I/O cabling with 8 inputs, 8 outputs and 24 VDC - Compact valve block with 10mm grid - One work-piece recognition module - One optical sensor - One Inductive sensor - One capacitive sensor - One linear analog sensor - One comparator with threshold potentiometers (2x) - One double acting rod less lifting cylinder - Four magnetic cylinder sensors - One pusher cylinder - Two slides for work-pieces - One safety optical reflex sensor - Material flow handshake signal via optical receiver - Material flow handshake signal via optical transmitter - Pneumatic maintenance unit with filter and pressure regulator - Station assembled on a mobile trolley equipped with its own PLC board Operator panel. is designed to be mounted at the front side of the mobile trolleys. It is compatible to the 19” electronic system. Additionally the following features are fulfilled: - Two illuminated push buttons - One additional push button - One key switch - Two LED indicators - 10 safety sockets for auxiliary I/O for communication - Interface to the PLC board via IEEE488/24 pin The PLC board is designed to control the different stations. The system interface must fit to the standard cabling system of the stations. It is designed to put it underneath the profile plates of the stations. The board control both, the stations and the control panel. Additionally the following features are fulfilled:

Fig 7. Material Testing Station

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- Industrial CPU with Profibus-DP for example: S7-313C-2DP and Ethernet communication module

- I/O Module for Station 8Inputs / 8Outputs - I/O Module for Station 8Inputs / 8Outputs - Emergency switch input - Board of sheet metal Adapter for communication with programming PC and cable for Ethernet switch

3.3 Material Distributing Station

The magazine station (See fig. 8) is designed to separate work-pieces out of a gravity magazine and to feed the work-pieces by the means of a pic&place device to the following station. Additionally the following features are fulfilled: - Station mounted on a grooved aluminum profile plate - Dimensions 350 x 700 mm, distance of grooves 50 mm - Sensors and actuators connected to a terminal block with

LED indicators for status of sensors and actuators. - Standardized terminal block connector IEEE488/24 pin - Standard I/O cabling with 8 inputs, 8 outputs and 24 VDC - Compact valve block with 10mm grid - One gravity feed magazine with tube of transparent plastic - One double acting cylinder for work-piece separation - One rotating cylinder with parallel guided arm as pic&place - One vacuum gripper with ejector - One vacuum sensor - Two micro limit switches - One optical light barrier for work-piece detection - Two magnetic cylinder sensors - Material flow handshake signal via optical receiver - Pneumatic maintenance unit with filter and pressure regulator - Station assembled on a mobile trolley - Must be equipped with its own PLC board Operator panel. It is designed to be mounted at the front side of the mobile trolleys. It is compatible to the 19” electronic system. Additionally the following features are fulfilled: - Two illuminated push buttons - One additional push button - One key switch - Two LED indicators - 10 safety sockets for auxiliary I/O for communication - Interface to the PLC board via IEEE488/24 pin The PLC board is designed to control the different stations. The system interface fits to the standard cabling system of the stations. It is designed to put it underneath the profile plates of the stations. The board control both, the stations and the control panel. Additionally the following features are fulfilled: - Industrial CPU with Profibus-DP for example: S7-313C-2DP and Ethernet

communication module - I/O Module for Station 8Inputs / 8Outputs - I/O Module for Station 8Inputs / 8Outputs - Emergency switch input - Board of sheet metal - Adapter for communication with programming PC and cable for Ethernet

switch

Fig 8. Material Distributing Station

3.4 CNC feeding robot

The CNC feeding robot station (See fig. 9) is designed to feed and reload both integrated CNC machines from and into buffering units and also incoming goods work cell. The following parameters included: Robot arm - Construction : vertical articulated - Number of axes : 6 revolute axes + gripper - Gripper type : pneumatic parallel 2 fingers - Rated load : 1 kg including the gripper - Repeatability : +/- 0.04 mm - Resultant speed : 3500 mm/S (max.)

Drive method : AC servomotor Robot controller: - Number of positions: 2500 each program - Number of programs: 88 - Number of program steps: 5000 - Number of I/O: 16 / 16 - Teach Box with deadman switch

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- Robot Interface adapter with LED indicators for all Inputs/Outputs - Ethernet device - Multitasking Linear slide axis to move robot as a 7th axis: - Tooth-belt drive - DC-servo unit including incremental encoder - High levels of process reliability tanks to integration of air and cables in

protective conduits - Length: 3000 mm - Accuracy +/- 0.5 mm - High-speed positioning up to 5 m/s [16 ft/s] - Driven y the robot controller as a 7th axis

Fig 9. CNC feeding robot

3.5 Milling machining center EMCO Mill 105

(See fig. 10) Machine features: - Longitudinal travel (X-axis): 200 mm - Cross travel (Y-axis): 150 mm - Vertical travel (Z-axis): 250 mm - Useful Z stroke: 150 mm - Distance spindle 95-245 mm - Milling table (LxW): 420x125 mm, max 10 kg - Main Drive power: 1.0 kW (100%) - Main Drive Speed range: 150 – 5000 rpm (step-less) - Feed Drive (X/Y/Z): 3-phase step motor - Speed Rapid traverse: 4 m/min - Step resolution: 0,0015 mm - Magazine tool system: drum with directional logic - Number of tool stations: 10 - Tool mounting: similar to DIN 2079, SK 30 - Lubrication (option): grease oil central for

Guideways - Dimensions (LxDxH): 1135x1100x1100 mm - Weight: up to 450 kg Automation accessories: - Automatic vice - 10 station automatic tool changer - Automatic door - Robotic-Interface - DNC-Interface

CNC Controller: - PC-based control software which emulates the Siemens

SINUMERIC 840D or Fanuc 21 controller - Control panel with original keyboard layout of Fanuc 21 or

SINUMERIC 840D incl. connection cable RS232C - Personal Computer with 15“ s VGA monitor - Communication serial, I/O, TCP/IP Documented solutions that covered - Design work piece - Simulate CNC milling - Analyze situation - Implement robot/CNC machine communication. - Teach robot positions precisely etc.

Fig. 10. Milling machining center EMCO Mill 105

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3.6

Robot station and Assembly Station for assembly work cell The robot assembly station (See fig. 11) is designed to assemble a work-piece consisting at minimum of 4 subparts. The station recognizes the type (colors) of the work-piece by the means of sensors. There is a device / process to find the correct orientation of a symmetrical cylindrical part for proper assembly process. The following features are fulfilled: - Industrial robot with 5 axis plus pneumatic gripper - Path control - Repeatability max +/-0,02 mm - Velocity min 2100mm/s - Handling load min. 2 kg - Reach min. 410 mm - AC servo drives with absolute encoders - Number of positions: 2500 each program - Number of programs: 88 - Number of program steps: 5000 - Number of I/O: 16 / 16 - Teach Box with dead man switch - Robot Interface adapter with LED indicators for all

Inputs/Outputs - Station mounted on two grooved aluminum profile plates - Sensors and actuators connected to a terminal block with

LED indicators for status of sensors and actuators. - Standardized terminal block connector IEEE488/24 pin - Standard I/O cabling with 8 inputs, 8 outputs and 24 VDC - Gravity feed magazine - Double acting rod less cylinder for work-piece separation - Special spring magazine - All magazine tubes of transparent plastic - Pallet for work-pieces - Assembly fixture with orientation sensor - 2 slides for work-pieces - Material flow handshake signal via optical receiver - Material flow handshake signal via optical transmitter - Pneumatic maintenance unit with filter and pressure regulator - Station assembled on two trolleys - Interface board for Profibus communication Operator panel. It must be designed to be mounted at the front side of the mobile trolleys. It must be compatible to the 19” electronic system. Additionally the following features must be fulfilled:

- Two illuminated push buttons - One additional push button - One key switch - Two LED indicators - 10 safety sockets for auxiliary I/O for communication Interface to the PLC board via IEEE488/24 pin

Fig. 11. Robot station and Assembly Station

3.7 Two axis handling station

(two stations are required) The 2 axis pneumatic handling station (See fig. 12) is designed for a wide range of pic&place tasks. It is possible to pick a work-piece at height level 1 and place it to a height level 2, which is different to level 1. The stroke of the x-axis as well as the height levels is adjustable easily. Additionally the following features are fulfilled: - Station mounted on a grooved aluminum profile plate - Sensors and actuators connected to a terminal block with

LED indicators for status of sensors and actuators. - Standardized terminal block connector IEEE488/24 pin - Standard I/O cabling with 8 inputs, 8 outputs and 24 VDC - Compact valve block with 10mm grid - Rod less double acting linear cylinder with high precision ball bearings - Flat cylinder as a Z-axis - Pneumatic parallel gripper - 6 micro magnetic cylinder switches with LED indicator - 2 slides for work-pieces - Material flow handshake signal via optical receiver - Material flow handshake signal via optical transmitter - Pneumatic maintenance unit with filter and pressure regulator - Station assembled on a mobile trolley

Fig.12. Two axis handling station (two

stations are required)

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- Must be equipped with its own PLC board Operator panel. It is designed to be mounted at the front side of the mobile trolleys. It is compatible to the 19” electronic system. Additionally the following features are fulfilled: - Two illuminated push buttons - One additional push button - One key switch - Two LED indicators - 10 safety sockets for auxiliary I/O for communication - Interface to the PLC board via IEEE488/24 pin The PLC board is designed to control the different stations. The system interface fit to the standard cabling system of the stations. It is designed to put it underneath the profile plates of the stations. The board control both, the stations and the control panel. Additionally the following features are fulfilled: - Industrial CPU with with Allen Bradley CompactLogix processor 1769 L35E - I/O Module for Station 8Inputs / 8Outputs - I/O Module for Station 8Inputs / 8Outputs - Emergency switch input - Board of sheet metal

Adapter cables for communication with programming PC RS232 port and Ethernet switch

3.8 Sorting station

The conveyor commissioning station (See fig.13) is designed to recognize the type of incoming work-piece and to sort them to 3 different output slides according their different features. The following features are fulfilled: - Station mounted on a grooved aluminum profile plate - Sensors and actuators connected to a terminal block with

LED indicators for status of sensors and actuators. - Standardized terminal block connector IEEE488/24 pin - Standard I/O cabling with 8 inputs, 8 outputs and 24 VDC - Compact valve block with 10mm grid - 2 Pneumatic shunt cylinders - 3 output slides - 1 inductive sensor - 1 optical sensor - 6 micro magnetic cylinder switches with LED indicator - 1 conveyor with 40 mm track - 1 DC motor - Material flow handshake signal via optical receiver - Material flow handshake signal via optical transmitter - Pneumatic maintenance unit with filter and pressure regulator - Station assembled on a mobile trolley - Must be equipped with its own PLC board Operator panel is designed to be mounted at the front side of the mobile trolleys. It is compatible to the 19” electronic system. Additionally the following features fulfilled: - Two illuminated push buttons - One additional push button - One key switch - Two LED indicators - 10 safety sockets for auxiliary I/O for communication - Interface to the PLC board via IEEE488/24 pin The PLC board is designed to control the different stations. The system interface fit to the standard cabling system of the stations. It is designed to put it underneath the profile plates of the stations. Both, the stations and the control panel is controlled by the boards. Additionally the following features fulfilled: - Industrial CPU with Profibus-DP for example: S7-313C-2DP and Ethernet

communication module - I/O Module for Station 8Inputs / 8Outputs - I/O Module for Station 8Inputs / 8Outputs - Emergency switch input - Board of sheet metal Adapter for communication with programming PC and cable for connecting to Ethernet switch

Fig.13. Sorting station

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3.9 Processing Station The processing station (See fig. 14) is designed as a pure electrical station without any pneumatic components. At least 5 different electrical drives must be included in the station. Workpieces must be transported and processed on a electrical driven indexing table. Additionally the following features fulfilled: • Station mounted on a grooved aluminum profile plate • Dimensions 350 x 700 mm • Distance of grooves 50 mm • Sensors and actuators connected to a terminal block with

LED indicators for status of sensors and actuators. • Standardized terminal block connector IEEE488/24 pin • Standard I/O cabling with 8 inputs, 8 outputs and 24 VDC • Turntable with 6 compartments for workpieces 40mm • DC motor with worm drive • Magnetic linear testing actuator • Magnetic linear clamping actuator • DC geared motor with tooth belt drive • Linear slide with ball bearings • Electrical drilling machine • Electrical rotating actuator • Inductive positioning sensor • Capacitive workpiece detection sensor • Two relays for direction control of the motor • Two micro limit switches • Material flow handshake signal via optical receiver • Material flow handshake signal via optical transmitter • Station assembled on a trolley 350x700x750mm with 4 castors

Fig.14. Processing station

3.10 Buffering conveyors

The buffering units (See fig. 15) are three single conveyors with DC drives and stoppers. One for material input and the other for material output. The conveyors communicate with the CNC feeding robot controller via I/O.

Fig.15 Buffering conveyors

4 Software 4.1 The FMS installation software

1. PLC programming software (for 3 controller types) Software for programming and simulation of PLC applications.

The software is compatible with the integrated PLC-s. 6 licenses e.g. Step 7 included for Siemens S7-300; 3 licenses RSLogix5000 included for Rockwell Automation CompactLogix controllers

2. Virtual PLC Learning software (for 2 controller types) 3. Robot programming (MelfaBasik IV; Cosimir Educational, Cosimir Professional). 4. Virtual robot-learning software (Cosimir Educational) 5. SCADA software (InTouch) 6. CAD/CAM Software

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4.2 Virtual PLC-Learning Environment

The PLC-Learning environment is a software package running under Windows 98 or higher up to Windows XP, (See fig. 16). Following features are fulfilled: - 3D-simulation of production cells including all 10 workstations - Graphic representation is based on OPEN GL standard - Sensor simulation of various types of sensors - Collision detection with the option to select objects being checked

for collision. - View point and distance can be easily changed via mouse and

keyboard - It is possible to open several view windows and simulation will be

done in all windows at the same time. - Simulation sequences can be saved with predefined viewpoints as

avi-files using different compression methods - Displays status of I/O connections - The control of a simulated automation work cell is done by a the

internal simulated internal PLC. - Simulation of more than one PLC in one work cell must be possible - Easy generation of time-cycle diagram without programming to test

actor behavior and to prepare programming must be possible - Software licensing via network license key or online registration Troubleshooting:

- Setting of faults based on statistics from the used components - Resetting of faults - online display of time-cycle diagram to compare with predefined diagrams

6 licenses included

Fig.16 Virtual PLC-Learning Environment

4.3 SCADA software for operating, visualization and supervisory of the system - The SCADA system use both, PROFIBUS and Ethernet

communication with the PLC controllers of the stations. OPC servers are provided.

- The SCADA software is typical industrial type such as InTouch - Remote access and remote supervisory functions via Internet must

be provided (12 student licenses included)

4.4 CAD/CAM software A CAD/CAM software for Milling and Lathing incl. 2 and 3D machining simulation as well as DXF DATA import and NC-processor for Fanuc or Sinumerik is included. Class (12) licenses for WinCam Mill type of CAD/CAM software included

4.5 Teach ware Training media language is English and some German. Integrated Systems CIM/FMS training media for teacher and for student is available for all cells, stations and Factory level system as well. Sample controller (PLC) control programs are provided. Training documentation and courseware include following topics: Fundamentals of open- and close-loop control; Sensors; Actuators; Programming software for instructor and students (Siemens Step 7 including Graph, S7-PLCSIM and Rockwell Automation RSLogix 5000);

CNC technology with cutting technology and NC programming; Mechatronics; Robot technology; Automated production, Production organization, planning, link to common ERP systems; The Festo Dictionary of Automation; Documentation provided at the same time with installed equipment - One set on paper, - One set on CD.