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
Contents
1
1.1
1.2
1.3
1.4
2
2.1
2,2
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
4
4.1
4.2
4.3
4.4
4.5
Training system of the laboratory of Industrial Automation …………………..
General …………………………………………………………………………
Organisation of equipmet ………………………………………………………
Combinations of equipment ……………………………………………………
FMS system overview …………………………………………………………
Control system ………………………………………………………………….
Control concept …………………………………………………………………
System interfaces ……………………………………………………………….
Multi-FMS stations …………………………………………………………….
Closed loop conveyor system ………………………………………………….
Material Testing Station ………………………………………………………..
Material Distributing Station ……………………………………………………
CNC feeding robot ……………………………………………………………..
Milling machining center EMCO Mill 105 …………………………………….
Robot station and Assembly Station for assembly work cell …………………..
Two axis handling station ………………………………………………………
Sorting station …………………………………………………………………..
Processing Station ………………………………………………………………
Buffering conveyors ……………………………………………………………
Software …………………………………………………………………….......
The FMS installation software ………………………………………………….
Virtual PLC-Learning Environment ……………………………………………
SCADA software for operating, visualization and supervisory of the system …
CAD/CAM software ……………………………………………………………
Teach ware ……………………………………………………………………..
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5
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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
Dig Factory
Factory Automation
ERP / MES
Mechatronics
Networking
Basics
PLC
Electric
Quality
Robotics
Sensorics
El Drives
Controller
CIM / FMS
CAD CAM CNC
Simulation
Safety
WEB
Microcontroller
VR
C++
Software
Electronic
Pneumatics
CNC
Mechanics
Education in the scope of Industrial Automation and Mechatronics
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.
3
-
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 workpiece.
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.
4
Fig. 4. Multi FMS System overview
2 Control system
2.1 Control concept
MULTIMASTER
The system consists of multiple work cells and separate control units
WORK(PLC or robot control unit) for each machine. They are designed to put it
CELL 6
underneath the profile plates of the stations.
WORKWORKThe control architecture has decentralized control structure and provide
CELL 5
CELL 7
at least 4 different levels according the industrial standards:
Machine level
Field level
CONVEYER
SCADA level
WORKSWITCH
CONTROLLER
CELL 4
Remote access supervisory level.
1) I/O communication between the stations and conveyor for
educational purposes.
WORK- This - I/O-Interface must guarantee the basic operation of the system
WORKCELL 1
CELL 3
even if the other communication (Profibus/Ethernet) is not active.
WORKCELL 2
- The I/O Interface work with standard connectors IEEE488 on 24 VDC
level
Fig. 5 Control system stations use Ethernet
- The I/O Interface is realized using a simulation box for faultfinding and
TCP/IP connections
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).
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.
5
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.
3
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:
6
Fig 7. Material Testing Station
-
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
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
7
Fig 8. Material Distributing Station
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):
Cross travel (Y-axis):
Vertical travel (Z-axis):
Useful Z stroke:
Distance spindle
Milling table (LxW):
Main Drive power:
Main Drive Speed range:
Feed Drive (X/Y/Z):
Speed Rapid traverse:
Step resolution:
Magazine tool system:
Number of tool stations:
Tool mounting:
Lubrication (option):
Guideways
Dimensions (LxDxH):
Weight:
200 mm
150 mm
250 mm
150 mm
95-245 mm
420x125 mm, max 10 kg
1.0 kW (100%)
150 – 5000 rpm (step-less)
3-phase step motor
4 m/min
0,0015 mm
drum with directional logic
10
similar to DIN 2079, SK 30
grease oil central for
1135x1100x1100 mm
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.
8
Fig. 10. Milling machining center EMCO Mill 105
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
Fig. 11. Robot station and Assembly Station
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
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
9
Fig.12. Two axis handling station (two
stations are required)
-
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
Fig.13. Sorting station
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
10
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.
2.
3.
4.
5.
6.
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
Virtual PLC Learning software (for 2 controller types)
Robot programming (MelfaBasik IV; Cosimir Educational, Cosimir Professional).
Virtual robot-learning software (Cosimir Educational)
SCADA software (InTouch)
CAD/CAM Software
11
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 Fig.16 Virtual PLC-Learning Environment
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
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.
12