LEARNING ACTIVITY PACKET MECHATRONICS PICK AND PLACE FEEDING B72001-AA03UEN

Transcription

1 MECHATRONICS LEARNING ACTIVITY PACKET PICK AND PLACE FEEDING B72001-AA03UEN

2 LEARNING ACTIVITY PACKET 3 PICK AND PLACE FEEDING INTRODUCTION Automated material delivery systems are a key component in most mechatronics systems. They automatically move parts from one location to the next as needed. Pick and place feeding systems are one type of material delivery system used in mechatronics. This LAP reviews different types of material handling systems, their adjustment, and programming. ITEMS NEEDED Amatrol Supplied: 87-MS1 Pick and Place Feeding Station 870-PS7313-AAU, 870-PS7314-AAU, or 870-PS7315-AAU Mechatronics Learning System for Siemens S one per station Siemens S7-300 Programming Cable Siemens Step 7 Programming Software School Supplied: Computer with Windows XP Operating System Amatrol or School Supplied Hand Tool Kit or Equivalent FIRST EDITION, LAP 3, REV. B Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Technovate are trademarks or registered trademarks of Amatrol, Inc. All other brand and product names are trademarks or registered trademarks of their respective companies. Copyright 2012, 2011 by AMATROL, INC. All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any means, electronic, optical, mechanical, or magnetic, including but not limited to photographing, photocopying, recording or any information storage and retrieval system, without written permission of the copyright owner. Amatrol,Inc., 2400 Centennial Blvd., Jeffersonville, IN USA, Ph , FAX

3 TABLE OF CONTENTS SEGMENT 1 STATION OPERATION OBJECTIVE 1 Describe three types of material feeding systems: ASRS, servo robot, and non-servo pick and place OBJECTIVE 2 Describe the operation of a powered parts feeder OBJECTIVE 3 Describe the operation of a pick and place pneumatic manipulator SKILL 1 Operate a pick and place feeding station SEGMENT 2 COMPONENT ADJUSTMENT OBJECTIVE 4 Describe how to adjust a vacuum gripper SKILL 2 Adjust a vacuum gripper OBJECTIVE 5 Describe how to adjust a vacuum switch SKILL 3 Adjust a vacuum switch OBJECTIVE 6 Describe how to adjust a shock absorber SKILL 4 Adjust a shock absorber SEGMENT 3 MODULE SEQUENCING OBJECTIVE 7 Describe a sequence of operation of a powered parts feeder SKILL 5 Design a PLC program that sequences a powered parts feeder OBJECTIVE 8 Describe a sequence of operation of a 2-axis pick and place manipulator SKILL 6 Design a PLC program that sequences a 2-axis pick and place pneumatic manipulator SEGMENT 4 STATION SEQUENCING OBJECTIVE 9 Describe a sequence of operation of a pick and place feeding station SKILL 7 Design a PLC program that sequences a pick and place feeding station OBJECTIVE 10 Describe the operation of a pick and place feeding station with manual/auto/reset functions SKILL 8 Design a PLC program that provides manual/auto/reset functions for a pick and place feeding station 3

4 SEGMENT 1 STATION OPERATION OBJECTIVE 1 DESCRIBE THREE TYPES OF MATERIAL FEEDING SYSTEMS: ASRS, SERVO ROBOT, AND NON-SERVO PICK AND PLACE Material feeding systems deliver individual parts to the manufacturing process. Three types of material feeding systems used are automatic storage and retrieval systems (ASRS), servo robot, and non-servo pick and place manipulators. ASRS An ASRS is a centralized automated system designed to perform inventory functions for an FMS or a CIM process. It has a storage system, carriage, and drive system, often operated by servo motors and a controller. Figure 1. Industrial ASRS 4

5 When parts are requested, the ASRS delivers the part from the inventory station to either a material-handling device, such as a conveyor, or to a pick up location. The ASRS can also be used to store finished goods. A centralized inventory control system like an ASRS is well suited for manufacturing processes that require a large quantity and variety of materials. By centralizing the inventory, every component is available in any order to any location. The ASRS is useful when there is a need to store materials and feed different kinds of parts to a process. Servo Robot Servo robots are often placed at the beginning of a conveyor line to place raw material and parts on the conveyor. They can also be part of a single workstation, removing material from feeders or a conveyor and loading an automated machine. Another common application is assembly, where the robot retrieves components from feeders and places them either on the assembly or in an assembly fixture. FEEDER SYSTEM ASSEMBLY PARTS BINS CONVEYOR Figure 2. Industrial Robot Workstation - Photo Courtesy of Adept Technology Inc. Servo robots, while more expensive than pick and place devices, can easily be reprogrammed for different tasks without having to modify tooling. They also are better suited for retrieving parts from multiple feeders than non-servo pick and place devices. 5

6 Non-Servo Pick and Place Manipulators Non-servo pick and place manipulators are very simple, limited sequence devices. These devices are often used to feed material to a process, either at a conveyor line or workstation. Non-servo pick and place units, which are commonly pneumatically powered, are low-cost, easy to maintain, fast, and accurate. TRANSFER MOTION CONTROLLER CONVEYOR B CONVEYOR A Figure 3. Non-Servo Pick and Place Manipulators Pick and place devices are normally less expensive than servo robots or an ASRS but have the least flexibility if there are significant changes in the process. For many applications, the lower cost is more important. 6

7 OBJECTIVE 2 DESCRIBE THE OPERATION OF A POWERED PARTS FEEDER A powered parts feeder provides parts from storage to the automated system as needed by the manufacturing process. They are typically equipped with an electropneumatic actuator to dispense parts and are controlled by a PLC. Parts can be stored in simple gravity feed chutes or slides, or they can be more complex, such as a vibratory bowl feeder. PARTS GRAVITY FEED CHUTE ELECTRO PNEUMATIC ACTUATOR Figure 4. Powered Parts Feeder 7

8 A powered parts feeder consists of some type of parts holder like a gravity feed chute or a magazine, where the parts sit on top of one another. A cylinder, typically equipped with sensors on either end of the stroke, is used to push the part out to the pickup location. The sensors tell the system when the cylinder is extended and when it is retracted. Typically, these feeders also include a part presence sensor to detect when there are no more parts available. GRAVITY FEED CHUTE PARTS INSIDE CHUTE PART ELECTRO PNEUMATIC ACTUATOR PART PRESENT SENSOR Figure 5. Diagram of a Powered Parts Feeder A powered parts feeder, such as the one shown in figure 5, drops the parts to the bottom of a magazine. The PLC gets a signal that a part is needed and energizes an electro-pneumatic valve, which causes a cylinder to extend and push the part out to a pick up location. A pick and place device is then signaled that the part is available for pick up. Another example is a vibratory bowl feeder. This feeder uses vibration to move parts from a hopper along channels within the feeder. The parts turn within the channels as they approach the pick up point. Vibratory feeders are used with small irregularly shaped parts that are difficult to sort by hand. These feeders also use a parts presence sensor to detect when there are no more parts. Figure 6. Vibratory Feeder 8

9 OBJECTIVE 3 DESCRIBE THE OPERATION OF A PICK AND PLACE PNEUMATIC MANIPULATOR Pick and place pneumatic manipulators are non-servo devices that use pneumatic actuators to move parts from one place to another. Each direction of movement, also called a degree of freedom or axis, is powered by a separate actuator. The most basic type is a 2-axis manipulator like the one shown in figure 7. X-AXIS Z-AXIS Figure 7. Two-Axis Pneumatic Manipulator 9

10 Pneumatic pick and place manipulators often use rodless cylinders because they are suitable for long-stroke applications. This design protects them from bending, piston binding, or uneven seal wear. Linear bearings and guide rods are normally used with the cylinders to provide a rigid structure that will accurately position the parts. The cylinders are typically controlled by a PLC and solenoidoperated pneumatic DCV s. Input sensors are placed at the ends of travel of each actuator to tell the system when the actuator has completed its stroke and the next step can take place. A pneumatic gripper, such as a vacuum gripper or a 2-point curvilinear gripper, is installed on the manipulator to pick up and place the parts in the desired locations. DCV S END OF TRAVEL SENSOR END OF TRAVEL SENSOR RODLESS END OF TRAVEL SENSOR VACUUM GRIPPER Figure 8. Construction of a Two-Axis Pneumatic Manipulator with Vacuum Gripper 10

11 A sample sequence of operations for a typical two-axis pneumatic manipulator with vacuum gripper is shown in figure 9. As you can see, one step of the sequence is completed before the next one is started. STEP INPUT OUTPUT 1 Operator presses Start pushbutton Extend Z-axis 2 Z-axis extended Vacuum (gripper) on 3 Vacuum (gripper) on Retract z-axis 4 Z-axis retracted Extend x-axis 5 X-axis extended Extend z-axis 6 Z-axis extended Vacuum (gripper) off 7 Vacuum (gripper) off Retract z-axis 8 Z-axis retracted Retract x-axis 9 X-axis retracted Cycle ends Figure 9. Sequence of Operations for a 2-Axis Pneumatic Manipulator with Vacuum Gripper Pick and place manipulators are also designed with three and four axes as well. These include movement along the y-axis and/or a twisting motion in the wrist. These units are often used for sorting or orienting parts and can be used to feed parts to multiple stations. X-AXIS Y-AXIS Z-AXIS Figure Axis Pick and Place Manipulator 11

12 SKILL 1 OPERATE A PICK AND PLACE FEEDING STATION Procedure Overview In this procedure, you will start up and operate the 87-MS1 Pick and Place Feeding station of the 870 Mechatronics System. 1. Locate the Pick and place Feeding station, shown in figure 11. Figure 11. Pick and Place Feeding Station 2. Verify that this station has been separated from the other stations. If it has not, then proceed with Step 3 to separate it from the other stations. If it has, then proceed to Step 4. 12

13 3. Perform the following substeps to separate the Pick and Place Feeding station from the other stations. A. Remove the power cord from the wall outlet. B. Remove the adjoining unit s power cord. C. Remove the adjoining unit s pneumatic hose. D. Disconnect the 9-pin to 9-pin handshaking cable from the pick and place unit. E. Loosen the connecting fasteners that hold the work surfaces together by turning the thumbscrews. F. Push the station away from the other stations to give yourself room to work. 4. Perform the following safety check before you begin working on the station. Make sure that you can answer yes to each item before proceeding. YES/NO SAFETY CHECKOUT Remove all obstructions from the work area Check for signs of damage to the equipment Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc. Tie up long hair Remove any robot teach pendants from the work area Locate the emergency stop button Ensure that safety glasses are worn by people in area Ensure that all people are outside any work envelopes Figure 12. Mechatronics Safety Check 13

14 5. Obtain the plastic parts bin and hook it onto the mounting arm, as shown in figure 13. This bin is used when the station is separated from the other stations. MOUNTING ARM PLASTIC PARTS BIN Figure 13. Mount the Parts Bin 6. Connect an air supply line to the station s air manifold quick connect. 7. Plug the station s electrical power cable into a wall outlet. 8. Perform the following substeps to power up the 87-MS1 Pick and Place Feeding station. A. Place the Mode Selector switch in the Manual position. B. Remove the lockout/tagout device from the electrical power source. C. Remove the lockout/tagout device from the pneumatic power source. D. Turn on the air to the station by shifting the lever on the lockout valve. E. Set the station s air supply regulator to 50 psi/345 kpa. F. Turn the station s Main Power switch to the On position. 9. Perform the following substeps to open the PLC programming software. A. Make sure that the interface from the personal computer to the PLC is connected. B. Power up the PC and monitor. C. Start the SIMATIC Manager. 14

15 10. Perform the following substeps to open project Feeder. A. Click the Open Project/Library button. The Open Project/Library dialog should open. B. Locate project Feeder. The project Feeder is provided on a supplemental disk. If it is not listed on the dialog, click the Browse button on the dialog to view the projects located in the S7Proj folder. C. Double-click the Feeder icon to open the project. D. Select Expand All from the View menu to expand the project s contents. The option is Expand All if using STEP 7 Version 5.2 or Show All Levels if using STEP 7 Version Perform the following substeps to download the PLC project named Feeder to the PLC. A. Place the PLC s Mode Selector switch in the RUN position. B. Reset the PLC. C. Download the SIMATIC 300 Station object to the PLC. Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart. D. Click Yes on the dialog to complete a warm restart. 12. Press the Output Power pushbutton to enable the PLC s outputs. 13. Turn the Mode Selector switch to Reset. This will home all of the actuators. Once these are all reset, the Start pushbutton light should turn off. 14. Turn the Mode Selector switch back to Manual. 15

16 15. Load the gravity feeder with valve bodies in the orientation shown in figure 14. The side with the two ports should face toward the front of the operator station. INSERT VALVE BODIES HERE FEEDER Figure 14. Valve Body Orientation for Feeder 16

17 16. Perform the following substeps to step the station through its sequence of operations using the single step, manual mode. Observe the system and notify your instructor of anything that does not function properly. A. Press and release the Start pushbutton to activate step 1 of the sequence. You should see the following sequence occur. 1. Feeder extends feeding part to pickup point 2. Extend z-axis to pickup location 3. Vacuum on 4. Retract feeder 5. Retract z-axis 6. Extend x-axis 7. Extend z-axis 8. Vacuum generator turns off 9. Retract z-axis 10. Retract x-axis 11. Cycle ends After receiving the input signal, the PLC energizes a solenoid valve and the feed cylinder extends, pushing a part from the feeder. The Start pushbutton should be off before you press it and on solid through each manual sequence step. B. Press and release the Start pushbutton to activate step 2 of the sequence. The manipulator s z-axis extends towards the pickup location. C. Press and release the Start pushbutton to activate step 3 of the sequence. After the z-axis extends, the vacuum switch on turns on. D. Press and release the Start pushbutton to activate step 4 of the sequence. Once the vacuum switch turns on, the feed cylinder retracts. E. Press and release the Start pushbutton to activate step 5 of the sequence. Once the feed cylinder retracts the z-axis retracts. The part is held on the gripper by the vacuum. F. Press and release the Start pushbutton to activate step 6 of the sequence. After the z-axis is fully retracted, the manipulator s x-axis extends. G. Press and release the Start pushbutton to activate step 7 of the sequence. Once the x-axis extends, the z-axis extends to the part drop off location. H. Press and release the Start pushbutton to activate step 8 of the sequence. After the z-axis extends, the vacuum generator turns off, dropping the part in the parts bin. I. Press and release the Start pushbutton to activate step 9 of the sequence. Once the vacuum switch turns off, the z-axis retracts. J. Press and release the Start pushbutton to activate step 10 of the sequence. After the z-axis retracts, the x-axis retracts to its home position. 17

18 17. Turn the Mode Selector switch to Auto. If you successfully single-stepped through the complete sequence and all of the actuators are back in their home position, the Start pushbutton lamp should be off and you can skip to Step 19. If it is not, perform Step 18 to reset the actuators. 18. Perform the following substeps to reset the actuators and put the system in Auto mode. A. Turn the Mode Selector switch to Reset. This will move all of the actuators back to their home positions. B. Turn the Mode Selector switch to Auto. The Start pushbutton lamp should be off at this time, indicating that the actuators are reset and the station is ready to run an automatic cycle. 19. Press the Start pushbutton to start the automatic cycle. Observe the station while it goes through one cycle. It is programmed to run through one cycle and then stop. The Start pushbutton indicator is on solid during the whole cycle to indicate the station is operating. 20. Perform the following substeps to record the operation of the station when the Stop pushbutton is pressed. This will show you how the system is programmed to respond to the stop pushbutton. A. Press the Start pushbutton to start the cycle again. B. During the middle of the cycle, press the Stop pushbutton to stop the system. Record whether the system executes a halt, cycle stop or emergency stop. You should observe that the station finishes its current step and stops. This means the Stop pushbutton has been programmed to perform a halt function. 18

19 C. Observe the operator panel indicators and record their status in the table below. Indicator Output Power lamp Start lamp Emergency Stop lamp Operator Panel Indicators Status (On/Off/Blinking) Figure 15. Operator Panel Indicators Since this is a halt, the machine can resume operation, so you should observe that Output power remains on and the Start pushbutton is off. It has been programmed to do so when the station is in the auto mode and ready to run its automatic cycle. The Emergency Stop lamp should be off because it is not pressed. D. Observe the PLC processor s status indicators and record their status. SF DC5V FRCE RUN STOP PLC PROCESSOR STATUS INDICATORS Indicator Status (On/Off) Figure 16. PLC Processor Status Indicators You should see that the PLC processor s DC5V and Run indicator lights are on, because the station is halted and ready to resume automatic operation. E. Observe the PLC I/O modules status indicators to see if some of them are on. You should see various input and output indicators on. This indicates I/O power is on. Which ones are on will depend on the point in the operation at which the stop button was pushed. 21. Press the Start pushbutton to restart the system. It should continue where it left off and finish the cycle. NOTE If any actuators are manually moved while the system is halted, the station may not resume operation when the start pushbutton is pressed. If this occurs, go to Step 23 and restart the system. 19

20 22. Repeat Steps 20 and 21 three times, stopping the cycle with the Stop pushbutton at different times to observe how it reacts. 23. Perform the following substeps to restart the station IF any of the inputs change after the Stop button is pressed, otherwise skip to Step 24. If any of the inputs were changed, like a part removed from the gripper, or a cylinder moved physically, the system cannot be restarted with the Start pushbutton. This is because the input signals will no longer match those needed to begin the sequence. This is a protective measure to prevent damage to the system. A. Remove any valve bodies that are in the pick up location or in the gripper. B. Turn the mode selector switch to Reset. This will move all of the actuators back to their home positions. It will also turn the vacuum to the gripper off. C. Turn the mode selector switch back to Auto. D. Press the Start pushbutton to start the automatic cycle. Observe the system while it goes through the cycle before continuing to the next step. 24. Check the valve body supply in the feeder and add more if necessary. 25. Perform the following substeps to record the operation of the station when the Emergency Stop pushbutton is pressed. This step will show you how the system is programmed to respond to the emergency stop pushbutton. A. Press the Start pushbutton to start the cycle again. B. During the middle of the cycle, press the Emergency Stop pushbutton to stop the system. C. Observe the operator panel indicators and record their status in the table below. OPERATOR PANEL INDICATORS Indicator Status (On/Off/Blinking) Output Power lamp Start lamp Emergency Stop lamp Figure 17. Operator Panel Indicators Since this is an emergency stop, the machine cannot resume operations. You should observe that the Output Power is off, the Start pushbutton lamp is off, and the Emergency Stop lamp is on. The Emergency Stop function does not remove the air supply. 20

21 D. Observe the PLC processor s status indicators and record their status. You should see the PLC processor s DC5V and Run indicator lights on. SF DC5V FRCE RUN STOP PLC PROCESSOR STATUS INDICATORS Indicator Status (On/Off) Figure 18. PLC Processor Status Indicators You should see the PLC processor s DC5V and Run indicator lights on. E. Observe the PLC I/O modules status indicators to see if some of them are on. You should see various input indicators on, but all output indicators are off. This is because the Emergency Stop circuit breaks power to the Output Power contactor, which drops all output power. 26. Perform the following substeps to recover from the Emergency Stop. A. Pull the Emergency Stop button out. B. Remove any valve bodies that are in the pick up location or in the grippers. C. Press the Output Power button to turn the outputs back on. You should hear the contactor pull in to re-establish the power to the outputs. D. Turn the Mode Selector switch to Reset. This will move all of the actuators back to their home positions. It will also turn the vacuum to the gripper off. E. Check the supply of valve bodies in the feeder and add more if necessary. F. Turn the Mode Selector switch back to Auto. G. Press the Start pushbutton to start the automatic cycle. Observe the system while it goes through the cycle before continuing to the next step. 27. Perform the following substeps to record the operation of the station when the station experiences a power loss. This will show you how the station is programmed to respond to a power loss. A. Press the Start pushbutton to start the cycle again. B. During the middle of the cycle, turn the Main Power switch to Off to remove power to the system. 21

22 C. Observe the operator panel indicators and record their status in the table below. OPERATOR PANEL INDICATORS Indicator Status (On/Off/Blinking) Output Power lamp Start lamp Emergency Stop lamp Figure 19. Operator Panel Indicators Because this is a power loss, simulated by turning the Main Power switch off, power to everything past the Main Power switch is turned off. You should see all operator panel indicator lamps and PLC indicators are off, but you will notice that the pneumatic power remains. You should also have seen any cylinders complete their strokes because they are pneumatically-operated. D. Observe the PLC processor s status indicators and record which indicators are on. SF DC5V FRCE RUN STOP PLC PROCESSOR STATUS INDICATORS Indicator Status (On/Off) Figure 20. PLC Processor Status Indicators You should see all indicators off because there is no power to the PLC. E. Observe the PLC I/O modules status indicators to see if some of them are on. Again, you should see all input and output indicators off because the modules have no power. 22

23 28. Perform the following substeps to recover from the power loss. A. Remove any valve bodies that are in the pick up location or in the grippers. B. Place the Mode Selector switch in the Manual position. C. Turn the station s Main Power switch to the On position. D. Press the Output Power pushbutton to enable the PLC s outputs You should also hear the contactor located next to the PLC module pull in. The Start pushbutton should be blinking because the station is not ready for operation E. Turn the Mode Selector switch to Reset. This will move all of the actuators back to their home positions. It will also turn the vacuum to the gripper off. Once the actuators are reset, the Start pushbutton should turn off. F. Check the supply of valve bodies in the gravity feeder and add more if necessary. G. Turn the Mode Selector switch to Auto. H. Press the Start pushbutton to restart the operation. You should see the system start through its sequences. I. Run the system through two complete cycles to make sure it has recovered correctly. 29. Perform the following substeps to shut down the 87-MS1 Pick and Place Feeding station. A. Close the LAD/STL/FBD Editor. B. Close the SIMATIC Manager. C. Turn off the PC and monitor. D. Turn the 87-MS1 s Main Power switch to Off. E. Perform a lockout/tagout on the system s electrical power source. F. Perform a lockout/tagout on the system s pneumatic power source. 23

24 SEGMENT 1 SELF REVIEW 1. Three types of material feeding systems are automatic storage and retrieval,, and non-servo pick and place manipulators. 2. Non-servo pick and place manipulators are low-cost, easy to maintain, fast, and. 3. Powered parts feeders are often equipped with a actuator to dispense parts. 4. A vibratory bowl feeder uses to move parts from a hopper to the pick up point. 5. Pick and place manipulators use because they are suitable for long-stroke applications. 6. Pick and place manipulators are designed with two to axes. 24

25 SEGMENT 2 COMPONENT ADJUSTMENT OBJECTIVE 4 DESCRIBE HOW TO ADJUST A VACUUM GRIPPER A vacuum gripper uses a vacuum or suction cup connected to a vacuum line to pick up parts using vacuum. These grippers are generally used for handling products that are too difficult or too fragile to handle by other means. Figure 21 shows a vacuum gripper on a robot arm. ROBOT ARM VACUUM GRIPPER Figure 21. Vacuum Gripper on a Robot Arm 25

26 The gripping or holding force of the vacuum gripper relies on the cup size and the amount of vacuum applied. The vacuum cup size determines the surface area that will be in contact with the payload. Generally, the larger the vacuum gripper, the greater the gripping or holding force. The actual lifting force is supplied by atmospheric pressure acting on the cup area of the object being lifted. VACUUM VACUUM CUP VACUUM PRESSURE ATMOSPHERIC PRESSURE PART Figure 22. Differential Force Created by Vacuum 26

27 The vacuum required by the vacuum gripper is often created by a vacuum generator, shown in figure 23. The vacuum generator, sometimes called the vacuum transducer pump, uses airflow through a device called a venturi to create the vacuum. A venturi is any flow channel with a narrowing (converging) entrance, a throat and an expanding (divergent) exit. When air flows through the vacuum generator, a vacuum will occur at the tap connected to the throat. VACUUM TAP AIR SUPPLY ENTERS THROUGH A CIRCULAR ORIFICE EXIT VENTURI DIAMETER NARROWING ENTRANCE EXHAUST THROAT Figure 23. Vacuum Generator The vacuum produced by the vacuum generator can be adjusted by using either a flow control valve or a pressure regulator. Vacuum levels rise with an increase in supply air pressure (usage), however, vacuum levels top out at some point and may even decrease. Increasing pressure (air usage) beyond where maximum vacuum is obtained would be a waste of energy. Vacuum generators are commonly used in automation systems when vacuum is only needed for a limited point of use application. The advantage of using vacuum generators is simplicity. They have no moving parts and are easily used, requiring no complicated connections. A vacuum generator can produce high vacuum levels and is ideal for use in lifting and banding applications. 27

28 Vacuum Gripper Adjustment Step 1: Turn on the vacuum generator - A vacuum generator is used to generate the vacuum for the gripper. The vacuum generator is typically controlled with a pneumatic valve. The generator can be turned on by a PLC or by using a manual override on the pneumatic valve. AIR REGULATOR WITH GAUGE VACUUM GENERATOR VACUUM CUP MUFFLER Figure 24. Schematic of a Vacuum Generator Circuit Step 2: Determine the lowest setting that will grip and hold a part - The lowest vacuum setting can be determined by setting the vacuum regulator to a high value. Grip the part using the gripper and slowly reduce the vacuum regulator setting until the part is no longer gripped. Even though this is the lowest setting that will grip a part, it is probably not enough vacuum to grip the part while it is being transported. Step 3: Determine the lowest setting that will allow a part to be gripped and transported - The lowest setting that will grip and transport a part can be determined by running the station, starting with a high vacuum setting and gradually reducing it while observing the operation of the gripper. The lowest setting that transports the part properly should be recorded. Step 4: Add a safety factor - A safety factor should be added to the vacuum regulator setting obtained in Step 3. The exact amount depends on several factors (i.e. part weight, vacuum level, number of grippers). Step 5: Adjust the vacuum regulator - The vacuum regulator should be adjusted to the value determined in Step 4. The station should then be run several times to observe the operation of the gripper and verify the new setting. 28

29 SKILL 2 ADJUST A VACUUM GRIPPER Procedure Overview In this procedure, you will adjust the vacuum gripper on the 87-MS1 Pick and Place Feeding station. This will familiarize you with adjusting vacuum grippers. 1. Locate the 87-MS1 Pick and Place Feeding station. 2. Verify that this station has been separated from any other stations. If it has not, then separate it from the other stations. If it has, then proceed to Step Perform the following safety check before you begin working on the module. Make sure that you can answer yes to each item before proceeding. YES/NO SAFETY CHECKOUT Remove all obstructions from the work area Check for signs of damage to the equipment Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc. Tie up long hair Remove any robot teach pendants from the work area Locate the emergency stop button Ensure that safety glasses are worn by people in area Ensure that all people are outside any work envelopes Figure 25. Mechatronics Safety Check 4. Connect an air supply line to the station s air manifold quick connect. 5. Plug the station s power cable into a wall outlet. 6. Perform the following substeps to power up the station. A. Place the Mode Selector switch in the Manual position. B. Remove the lockout/tagout device from the electrical power source. C. Remove the lockout/tagout device from the pneumatic power source. D. Turn on air to the station by shifting the lever on the lockout value. E. Set the station s air supply regulator to 50 psi/345 kpa. F. Turn the station s Main Power Switch to the On position. 7. Perform the following substeps to open the PLC programming software. A. Make sure that the interface from the personal computer to the PLC is connected. B. Power up the PC and monitor. C. Start the SIMATIC Manager. 29

30 8. Perform the following substeps to open project Feeder. A. Click the Open Project/Library button. The Open Project/Library dialog should open. B. Locate project Feeder. The project Feeder is provided on a supplemental disk. If it is not listed on the dialog, click the Browse button on the dialog to view the projects located in the S7Proj folder. C. Double-click the Feeder icon to open the project. D. Select Expand All from the View menu to expand the project s contents. The option is Expand All if using STEP 7 Version 5.2 or Show All Levels if using STEP 7 Version Perform the following substeps to download the PLC project named Feeder to the PLC. A. Place the PLC s Mode Selector switch in the RUN position. B. Reset the PLC. C. Download the SIMATIC 300 Station object to the PLC. Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart. D. Click Yes on the dialog to complete a warm restart. 10. Press the Output Power pushbutton to enable the PLC s outputs. 11. Perform the following substeps to home the station and set Manual mode. A. Turn the Mode Selector switch to Reset. This will home all of the actuators. B. Turn the Mode Selector switch back to Manual. 12. Perform the following substeps to run the station through an automatic cycle. A. Check the supply of valve bodies in the parts feeder. B. Turn the Mode Selector switch to Auto. C. Press the Start pushbutton to start the automatic cycle. Observe the system while it goes through a cycle before continuing to the next step. 30

31 13. Perform the following substeps to determine the lowest setting that will grip and hold a part. You will need both an acrylic and an aluminum valve body, if available, to perform this skill. Ask you instructor to provide you with the valve bodies. A. Locate the vacuum generator, shown in figure 26. The vacuum generator is located directly underneath the vacuum switch. The vacuum switch is used to detect when there isn t enough vacuum to grip the part. You will learn about this switch in the next objective. VACUUM GENERATOR VACUUM SWITCH Figure 26. Vacuum Generator and Switch on the 87-MS1 Pick and Place Feeding 31

32 B. Use the manual override on the pneumatic DCV to turn on the vacuum generator, as shown in figure 27. VACUUM ON VACUUM OFF Figure 27. DCV Manual Override for Vacuum Generator C. Place an acrylic valve body against the vacuum gripper. VACUUM GRIPPER ACRYLIC VALVE BODY Figure 28. Valve body on Vacuum Cup 32

33 D. Locate the vacuum module air regulator, shown in figure 29. This regulator controls the pressure to the gripper. ADJUSTMENT KNOB VACUUM MODULE AIR REGULATOR Figure 29. Vacuum Module Air Regulator E. Pull up the adjustment knob to unlock it. F. Slowly rotate the adjustment knob CCW until the acrylic valve body falls off of the gripper. Record the pressure setting in the space provided. Minimum pressure to hold acrylic body (psi) You should find that it requires less than 10 psi/69 kpa to hold the acrylic valve body. G. Rotate the adjustment knob CW until the gauge reads approximately 40 psi/276 kpa. H. Place an aluminum valve body against the vacuum gripper. The gripper should hold the valve body. I. Slowly rotate the adjustment knob CCW until the aluminum valve body falls off of the gripper. Record the pressure setting in the space provided. Minimum pressure to hold aluminum body (psi) You should find that it requires less than 20 psi/138 kpa to hold the aluminum body. Even though it requires less than 20 psi/138 kpa to hold both the aluminum and acrylic valve bodies, a higher setting is required to make sure that both types of valve bodies remain gripped securely while they are being transported. 33

34 14. Perform the following substeps to determine the lowest setting that will allow a part to be gripped and transported. A. Load the feeder assembly with aluminum valve bodies. B. Rotate the adjustment knob on the vacuum regulator to until it is set to 50 psi/345 kpa. C. Set the Mode Selector switch to Reset. D. Set the Mode Selector switch to Auto. E. Press the Start pushbutton. The gripper should pick up the valve body and transport it to the other end of the station. Observe the valve body on the gripper as it is being transported. It should be held firmly in place as it moves from one end of the station to the other. F. Set the vacuum regulator to the values listed in figure 30 and run an automatic cycle with each setting. Record your observations in the space provided for each setting. You will have to turn the vacuum on and off using the manual override on the vacuum DCV to change the settings. Make sure to reload aluminum valve bodies as necessary. Vacuum Regulator Settings 40 psi/276 kpa 35 psi/241 kpa 30 psi/207 kpa 25 psi/172 kpa 20 psi/138 kpa 15 psi/103 kpa 10 psi/69 kpa VACUUM REGULATOR SETTINGS Valve Body Held Firmly (Yes/No) Figure 30. Vacuum Regulator Settings NOTE You may need to adjust the vacuum switch to a lower setting for the lower vacuum regulator settings if the sequence won t start in the automatic mode. You should find a setting where the valve body is gripped, but is not held firmly while being transported. It may even fall off during the transport or when the pneumatic cylinder on the 2-axis manipulator hits the hard stops at the end of the station. 34

35 15. Perform the following substeps to add a safety factor to the setting determined in step 14. A. Record the lowest vacuum setting that gripped the valve body firmly as it was transported in the space provided. Vacuum Regulator Setting (psi) B. Add 10 psi/69 kpa to the result recorded in substep A and record the result in the space provided. Vacuum Regulator Setting (psi) 16. Set the vacuum regulator to the setting recorded in step 15B. This is the final setting for the vacuum regulator. 17. Perform the following substeps to run the station through an automatic cycle. A. Check the supply of valve bodies in the parts feeder. B. Turn the Mode Selector switch to Auto. C. Press the Start pushbutton to start the automatic cycle. Observe the system while it goes through a cycle to make sure that the valve bodies are being picked up and transported correctly before continuing to the next step. 18. Perform the following substeps to power down the station. A. Close the LAD/STL/FBD Editor. B. Close the SIMATIC Manager. C. Turn off the PC and monitor. D. Turn the Main Power switch Off. E. Perform a lockout/tagout on the system s electrical power source. F. Perform a lockout/tagout on the system s pneumatic power source. 35

36 OBJECTIVE 5 DESCRIBE HOW TO ADJUST A VACUUM SWITCH A vacuum switch converts a sensed pressure or vacuum into a discrete (on/off) electrical signal that can be used as an input to a controller. Figura 31. Vacuum Switches Vacuum switches are used in a wide variety of applications including monitoring the vacuum supplied to the vacuum grippers used to lift fragile items such as plate glass. The vacuum switch must send a signal to indicate that sufficient vacuum is present before the machine will attempt to lift the part. VACUUM CUPS GLASS PLATE Figura 32. Lifting Plate Glass 36

37 A typical vacuum switch is the diaphragm-operated type shown in figure 33. The diaphragm is a flexible disk that deforms based on the amount of pressure/ vacuum applied to the vacuum port. The adjustment screw determines the amount of movement required by the diaphragm to connect the two contacts and actuate the switch. Rotating the adjustment screw clockwise reduces the gap between the contacts, requiring less vacuum for the contacts to close. Rotating the adjustment screw counterclockwise increases the gap between the contacts, requiring more vacuum to close the contacts. The vacuum port is connected to the vacuum line, which allows the internal workings of the vacuum switch to sense the vacuum present in the system. VACUUM PORT ADJUSTING SCREW ELECTRICAL WIRES DIAPHRAGM CONTACTS Figure 33. Vacuum Switch Components 37

38 Vacuum Switch Adjustment Step 1: Close or block the vacuum line leading to the vacuum gripper - If the vacuum line is not closed, the amount of vacuum cannot be set because air will be drawn into the line. If a port is available, a vacuum gauge can be connected to the vacuum line to measure the amount of vacuum. AIR SUPPLY EXHAUST PORT VACUUM LINE VACUUM GENERATOR VACUUM GAUGE VACUUM CUP VAC - + VACUUM SWITCH Figure 34. Vacuum Gauge Connected to a Vacuum Line Step 2: Set the vacuum created by the vacuum generator to the setting desired on the vacuum switch - The air supplied to the vacuum generator is adjusted until a vacuum gauge reads the desired amount of vacuum. Step 3: Adjust the adjustment screw on the vacuum switch until the switch closes - The adjustment screw should be turned until the vacuum switch has closed. The PLC s status indicator for the vacuum switch input can be observed to see if it turns on. When the vacuum switch closes the PLC status indicator light should turn on. 38

39 SKILL 3 ADJUST A VACUUM SWITCH Procedure Overview In this procedure, you will adjust the vacuum switch on the 87-MS1 Pick and Place Feeding station. The vacuum switch setting tells the system when sufficient vacuum pressure is present to safely continue its operation. This will familiarize you with adjusting vacuum levels and switches. 1. Locate the 87-MS1 Pick and Place Feeding station. 2. Verify that this station has been separated from any other stations. If it has not, then separate it from the other station. If it has, then proceed to Step Perform the following safety check before you begin working on the module. Make sure that you can answer yes to each item before proceeding. YES/NO SAFETY CHECKOUT Remove all obstructions from the work area Check for signs of damage to the equipment Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc. Tie up long hair Remove any robot teach pendants from the work area Locate the emergency stop button Ensure that safety glasses are worn by people in area Ensure that all people are outside any work envelopes Figure 35. Mechatronics Safety Check 4. Connect an air supply line to the station s air manifold quick connect. 5. Plug the station s power cable into a wall outlet. 6. Perform the following substeps to power up the station. A. Place the Mode Selector switch in the Manual position. B. Remove the lockout/tagout device from the electrical power source. C. Remove the lockout/tagout device from the pneumatic power source. D. Turn on air to the station by shifting the lever on the lockout valve. E. Set the station s air supply regulator to 50 psi/345 kpa. F. Turn the station s Main Power switch to the On position. 39

40 7. Perform the following substeps to open the PLC programming software. A. Make sure that the interface from the personal computer to the PLC is connected. B. Power up the PC and monitor. C. Start the SIMATIC Manager. 8. Perform the following substeps to open project Feeder. A. Click the Open Project/Library button. The Open Project/Library dialog should open. B. Locate project Feeder. The project Feeder is provided on a supplemental disk. If it is not listed on the dialog, click the Browse button on the dialog to view the projects located in the S7Proj folder. C. Double-click the Feeder icon to open the project. D. Select Expand All from the View menu to expand the project s contents. The option is Expand All if using STEP 7 Version 5.2 or Show All Levels if using STEP 7 Version Perform the following substeps to download the PLC project named Feeder to the PLC. A. Place the PLC s Mode Selector switch in the RUN position. B. Reset the PLC. C. Download the SIMATIC 300 Station object to the PLC. Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart. D. Click Yes on the dialog to complete a warm restart. 10. Press the Output Power pushbutton to enable the PLC s outputs. 40

41 11. Perform the following substeps to record the vacuum generator pressure. The pressure was set in a previous skill. A. Locate the Vacuum Switch, shown in figure 36. The vacuum generator is located directly underneath the vacuum switch. You will have one of the vacuum switches shown in figure 36. VACUUM GENERATOR VACUUM SWITCH VACUUM GENERATOR VACUUM SWITCH Figure 36. Vacuum Switch on the 87-MS1 Pick and Place Feeding Station 41

42 B. Use the manual override on the pneumatic DCV to turn on the vacuum generator, as shown in figure 37. VACUUM ON VACUUM OFF Figure 37. DCV Manual Override for Vacuum Generator C. Place a valve body against the vacuum gripper. This will close the line. Record the reading on the vacuum regulator in the space provided. Vacuum Regulator Setting (psi) 42

43 12. Perform the following substeps to adjust the VACCON vacuum switch. If you have the EDCO USA vacuum switch, go onto Step 13. A. Locate the PLC s indicator light for input I2.6, as shown in figure 38. The vacuum switch is connected to the PLC through input I2.6. When the switch s contacts close, this indicator light should turn on. I2.6 STATUS INDICATOR Figure 38. Input I2.6 Indicator B. Use an insulated flat-bladed screwdriver to turn the vacuum switch s adjustment screw CCW until the indicator light goes off. CAUTION Not using an insulated screwdriver may cause an electrical short that will damage the switch. C. Check the condition of input I2.6 s indicator. Input I2.6 Indicator (On/Off) The indicator should be off. D. Use the screwdriver to slowly rotate the adjustment screw CW until the indicator turns on. The vacuum switch is now set to the setting recorded in Step 5. E. Rotate the adjustment screw ½ turn clockwise to add a small safety factor. F. Use the manual controls to deactivate the vacuum generator. G. Continue to Step

44 13. Perform the following substeps to adjust the EDCO USA vacuum switch. A. Locate the LED on the face of the vacuum switch. It is located above the potentiometer. When the switch s contacts close, the red LED will turn on. B. Locate the PLC s indicator light for input I2.6, as shown in figure 38. The vacuum switch is connected to the PLC through input I2.6. When the switch s contacts close, this indicator light should also turn on. This gives you a second method of verifying the vacuum switch operation. CAUTION Use a gentle force when adjusting the potentiometer. Excessive force can cause the potentiometer to turn past the 180 degree limit. Turning the potentiometer past the 180 degree limit will destroy the vacuum switch. C. Use an insulated flat-bladed screwdriver to turn the vacuum switch s adjustment screw slowly and gently CCW until the indicator light goes off. CAUTION Not using an insulated screwdriver may cause an electrical short that will damage the switch. D. Check the condition of input I2.6 s indicator, shown in figure 38. Input I2.6 Indicator (On/Off) The indicator should be off. E. Use the screwdriver to slowly rotate the adjustment screw CW until both indicators turn on. The vacuum switch is now set to the setting recorded in Step 5. F. Use the manual controls to deactivate the vacuum generator. 44

45 14. Perform the following substeps to home the station and set Auto mode. A. Turn the Mode Selector switch to Reset. This will home all of the actuators. B. Turn the Mode Selector switch back to Auto. 15. Perform the following substeps to run the station through an automatic cycle. A. Check the supply of valve bodies in the parts feeder. B. Press the Start button to start the automatic cycle. Observe the system while it goes through a cycle before continuing to the next step. 16. Perform the following substeps power down the station. A. Close the LAD/STL/FBD Editor. B. Close the SIMATIC Manager. C. Turn off the PC and monitor. D. Turn the Main Power switch off. E. Perform a lockout/tagout on the system s electrical power source. F. Perform a lockout/tagout on the system s pneumatic power source. 45

46 OBJECTIVE 6 DESCRIBE HOW TO ADJUST A SHOCK ABSORBER Shock absorbers are devices that reduce the shock and vibration of a machine by gently decelerating its moving parts. Shock absorbers enable machines to run at faster speeds and still maintain long life. Figure 39. Shock Absorber Shock absorbers are used in place of cylinder cushions because cushions are limited in their range of operation. When high impacts are being created, cushions are not able to absorb enough of the energy to avoid causing shock loading and vibration. Shock absorbers function by converting the kinetic energy of the actuator into thermal energy (i.e. heat) that is transferred through its body to the atmosphere. Shock absorbers decelerate an actuator, such as a rodless cylinder, using a combination mechanical/hydraulic system to oppose the actuator s motion. The main components of a shock absorber are shown in figure 40. PISTON ROD CHECK BALL OIL COIL SPRING ADJUSTMENT BALL FOAM ACCUMULATOR PISTON HEAD SHOCK TUBE ORIFICE ADJUSTMENT KNOB Figure 40. Shock Absorber Components 46

47 Shock Absorber Operation When the load strikes the piston rod, the piston forces the fluid contained in the shock tube through the orifice. The fluid flows around the outside of the shock tube to the rod side of the piston. Because the rod side has less area, foam accumulators are used to create the required area when the shock absorber is in operation. Once the load is removed, the compression spring extends the piston rod back to its original position. A check ball in the piston head opens to allow the fluid on the rod side to flow back into the shock tube. PISTON ROD COMPRESSED L O A D FOAM ACCUMULATOR ADJUSTMENT KNOB Figure 41. Shock Absorber Decelerates Load The amount of deceleration provided by the shock absorber is determined by the size of the orifice through which the fluid flows. When the adjustment knob is turned, it changes the position of the adjustment ball, which in turn changes the size of the orifice. While the return spring performs some deceleration, it is mainly used to return the piston rod to its original position. ORIFICE SIZE ADJUSTMENT KNOB ADJUSTMENT BALL Figure 42. Orifi ce Adjustment 47

48 Shock Absorber Adjustment Some shock absorbers have no adjustment. They are matched to a specific application by their load handling ability. The only adjustment on these types of shock absorbers is the physical position of the shock absorber. The shock absorber must be oriented so that it cushions the load and at the same time allows the load to reach its final position. Adjustable shock absorbers must be adjusted so they give the proper cushioning. Too much cushioning slows the machine down while too little cushioning creates a shock load on the system. There are five steps used to adjust an adjustable shock absorber: Step 1: Determine adjustment setting - The adjustment setting is determined using a graph supplied by the manufacturer of the shock absorber. First, the application s impact velocity is located on the y-axis of the graph. Then, its intersection with the graph line representing the shock absorber is determined. The shock absorber setting is then read from the x-axis of the graph. For example, an impact velocity of 40 in/sec would require a shock absorber setting of IMPACT VELOCITY (in/sec) MODEL.35 MODEL.5 MODEL 0.1M,.15M,.25, 1.0, 1.15/ ADJUSTMENT SETTING Figure 43. Shock Absorber Adjustment Setting 48

49 Step 2: Loosen setscrew - The setscrew is used to prevent the adjustment knob from vibrating loose. It must be loosened to enable the adjustment knob to be turned. ADJUSTMENT KNOB SET SCREW Figure 44. Adjustment Knob and Setscrew Step 3: Set Adjustment Knob - The adjustment knob is rotated to the setting determined by the graph. For example, the shock absorber shown in figure 45 is set to 3-1/2. SET AT 3-1/2 Figure 45. Shock Absorber Setting 49

50 Step 4: Tighten setscrew - The setscrew is retightened to lock the adjustment knob in its current position. Step 5: Set position - Many shock absorbers have threaded bodies and locknuts that allow the position to be easily set and slotted brackets that provide side to side adjustment. With a non-adjustable shock absorber, this is the only adjustment. The shock absorber must be accurately positioned for two reasons. The first reason is to prevent the load from striking the shock absorber s piston rod offcenter, which could bend or break the rod. The load should strike the centerline of the shock absorber s piston as shown in figure 46. INCORRECT SHOCK ABSORBER CORRECT ROTARY ACTUATOR LOAD Figure 46. Shock Absorber Set to Load s Centerline The second reason is to prevent the load from bottoming out the piston. If this occurs, the fluid resistance no longer cushions the load and the load s force is transmitted to the shock absorber s body and its bracket. This can damage the shock absorber s body and its bracket. More importantly, it may damage the load that the shock absorber was installed to protect. 50

51 SKILL 4 ADJUST A SHOCK ABSORBER Procedure Overview In this procedure, you will adjust the physical position of the shock absorber on the 87-MS1 Pick and Place Feeding station and observe the effect it has on the operation of the rodless cylinder. You will then set the shock absorber correctly and observe the operation of the pick and place module. 1. Locate the 87-MS1 Pick and Place Feeding station. 2. Verify that this station has been separated from any other stations. If it has not, then separate it from the other stations. If it has, then proceed to Step Perform the following safety check before you begin working on the module. Make sure that you can answer yes to each item before proceeding. YES/NO SAFETY CHECKOUT Remove all obstructions from the work area Check for signs of damage to the equipment Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc. Tie up long hair Remove any robot teach pendants from the work area Locate the emergency stop button Ensure that safety glasses are worn by people in area Ensure that all people are outside any work envelopes Figure 47. Mechatronics Safety Check 4. Perform the following substeps to power up the station. A. Connect an air supply line to the station s air manifold quick connect. B. Remove the lockout/tagout device from the pneumatic power source. C. Turn on air to the station by shifting the lever on the lockout value. D. Set the station s air supply regulator to 50 psi/345 kpa. 51

52 5. Perform the following substeps to vary the position of the shock absorber and test its operation. A. Locate the shock absorber, shown in figure 48, on the 87-MS1 Pick and Place Feeding station. The shock absorber includes a stop collar and two locking nuts, one to lock the stop collar and one to lock the shock absorber onto the rodless cylinder. The only adjustment on the shock absorber is the physical amount of the shock that protrudes into the rodless cylinder. The stop collar is used to prevent the shock absorber from bottoming out. STOP COLLAR STOP COLLAR LOCK NUT SHOCK ABSORBER LOCK NUT TO ATTACH SHOCK ABSORBER TO Figure 48. Shock Absorber B. Use the manual overrides to operate the rodless cylinder while observing the operation of the shock absorber. Watch to see if the shock absorber is centered with the load and if the shock absorber s piston is bottoming out. Record your observations. Observations: You should have noticed that the shock absorber decelerated the load. You should also have noticed that the shock absorber is centered on the load. C. Mark the position of the shock absorber with a sharp-tip marker. D. Loosen the locknut that secures the shock absorber to the rodless cylinder. E. Rotate the shock absorber CCW (when viewed from the back of the shock absorber) several turns to increase the stroke of the cylinder. F. Tighten the locking nut. 52

53 G. Use the manual overrides to operate the rodless cylinder while observing the operation of the shock absorber. Watch to see if the shock absorber is centered with the load. Record your observations. Observations: You should notice that the cylinder stops slightly past its final position. H. Loosen the locknut that secures the shock absorber to the rodless cylinder. I. Rotate the shock absorber CW several turns to place it back in its original position, which you previously marked. J. Tighten the locking nut. K. Use the manual overrides to operate the rodless cylinder while observing the operation of the shock absorber. Watch to see if the shock absorber is centered with the load and if the shock absorber s piston is bottoming out. Record your observations. Observations: You should find that the shock absorber and rodless cylinder operate as they were originally installed. 6. Perform a lockout/tagout on the system s pneumatic power source. 53

54 SEGMENT 2 SELF REVIEW 1. Vacuum grippers are usually used on items that are too difficult or too to handle by any other means. 2. The vacuum required by the gripper is created by a. 3. A vacuum switch converts a sensed pressure or vacuum into a electrical signal. 4. A typical vacuum switch is the -operated type. 5. A shock absorber reduces shock and of a machine by gently decelerating its moving parts. 6. Too much cushioning by a shock absorber slows the down. 54

55 SEGMENT 3 MODULE SEQUENCING OBJECTIVE 7 DESCRIBE A SEQUENCE OF OPERATION OF A POWERED PARTS FEEDER A typical powered parts feeder, shown in figure 49, includes a single-solenoid directional control valve and a double-acting cylinder that dispenses parts from a magazine to the pickup location. The feeder will often be equipped with a sensor to determine if there are parts in the magazine, and sensors to detect when the feed cylinder is in its fully extended and fully retracted positions. In this example, a photoelectric sensor (PE1) monitors for part presence while two Hall effect (HES1 and HES2) sensors detect the cylinder position. MAGAZINE RETRACTED SENSOR (HES1) EXTENDED SENSOR (HES2) FEED SOLENIOD VALVE (SOL1) FEEDER EMPTY SENSOR (PE1) Figure 49. Feeder Construction 55

56 The parts feeder is generally controlled by a PLC, but could also be controlled by robotic I/O. In either case, the sequence will be similar to that shown in the table below. POWERED PARTS FEEDER SEQUENCE Step INPUT OUTPUT 1 Receive start input (S1 on) Extend feed cylinder (SOL1 on) 2 Feed cylinder fully extended (HES2 on) Retract feed cylinder 3 Feed cylinder retracted (HES1 on) Cycle ends Figure 50. Powered Parts Feeder Sequence Initial Condition The feeder must be in some pre-determined state before any sequence may take place. Many times this will be a state in which the feed cylinder is retracted (HES1 actuated) and parts are present (PE1 on). If either of these conditions is not present, the feeder will not operate and the PLC controlling the feeder may even provide an alarm light or message to the operator, indicating that operator intervention is necessary. HES1 ON PE1 ON FROM SOURCE FEED RETRACTED SOL1 RETRACTED HES1 EXTENDED HES2 FEED Figure 51. Initial Condition 56

57 Step 1: Receive Start Input, Extend Feed Cylinder In this step, the PLC controlling the feeder receives an input to start the feeder sequence. The input may be from another workstation, an operator, or the manipulator tending the feeder. After receiving the input signal, the PLC energizes solenoid valve SOL1 and the feed cylinder extends, pushing a part from magazine. STARTS TO EXTEND FROM SOURCE RETRACTED HES1 EXTENDED HES2 SOL1 FEED Figure 52. Step 1: Input Signal Received, SOL1 Energized 57

58 Step 2: Cylinder Fully Extends, Retract Feed Cylinder Once the feed cylinder is fully extended (HES2 on) and the part dispensed, SOL1 is de-energized by the controller and the feed cylinder retracts. FEED BEGINS TO RETRACT HES1 OFF HES2 ON PART DISPENSED FROM SOURCE SOL1 RETRACTED HES1 EXTENDED HES2 FEED Figure 53. Step 2: Cylinder Fully Extends (HES2 actuated), Cylinder Retracts 58

59 Step 3: Cylinder Fully Retracted, Cycle Ends The feed cylinder continues to retract until it is in its fully retracted position (HES1 actuated). If parts are fed from a gravity chute, a part will drop into position when the feed cylinder becomes fully retracted. The cycle will repeat when the part is removed and the PLC receives the start input again. HES1 ON HES2 OFF FROM SOURCE FEED RETRACTED SOL1 RETRACTED HES1 EXTENDED HES2 FEED Figure 54. Step 3: Cylinder Fully Retracted 59

60 As long as there is a part in the feeder and the cylinder is fully retracted, the feeder will operate the next time the start input is energized. This sequence just described is summarized by sequence diagram in figure 55. POWERED PARTS FEEDER SEQUENCE OF OPERATION INPUTS OUTPUTS Step InputAction OutputAction 0 Start condition Receive start input Extend feed cylinder 1/0 1 2 Feed cylinder fully extended Retract feed cylinder Feed cylinder fully retracted Cycle ends 1 0 End condition Figure 55. Sequence Diagram Start PB Stop PB HES1 HES2 PE1 SOL1 60

61 SKILL 5 DESIGN A PLC PROGRAM THAT SEQUENCES A POWERED PARTS FEEDER Procedure Overview In this procedure, you will design and test a PLC program that uses a single-solenoid DCV to control the powered parts feeder on the 87-MS1 Pick and Place Feeding station. 1. Design a PLC program given the following information. The general sequence, I/O diagram, and power diagram are as follows: General Sequence: 1) Pressing the Start pushbutton (PB1) causes the powered parts feeder to extend. 2) Once the cylinder has fully extended, activating HES2, it will retract. 3) When the cylinder has fully retracted, activating HES1, the process will stop. Special Conditions: Pressing the Stop pushbutton at any time will cause the cylinder to stop (or halt) at the end of its current step. Pressing the Start pushbutton will resume the sequence. A proximity sensor is used to monitor the parts in the parts feeder. As long as there are valve bodies in the parts feeder, the inventory feeder will operate normally and the Start pushbutton lamp will be off when the station is ready to operate. If there are no parts in the feeder, the feeder will not extend and the Start pushbutton lamp should blink indicating that the station needs attention; in this case the part feeder is empty. 61

62 INPUTS I/O DIAGRAM OUTPUTS PB START INPUT I0.0 Q4.0 ACTIVE LAMP HES1 HES2 RETRACTED I1.2 SOL 1 Q4.5 FEED EXTEND EXTENDED I1.3 PE1 PARTS PRESENT I2.7 Figure 56. I/O Diagram FROM SOURCE SOL1 RETRACTED HES1 EXTENDED HES2 FEED Figure 57. Power Diagram 62

63 POWERED PARTS FEEDER SEQUENCE OF OPERATION INPUTS OUTPUTS Step Input Action Output Action 0 Start condition Receive start input Extend feed cylinder 1/0 1 2 Feed cylinder fully extended Retract feed cylinder Feed cylinder fully retracted Cycle ends 1 0 End condition Start PB (I0.0) Stop PB (I0.1) HES1 (I1.2) HES2 (I1.3) PE1 (I2.7) SOL 1 (Q4.5) Figure 58. Sequence Diagram 2. Perform the following substeps to open the PLC programming software. A. Make sure that the interface from the personal computer to the PLC is connected. B. Power up the PC and monitor. C. Start the SIMATIC Manager. 3. Perform the following substeps to create a project. A. Create a Project named L3S5XXX where XXX represents your initials. B. Create an S7 Station object for the station and configure its hardware. C. Open Organizational Block OB1. D. Enter the program that you developed in Step 1 into Organizational Block OB1. E. Save OB1. 4. If the 87-MS1 Pick and Place Feeding station is connected to another station, separate the stations. If the 87-MS1 Pick and Place Feeding station is already disconnected, continue to Step 5. 63

64 5. Perform the following safety check before you begin working on the station. Make sure that you can answer yes to each item before proceeding. YES/NO SAFETY CHECKOUT Remove all obstructions from the work area Check for signs of damage to the equipment Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc. Tie up long hair Remove any robot teach pendants from the work area Locate the emergency stop button Ensure that safety glasses are worn by people in area Ensure that all people are outside any work envelopes Figure 59. Mechatronics Safety Check 6. Connect an air supply line to the station s air manifold quick connect. 7. Plug the station s power cable into a power outlet. 8. Perform the following substeps to power up the 87-MS1 Pick and Place Feeding station. A. Remove the lockout/tagout device from the electrical power source. B. Remove the lockout/tagout device from the pneumatic power source. C. Turn on the air to the station by shifting the lever on the lockout value. D. Set the station s air supply regulator to 50 psi/345 kpa. E. Turn the station s Main Power Switch to the On position. 9. Perform the following substeps to download the project to the PLC. A. Place the Mode Selector Switch in the RUN position. B. Reset the PLC. C. Download the SIMATIC 300 Station object to the PLC. Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart. D. Click Yes on the dialog to complete a warm restart. 10. Go online with the processor and monitor the OB1 Block. 11. Press the Output Power pushbutton to enable the PLC s outputs. 64

65 12. Load the gravity feeder with valve bodies. Orient the valve bodies as shown in figure 60. The side with two ports should face toward the operator panel. INSERT VALVE BODIES HERE FEEDER Figure 60. Valve Body Orientation 13. Perform the following substeps to test the PLC program. At this time, the Start pushbutton lamp should be off, indicating that the parts feeder contains at least one valve body. A. Press the Start pushbutton momentarily. The parts feed cylinder should extend completely, feeding a part to the pickup location and then retract. B. Remove the valve body from the pick up location. C. Press the Start pushbutton and then quickly press the Stop pushbutton before the cylinder has become fully extended. The parts feeder should extend completely, feeding another part and then halt in the extended position. D. Press the Start pushbutton again. The feed cylinder should continue its current sequence, retract and stop. E. Remove the valve body from the pick up location. F. Repeat substeps A and B until there are no more valve bodies in the feeder. The Start pushbutton lamp should blink indicating that the parts feeder is empty. G. Press the Start pushbutton momentarily. The parts feeder should do nothing, because there are no parts to feed. 65

66 14. Perform the following substeps to shut down the 87-MS1 Pick and Place Feeding station. A. Close the LAD/STL/FBD Editor. B. Close the SIMATIC Manager. C. Turn off the PC and monitor. D. Turn the 87-MS1 s main power switch to Off. E. Perform a lockout/tagout on the system s electrical power source. F. Perform a lockout/tagout on the system s pneumatic power source. 66

67 OBJECTIVE 8 DESCRIBE A SEQUENCE OF OPERATION OF A 2-AXIS PICK AND PLACE MANIPULATOR A 2-axis pick and place manipulator has two actuators, which typically move in the x and z-planes to pick parts up from one location, such as a parts feeder, and place them in another location. A 2-axis manipulator requires three directional control valves. Two valves control the manipulator s x and z axes, and one valve to control the gripper. These valves are usually double-solenoid types so a power loss doesn t cause the manipulator to drop the part or move an axis in the opposite direction. X-AXIS DCV Z-AXIS DCV Z-AXIS X-AXIS GRIPPER DCV Figure Axis Pick and Place Manipulator 67

68 The 2-axis manipulator usually has two sensors on each axis to determine when the manipulator s axes have reached their fully extended and retracted positions. The gripper may also have one or more sensors to determine when the gripper has grasped a part. If the gripper is a vacuum type, this sensor would be a vacuum sensor. In the example of figure 62, the manipulator uses magnetic reed switches to detect cylinder position, and a vacuum switch to determine whether a part has been grasped. Z-AXIS RETRACTED (MR1) X-AXIS RETRACTED (MR3) Z-AXIS EXTENDED (MR2) VACUUM SWITCH (V1) X-AXIS EXTENDED (MR4) PART Z-AXIS EXTENDED (MR2) Figure 62. Z-Axis Pick and Place Module Construction 68

69 The sequence of a typical 2-Axis pick and place manipulator is similar to that shown in the table of figure AXIS PICK AND PLACE SEQUENCE STEP INPUT OUTPUT 1 PLC receives start input (S1 on) Extend z-axis to pickup location (SOL3A on) 2 Z-axis extended (MR2 on) Vacuum on (SOL2A on) 3 Vacuum applied (V1 on) Retract z-axis (SOL3B on) 4 Z-axis retracted (MR1 on) Extend x-axis (SOL4A on) 5 X-axis extended (MR4 on) Extend z-axis (SOL3A on) 6 Z-axis extended (MR2 on) Vacuum generator turns off (SOL2B on) 7 Vacuum generator turned off Retract z-axis (SOL3B on) 8 Z-axis retracted (MR1 on) Retract x-axis (SOL4B on) 9 X-axis retracted (MR3 on) Cycle ends Figure 63. Pick and Place Sequence 69

70 Initial Condition The 2-axis manipulator must be in some pre-determined state before any sequence may take place. In this case, the location should be near the pickup point with both the x and z axes retracted (MR3 and MR1 actuated respectively) and the vacuum gripper off. X-AXIS RETRACTED MR3 ON Z-AXIS RETRACTED MR1 ON VACUUM OFF FROM SOURCE RETRACTED MR3 EXTENDED MR4 SOL4A X-AXIS RODLESS SOL4B SOL3A Z-AXIS RETRACTED MR1 SOL3B EXTENDED MR2 SOL2A VACUUM GRIPPER VACUUM SWITCH VACUUM CUP VENTURI SOL2B Figure 64. Initial Condition 70

71 Step 1: PLC Receives Manipulator Start Input, Extend Z-Axis In this step, the PLC receives an input to start the pick and place sequence. The input may be from an operator, another workstation, or the feeder itself indicating that a part is in place. After receiving the input signal, the PLC energizes solenoid valve SOL3A and the z-axis extends towards the pickup point, as shown in figure 65. As the z-axis extends, MR1 is de-actuated. Z-AXIS BEGINS TO EXTEND FROM SOURCE RETRACTED MR3 EXTENDED MR4 SOL4A X-AXIS RODLESS SOL4B SOL3A Z-AXIS RETRACTED MR1 EXTENDED MR2 SOL3B SOL2A VACUUM GRIPPER VACUUM SWITCH VACUUM CUP VENTURI SOL2B Figure 65. Step 1: PLC Receives Manipulator Start Input, Extend Z-Axis 71

72 Step 2: Z-Axis Cylinder Extended, Vacuum On When the z-axis cylinder has fully extended, it actuates sensor MR2, as shown in figure 66. This causes the vacuum gripper to turn on (SOL2A). MR1 OFF MR2 ON Z-AXIS EXTENDED VACUUM ON FROM SOURCE RETRACTED MR3 EXTENDED MR4 SOL4A X-AXIS RODLESS SOL4B SOL3A Z-AXIS RETRACTED MR1 EXTENDED MR2 SOL3B SOL2A VACUUM GRIPPER VACUUM SWITCH VACUUM CUP VENTURI SOL2B Figure 66. Step 2: Z-Axis Cylinder Extended, Vacuum On 72

73 Step 3: Vacuum Applied, Retract Z-Axis When the vacuum switch closes, indicating that the part is grasped, the PLC energizes SOL3B and de-energizes SOL3A, causing the z-axis to retract as shown in figure 67. As the z-axis retracts, it leaves MR2. Note that the vacuum generator (SOL2A) remains on and will remain on until the part is at the dropoff (place) point. MR1 OFF MR2 ON Z-AXIS BEGINS TO RETRACT PART IS GRIPPED FROM SOURCE RETRACTED MR3 EXTENDED MR4 SOL4A X-AXIS RODLESS SOL4B SOL3A Z-AXIS RETRACTED MR1 SOL3B EXTENDED MR2 SOL2A VACUUM GRIPPER VACUUM SWITCH VACUUM CUP VENTURI SOL2B Figure 67. Step 3: Vacuum Applied, Retract Z-Axis 73

74 Step 4: Z-Axis Retracted, Extend X-Axis Once fully retracted, the z-axis actuates sensor MR1, causing the x-axis to extend (SOL4A on). As the x-axis extends, sensor MR3 is de-actuated. MR1 ON X-AXIS BEGINS TO EXTEND MR2 OFF Z-AXIS RETRACTED FROM SOURCE RETRACTED MR3 EXTENDED MR4 SOL4A X-AXIS RODLESS SOL4B SOL3A Z-AXIS RETRACTED MR1 SOL3B EXTENDED MR2 SOL2A VACUUM GRIPPER VACUUM SWITCH VACUUM CUP VENTURI SOL2B Figure 68. Step 4: Z-Axis Retracted, Extend X-Axis 74

75 Step 5: X-Axis Extended, Extend Z-Axis When the x-axis cylinder is fully extended, it actuates sensor MR4. As a result, the PLC de-energizes the z-axis retract solenoid (SOL3B) and energizes SOL3A, causing the z-axis to extend towards the drop off point. As the z-axis extends, it leaves sensor MR1. MR3 OFF MR4 ON X-AXIS EXTENDED Z-AXIS BEGINS TO EXTEND FROM SOURCE RETRACTED MR3 EXTENDED MR4 SOL4A X-AXIS RODLESS SOL4B SOL3A Z-AXIS RETRACTED MR1 EXTENDED MR2 SOL3B SOL2A VACUUM GRIPPER VACUUM SWITCH VACUUM CUP VENTURI SOL2B Figure 69. Step 5: X-Axis Extended, Extend Z-Axis 75

76 Step 6: Z-Axis Extended, Vacuum Off When the z-axis is extended fully, it actuates sensor MR2. This causes the vacuum to go off (SOL2B on, SOL2A off). As a result, the vacuum is turned off and the part is released. MR1 OFF MR2 ON Z-AXIS EXTENDED FROM SOURCE RETRACTED MR3 EXTENDED MR4 SOL4A X-AXIS RODLESS SOL4B SOL3A Z-AXIS RETRACTED MR1 EXTENDED MR2 SOL3B SOL2A VACUUM GRIPPER VACUUM SWITCH VACUUM CUP VENTURI SOL2B Figure 70. Step 6: Z-Axis Extended, Vacuum Off 76

77 Step 7: Vacuum Switch Off, Retract Z-Axis After the vacuum is turned off (vacuum switch off), the part is released and the PLC energizes the z-axis retract solenoid (SOL3B) and de-energizes the z-axis extend solenoid (SOL3A). This causes the z-axis to retract, as shown in figure 71. As the z-axis retracts, it leaves sensor MR2. Z-AXIS BEGINS TO RETRACT VACUUM OFF PART RELEASED FROM SOURCE RETRACTED MR3 EXTENDED MR4 SOL4A X-AXIS RODLESS SOL4B SOL3A Z-AXIS RETRACTED MR1 SOL3B EXTENDED MR2 SOL2A VACUUM GRIPPER VACUUM SWITCH VACUUM CUP VENTURI SOL2B Figure 71. Step 7: Vacuum Switch Off, Retract Z-Axis 77

78 Step 8: Z-Axis Retracted, Retract X-Axis Once fully retracted, the z-axis actuates MR1, causing the x-axis to retract (SOL4B on, SOL4A off). This turns off SOL3B (z-axis retract). As the x-axis retracts, it leaves sensor MR4 and continues towards the pickup point. MR2 OFF MR1 ON Z-AXIS RETRACTED X-AXIS BEGINS TO RETRACT PART FROM SOURCE RETRACTED MR3 EXTENDED MR4 SOL4A X-AXIS RODLESS SOL4B SOL3A Z-AXIS RETRACTED MR1 SOL3B EXTENDED MR2 SOL2A VACUUM GRIPPER VACUUM SWITCH VACUUM CUP VENTURI SOL2B Figure 72. Step 8: Z-Axis Retracted, Retract X-Axis 78

79 Step 9: X-Axis Retracted, Cycle Ends Once the x-axis is fully retracted, the cylinder actuates sensor MR3. As it does, the x-axis retract solenoid turns off and the cycle is ended. The 2-axis manipulator will remain in this condition until it the PLC receives an input indicating that a part is ready to be picked up. The cycle will repeat when the part is moved out of the way and the PLC receives another start input. MR3 ON MR4 OFF X-AXIS RETRACTED FROM SOURCE RETRACTED MR3 EXTENDED MR4 SOL4A X-AXIS RODLESS SOL4B SOL3A Z-AXIS RETRACTED MR1 SOL3B EXTENDED MR2 SOL2A VACUUM GRIPPER VACUUM SWITCH VACUUM CUP VENTURI SOL2B Figure 73. Step 9: X-Axis Retracted, Cycle Ended 79

80 74. This sequence just described is summarized by the sequence diagram in figure 2AXISPICKANDPLACESEQUENCEOFOPERATIONS INPUTS OUTPUTS Start PB Stop PB Auto MR1 MR2 MR3 MR4 Vacuum Switch SOL3A SOL3B SOL2A SOL2B SOL4B SOL4A Step Input Action Output Action 0 StartCondition Recieve Start Input Extend Z-Axis to pickup location 1/0 1 2 Z-AxisExtended VacuumOn Vacuum Applied Retract Z-Axis Z-Axis Retracted Extend X-Axis X-AxisExtended ExtendZ-Axis Z-AxisExtended VacuumOff Vacuum Removed Retract Z-Axis Z-Axis Retracted Retract X-Axis X-Axis Retracted Cycle Repeats End Condition Figure 74. Sequence Diagram 80

81 SKILL 6 DESIGN A PLC PROGRAM THAT SEQUENCES A 2-AXIS PICK AND PLACE PNEUMATIC MANIPULATOR Procedure Overview In this procedure, you will design and test a PLC program that uses double solenoid DCVs to control the 2-Axis pick and place pneumatic manipulator on the 87-MS1 Pick and Place Feeding station. 1. Design a ladder logic routine given the following information. The general sequence, I/O diagram, and power diagram are as follows: General Sequence 1) Pressing the Start button causes the 2-axis pick and place manipulator s z-axis (SOL3A on) to extend 2) Once the z-axis is extended (MR2 on), the vacuum generator turns on (SOL2A on) 3) Vacuum applied (Vacuum Switch on), z-axis retracts (SOL3B on, SOL3A off ) 4) Z-axis retracted (MR1 on), x-axis extends (SOL4A on) 5) X-axis extended (MR4 on), z-axis extends (SOL3A on, SOL3B off ) 6) Z-axis extended (MR2 on), vacuum generator turns off (SOL2B on, SOL2A off) 7) Vacuum generator turned off, z-axis retracts (SOL3B on, SOL3A on) 8) Z-axis Retracted (MR1 on), x-axis retracts (SOL4B on, SOL4A off) 9) X-axis retracted (MR3 on), Cycle ends Special Conditions Pressing the Stop pushbutton at any time will cause the 2-axis manipulator to stop (or halt) at the end of its current step. Pressing the Start pushbutton will resume the sequence. The Start pushbutton lamp should be off, indicating that the station is ready, when the manipulator is in its home position (z and x axes retracted and the vacuum gripper off). It should be on solid during the cycle. Program logic should start the manipulator sequence from its home position. The manipulator should not extend to pick up a part unless there is a part present in pickup location (3-position switch in Auto position. This simulates the parts present sensor). 81

82 If the part is not grasped (vacuum switch on) within 500 ms, the cycle will stop and cause the Start pushbutton indicator to blink. INPUTS I/O DIAGRAM OUTPUTS PB SS START INPUT I0.0 Q4.0 ACTIVE LAMP RESET I1.0 Q4.6 Z-AXIS EXTEND (SOL3A) AUTO I1.1 Q4.7 Z-AXIS RETRACT (SOL3B) MR1 Z-AXIS RETRACTED I1.4 Q5.3 VACUUM ON (SOL2A) MR2 Z-AXIS EXTENDED I1.5 Q5.4 VACUUM OFF (SOL2B) MR3 X-AXIS RETRACTED I2.0 Q5.5 X-AXIS RETRACT (SOL4B) MR4 X-AXIS EXTENDED Q5.6 X-AXIS EXTEND (SOL4A) I2.1 SW VACUUM SWITCH I2.6 Figure 75. I/O Diagram 82

83 FROM SOURCE X-AXIS RETRACTED MR3 X-AXIS EXTENDED MR4 SOL4A X-AXIS RODLESS SOL4B SOL3A Z-AXIS Z-AXIS RETRACTED MR1 SOL3B Z-AXIS EXTENDED MR2 SOL2A VACUUM GENERATOR VACUUM SWITCH VACUUM CUP VENTURI SOL2B Figure 76. Power Diagram 2 AXIS PICK AND PLACE SEQUENCE OF OPERATIONS INPUTS OUTPUTS Start PB (I0.0) Stop PB (I0.1) Auto (I1.1) MR1 (I1.4) MR2 (I1.5) MR3 (I2.0) MR4 (I2.1) Vacuum Switch (I2.6) SOL3A (Q4.6) SOL3B (Q4.7) SOL2A (Q5.3) SOL2B (Q5.4) SOL4B (Q5.5) Step Input Action Output Action 0 Start Condition Recieve Start Input Extend Z-Axis to pickup location 1/0 1 2 Z-Axis Extended Vacuum On Vacuum Applied RetractZ-Axis Z-Axis Retracted Extend X-Axis X-Axis Extended Extend Z-Axis Z-Axis Extended Vacuum Off Vacuum Removed Retract Z-Axis Z-Axis Retracted Retract X-Axis X-Axis Retracted Cycle Repeats End Condition Figure 77. Sequence Diagram 83

84 2. Perform the following substeps to open the PLC programming software. A. Make sure that the interface from the personal computer to the PLC is connected. B. Power up the PC and monitor. C. Start the SIMATIC Manager. 3. Perform the following substeps to create a project. A. Create a Project named L3S76XXX where XXX represents your initials. B. Create an S7 Station object for the station and configure its hardware. C. Open Organizational Block OB1. D. Enter the program that you developed in Step 1 into Organizational Block OB1. E. Save OB1. 4. If the 87-MS1 Pick and Place Feeding station is connected to another 87-MS station, separate the stations. If the 87-MS1 Pick and Place Feeding station is already disconnected, continue to Step Perform the following safety check before you begin working on the station. Make sure that you can answer yes to each item before proceeding. YES/NO SAFETY CHECKOUT Remove all obstructions from the work area Check for signs of damage to the equipment Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc. Tie up long hair Remove any robot teach pendants from the work area Locate the emergency stop button Ensure that safety glasses are worn by people in area Ensure that all people are outside any work envelopes Figure 78. Mechatronics Safety Check 6. Connect an air supply line to the station s air manifold quick connect. 7. Plug the station s power cable into a power outlet. 8. Perform the following substeps to power up the 87-MS1 Pick and Place Feeding station A. Remove the lockout/tagout device from the electrical power source. B. Remove the lockout/tagout device from the pneumatic power source. C. Turn on air to the station by shifting the lever on the lockout valve. D. Set the station s air supply regulator to 50 psi/345 kpa. E. Turn the station s Main Power switch to the On position. 84

85 9. Perform the following substeps to download the project to the PLC. A. Place the Mode Selector Switch in the RUN position. B. Reset the PLC. C. Download the SIMATIC 300 Station object to the PLC. Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart. D. Click Yes on the dialog to complete a warm restart. 10. Go online with the processor and monitor the OB1 Block. 11. Press the Output Power pushbutton to enable the PLC s outputs. 12. Use the valves manual overrides to return the 2-axis manipulator to its home position, x-axis retracted, z-axis retracted, and vacuum off. 13. Place a parts bin at the manipulator s dropoff point to capture the parts as they are dropped off. 14. Perform the following substeps to test the operation of the program. At this time, the Start pushbutton light should be off indicating that the manipulator is in its homed position. A. Press and release the Start pushbutton. The manipulator should not move because the part present sensor is not activated. B. Place a valve body at the pickup point as shown in figure 79. Figure 79. Valve Body Orientation in Parts Feeder 85