Project 4: Optimizing of a production line by integration of a safety modules

Transcription

1 Project 4: Optimizing of a production line by integration of a safety modules Weighting (points out of total) 17/100 t max 120 min Scenario Atone station you have to reduce the the risk of injury by assembling of a sagfety door. Task Your task is to prepare yourself as good as possible for the optimisation and after that to realise the modification as fast as possible. Develop a program and commission the production line. Your task is complete when: 1. The production line has been mechanically assembled, correctly wired and connected and its correct operation is guaranteed (based on evaluation using the simulation box). 2. Correct execution of the program with PLC activation (based on evaluation/plc board) is guaranteed. 3. The system meets the specifications (in accordance with the 'Agreement on Professional Practice'). The system must run at the latest after 1 hour. You will have no opportunity to make improvements later. WorlSkills Germany Mechatronics Competition

2 1. Procedure for the optimization: After a max preparation time of 60 minutes all together will start. For the realisation of the optimization on the station you have again further 60 minutes Target: Integration and Commissioning of a safety door in the shortest time at Handling station. Condition: The PLC-program can be already modified during the preparation time. The PLC-program will not be downloaded into the PLC and tested during the preparation time! During the preparation time you do not work and you do no modification at the system. Via a help-cable you can take 0V and 24 V from a power supply. All teams prepare the safety function There are no points fort he preparation time The function of the program is the same like in task 3 If you open the door all actuators of the station will be switched off (not the control panel) If you open the door the red signal lamp flashes with 2 Hz. After closing the door you have to reset the safety relay After that via the Reset-Lamp the station asks for moving to initial position. From every situation of the station it must be possible to move to the initial position If the gripper has gripped a, at first it must be placed on slide 1. The components: Support system for safety door and switch Use the big door with safety switch Pilz-Safety relay (PNOZ S4); Assembling on rail at the MPS-Station Use the Reset- Button only. (Quittieren) WorlSkills Germany Mechatronics Competition

3 Connectors on the switch: Betätiger gesteckt gezogen Actuator inserted removed Elemento de accionamiento insertado extraído Actionneur inséré sorti Kabel-Belegung Wiring allocation Distribución de conexiones Câblage Pin Aderfarbe Core colour Color del hilo Coul. du cond. Funktion function función fonction 1 Weiß White Blanco Blanc 11 (24 V) Öffner 1 NC contact 1 contacto normalmente cerrado 1 contact NF 1 2 Braun Brown Marrón Marron 21 (24 V) Öffner 2 NC contact 2 contacto normalmente cerrado 2 contact NF 2 3 Grün Green Verde Vert 4 Gelb Yellow Amarillo Jaune 5 Grau Grey Gris Gris 12 Öffner 1 NC contact 1 contacto normalmente cerrado 1 contact NF 1 6 Rosa Pink Rosa Rose 22 Öffner 2 NC contact 2 contacto normalmente cerrado 2 contact NF 2 7 Blau Blue Azul Bleu 8 (Rot Red Rojo Rouge) Shield nicht belegt not connected no ocupado non connecté Änderungen vorbehalten Subject to change Reservado el derecho de modificación Sous réserve de modifications WorlSkills Germany Mechatronics Competition

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5 Evaluation Project 4 Optimizing of a production line by integration of a safety system Team: Verification of acceptance by experts (names, signatures): _ Time max.: 60 min (PT) +60 min (RT). Points max.: 17 Time: Description Evaluation Maximum evaluation Function to be checked using simulation box in the Handling station if there is not full function with PLC Done Max Points (Output 0 7: Signal 1 or 0) Preparation: Insert a into the magazine, connect the simulation box to the I/O terminal. (Output 0 7: signal 1 or 0) Open gripper (Out 3: 1) Eject from magazine (Out 4: 1) Gripper unit to position magazine (Out 1: 0; Out 0: 1) Retract ejecting arm (Out 4: 0) Gripper down (Out 2: 1) Close gripper (Out 3: 0) Gripper up (Out 2: 0) Gripper unit to position next station/slide 2 (Out 1: 1; Out 0: 1) SimuBox Handling station 0,8 WorlSkills Germany Mechatronics Competition

6 Description Evaluation Maximum evaluation Function to be checked using simulation box in the Turning station if there is not full function with PLC Done Max Points (Output 0 7: Signal 1 or 0) Preparation: Put on the belt, connect the simulation box to the I/O terminal. Station in Initial position ((Out 6: 1); (Out 4: 0; Out 3: 1) Transport to the stopper (Out 0: 1) Conveyor of (Out 0: 0) Retract stopper (Out 2: 1) Move turning module to pick up position (Out 4: 1; Out 3:0) Glose gripper (Out 6: 0) Move turning module to slide (Out 4: 0; Out 3:1) Open Grippper (Out 6: 1) Extend stopper (Out 2: 0) Put a on stopper and close the gate (Out 7: 1) Transport tot he small slide (Out 1: 1) Open gate (Out 7: 1) Conveyor OFF (Out 1: 0) SimBox Turnning station 1,2 SimBox total 2,0 WorlSkills Germany Mechatronics Competition

7 Description Evaluation Maximum evaluation Function check with PLC Done Max. Points Preparation: Remove all s from the stations, connect the PLC boards to the I/O terminals and the control panels, switch key to the position AUTO, start the PLCs, no programming cable / WLAN between PC and PLC, valve for air opened, Handling linear drive between sensors, Turning module Gripper at position belt, Door in Handling station closed Function START Signal lamp RED ON ** Turning station Lampe Reset AN (Turning Station) Switch key to the position MAN (Turning Station) then signal lamp YELLOW ON ** Press Reset button (Turning Station) then system moves to initial position Lamp Reset OFF if system is in the initial position Switch key to the position AUTO (Turning Station) then lamp START ON (Turning station) Handling station Lamp Reset ON (Handling Station) Switch key to the position MAN (Handling Station) Press Reset button (Handling Station) then system moves to initial position Lamp Reset OFF if system is in the initial position Switch key to the position AUTO (Handling Station) then lamp START ON (Handling station) And signal lampe GREEN flashing with 1 Hz** Put a number of pots (min 6) into the magazine of the Handling station* as instructed by the evaluation team Press the START button (Handling Station) then lamp START OFF (Handling Station) (no movements) Press the START button (Turning station) then Signal lamp GREEN ON ** and lamp START OFF (Turning station) A: Eject if pickup position empty Transfer pot to the next station 0,3 Partial points 2,6 WorlSkills Germany Mechatronics Competition

8 If red or silver with hole Done Max. Points If red or silver with Done Max. Points on top hole down Transport to conveyor end Workpiece stops at stopper If at conveyor end*** then flashing lamp Q2 with mit 2 Hz (Turning station) Take of the from the belt by hand, then Q2 OFF Continue automaticaly with A: if the belt is free until the Magazin is empty The turning module pick up the The turning module turns the The turning module put the back on the belt The turning module moves to its initial position Transport to conveyor end If at conveyor end*** then flashing lamp Q2 with mit 2 Hz (Turning station) Take of the from the belt by hand, then Q2 OFF Continue automaticaly with A: if the belt is free until the Magazin is empty Partial points 0,6 Partial points 1,0 If black with hole on top Done Max. Points If black with hole down Done Max. Points Workpiece stops at stopper Workpiece stops at stopper Glose gate The turning module pick up the Transport onto the small slide Continue automaticaly with A: if the belt is free until the Magazin is empty The turning module turns the The turning module put the back on the belt The turning module moves to its initial position Glose gate Transport onto the small slide Continue automaticaly with A: if the belt is free until the Magazin is empty Partial points 0,6 Partial points 1,0 WorlSkills Germany Mechatronics Competition

9 If transparent with hole Done Max. Points If transparent with Done Max. Points on top hole down Workpiece stops at stopper Workpiece stops at stopper The turning module pick up the The turning module put the onto the slide The turning module moves to its initial position Continue automaticaly with A: if the belt is free until the Magazin is empty The turning module pick up the The turning module turns the The turning module put the back on the belt The turning module moves to its initial position Continue automaticaly with A: if the belt is free until the Magazin is empty Partial points 0,6 Partial points 1,0 Partial points 2 aus 6 (1 x ohne drehen; 1 x mit drehen) 1,6 WorlSkills Germany Mechatronics Competition

10 If pot magazine empty Q1 ON (Lamp at Control panel) Ejecting arm retraced Gripper stops at basic position if the previous job is finished Lamp Start ON (Handling station) Signal lamp YELLOW flashing with 2 Hz ** Put a pot into magazine n Press the START button (Handling Station) then lamp START OFF (Handling Station) And signal lamp GREEN ON ** And Lamp Q2 OFF And Continue with A automatically 0,3 Check of the safety function If you open the door all actuators of the station will be switched off (not the control panel) 0,5 If you open the door the red signal lamp flashes with 2 Hz 0,5 After closing the door you have to reset the safety relay 0,5 After that via the Reset-Lamp the station asks for moving to initial position 0,5 From every situation of the station it must be possible to move to the initial position 0,5 Press Reset Button (Handling Station) ==> Station moves to initial position If the gripper has gripped a, at first it must be placed on slide 1. 0,6 ** At any time only one lamp of the signal column is on Partial points 4,8 PLC board total 9 * Red, black, silver or transparent will be chosen by the evaluation team. *** Stop at conveyor end max 1 mm WorlSkills Germany Mechatronics Competition

11 Description Evaluation Maximum Evaluation Professional practice List of Professional Practice will be checked in samples PP item no. Not fullfiled * -0,5 * -0,5 * -0,5 * -0,5 * -0,5 Professional practice total 2,5 * Each deviation will result in 0,5 points being deducted Description Evaluation Maximum evaluation Time evaluation (only if the maximum number of points is achieved for PLC board and simulation box function and at least 1,5 points for professional practice) Points for time = (max. time actual time) x max. points /(max. time min. time) = ( ) x 3,5 Points / ( ) 3,5 Total evaluation Project 4: Description Evaluation Maximum evaluation Points for operation based on simulation box 2 Points for operation based on PLC board 9 Points for professional practice 2,5 Points for time evaluation 3,5 Total points 17 WorlSkills Germany Mechatronics Competition