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ER-MicroCIM User`s Manual

1. SST 45 J15 MN m FROM CONTROLLER B BLOCKS A C FROM CONTROLLER B BLOCKS B D 5253 M S S 8 25 SIR NOTE FROM CONTROLLER A v EMERGENCY BLOCK COMMONS NOT FUNCTIONAL INPUTS BLOCK C INPUTS BLOCK D JI JI J10 m J12 13 INS 1 13 5 COM 8 NS 6 LJEJLEJI LJ J J J8 J9 COM 05 06 07 08 09 010 COM COM 011 012 013 014 015 016 COM OUTPUTS BLOCK AB OUTPUTS BLOCK B RELAY RELAY 2 OUTPUTS 23 OUTPUTS 25 2 2 NC C NC C NO NC C NC C NO OUT 1 OUT 2 OUT 3 OUT 4 J 97 24VDC 12VDC COMMON EARTH 1 09 B M USER POWER SUPPLY ESHED ROBOTEC 1982 170 REMOTE EMERGENCY Figure 7 I O Box Connectors ER MicroCIM 14 User s Manual 9602 4 5 4 5 1 Note Note Software Installation The software installation procedures will be performed in the following order Installation of the ER MicroCIM version of the Open CIM software on the CIM Manager PC Installation of the ROBOTVISIONpro software ACL for ACL controller version on the Vision PC Configuration of the ACL controller and downloading o
2. Figure 35 Aluminum Cylinder Material ALUMINUM 6061 Surf Rough N9 Fillet Rad 0 2 Break Edges 0 2 X 45 Dimensions MM User s Manual 51 ER MicroCIM 9602 8 5 Barcode Reader Setup To set up the LS 6x20 barcode scanner for operation in the ER MicroCIM cell it must be programmed using the barcodes listed in the following table These barcodes can be found in the section Programmer s Guide of the Product Reference Guide for the LS 6x20 scanner The barcodes must be scanned in the order in which they appear in the table Note prevent interference from adjacent barcodes on the same page it may be useful to cut a hole in a blank sheet of paper and place it over the barcode before scanning If you make a mistake when scanning you must repeat the entire sequence from Step 1 Step Name of Barcode Pg in to Scan LS6x20 Reference Guide 1 SET DEFAULT 19 2 INTERLEAVED 2 OF 5 22 LENGTH 1 Range 01 31 3 0 23 4 6 23 5 23 6 PARITY 28 7 SPACE 28 8 ENTER 28 This procedure sets the barcode scanner for the following setup RS232 parameters Barcode type Baud rate 9600 8 data bits 2 stop bits No parity No handshake Interleaved 2 of 5 first length 6 ER MicroCIM 52 User s Manual
3. Play File Figure 22 Workstation 1 Stand Alone Operation 7 3 2 Stand Alone Operation Station 2 Workstation 2 is a complete vision system To operate Workstation 2 as a stand alone system you will work directly on the Vision Computer and perform all operations as described in the ROBOTVISIONpro User s Manual Place a light table or a small board on the conveyor under the camera Be sure that the conveyor will not be moved during Alternately you can turn the camera away from the conveyor and work on another table top Be certain you can and will return the camera to its proper position in order to resume integrated use of the ER MicroCIM system ER MicroCIM 40 User s Manual 9602 8 Technical Data 8 1 Reports From either the User or System Manager group window click on the OpenCIM Report icon to open the Open CIM Report Generator menu See Figure 24 The Report Generator allow you to view all data and definitions in the ER MicroCIM environment Figures 25 through 31 show the reports which result from the sample application supplied with the system Report Generator Ver 1 4 Select The Requested Report Print Destination Part Report C Analysis Report Print to Window C Sub Part Report C Location Status C Print to Printer C Order Report C Report C Print to File C Machine Report C User Report 1 C Process Repor
4. 55 ER MicroCIM vi User s Manual 9602 10 Suggested Study 5 56 10 1 Modules Sete m ROM 56 E ES 56 10 1 2 Robot Mechanisms 56 10 1 9 PID Gontrol uo vM EIN wee Se 57 10 1 4 Computer Communication 57 10 1 5 Pneumatic Systems 57 10 1 6 Sensors PLC Control 57 10 1 7 Identification Systems 57 10 1 8 Vision and Quality Control 58 10 1 9 Manufacturing Software 58 10 2 GOUISOS iacu 4 ot u sS dog ute elu utendo 58 10 2 1 AMT Semesterl 58 10 22 AMT Semester ll i omo EROR 59 10 43 AMT Semester ll 2 0200 59 10 24 AMT SemesterlV 59 User s Manual Vii ER MicroCIM 9602 1 Introduction Read this manual thoroughly before you install or operate the ER MicroCIM 1 1 About ER MicroCIM The ER MicroCIM system demonstrates the integration of various educational disciplines which are usually taught independent of one another These technologies include robotics electronics pneumatics programmable logic controllers sensors machine vision barcodes software programming manufacturing processes
5. RN ENDEL Bi xi PENDEL BLU 15 COMOUTI 1816 COMOUT2 TBI coun TB18 noa Old Lat DIO om mm 20 um 1821 um 1877 um TB22 um 5 RED J nz um TR23 xx WHT BLK BRN Cus wu TB24 um WHT BUK YLW_ 6 yg um 1825 7 8 68 C ns um 1826 91 8 80 C we 1827 CT um 2 us 1629 A ne m 1830 mm pon u T851 um 759 1832 C7 wi um B33 m SEO amp x 1834 om amp x 1835 mm peen C ms um 1836 um um 37 um mm 38 mm 0211007 VOX 21 JdNI 18 THM d8 318V3 NES 59 31899 dw 318V3 Xi8 dy 318V3 4g 318v3 gt q13NYd 101NO2 W103 RED Figure 33 System Wiring User s Manual 47 ER MicroCIM 9602 MICRO INTERCONNECTION WIRE LIST END1 END2 CABLE LENGTH mm DESCRIPTION N PNL START 23 E28 2 1 402280 B29 2 D40228 GRN STO B34 2 D40228 BRN B36 2 D40228 BLK CONPNLEMG 14 TE3 2 4028 EMO4 COAIN
6. S hua 5 RT dede ded on Yorke 5 A installation su nr TEC eoe i le ee re twr S 7 41 Unpacking sha eu 7 42 SOUP xA Poe we 7 43 7 4 3 1 Pneumatic Parts Feeder xoxo xw RE ES 7 4 3 2 SCORBOT ER Vplus Robot 9 439 GonbrollersN ox 9 4344 ASRS suse ee ae isma Topo kie Sio Ae 9 4 3 5 Barcode Reader sexe mE rwr AE ode ECT Ancien 9 43 5 Conveyor Pallets AR s 10 4 3 7 Templates 10 4 3 8 Palletizing Finished Parts 10 4 3 9 Computers 10 49 10 VISION EE ee 10 e Ae Ree de dou e ren corr d 12 4 5 5 15 4 5 1 Installation oaoa 15 4 5 2 ROBOTVISIONpro Installation ls 16 4 5 3 16 46 Teaching Robot 5 5 19 47 Stand Alone Testing and Adjustment of Devices 23 4 7 1 CONVEYOR s Ed
7. CONPNLEMG 22 8352 fD4022 ORN EMGXPLCINI5 CONPNLEMG 21 TB14 2 fD4022 BRED EMO1 24VDC O CON PNL AUTO MAN 13 Cc 0 z z z m z c 2 WOCARDJ1 COMMON TB36 1 HD4022 BLK CONTACOMMON CARD J10 INT 371 HD4022 RED CARD J2 C TB18 1 HD40220 NwNTT CONTAOUT1COM CARD J2 NO 7821 HD40229 GRN CONTAOUT1NO LC IN 3 B23 1 TA2 ARID1 LC IN 4 B24 1 500 TA3 IDO LC IN 5 B25 1 500 TA3 ARID1 LC IN 6 B26 1 4 100 829 RHD411823 WHTYLW 500 STOP LC IN 11 B31 1 LT INPLACE LC IN 12 B32 1 500 UP INPLACE LC IN13 B33 1 500 LC IN14 B34 1 D411823 WHT BLK LC IN15 B35 1 D411823 WHTIGRN LC COM IN1 B17 1 D411823 RED LC COM IN2 B17 3 D411823 BLK LC OUT B7 1 D411823 BRN LC OUT 1 B6 1 D411823 PUR LC OUT 2 B5 1 500 IBTON 3 LC OUT3 B4 1 500 4 IPLCOUT4 TE31 HD41182 2GRN PLC PWR 151 MIO4BLK TWISTEDP GNDBUS LC CHASSIS GND 350 CHASSIS GND WR SPLY BRN B14 4 WR SPLY BLU B15 2 B3 2 LC OUT4 n TB153 MIO4BLK MOTH RLI MBLK RLI24 y RL1 21 RED 1 RLI C2
8. Click on Start CIM simulation Device drivers will be loaded and the OpenCIM System Manager screen is displayed See Figures 14 and 15 Micro CIM System Manager 25 Start simulation Figure 13 m Storage Refresh zi Asrs Start zt fes Manager Log Not OK Start Start R Pma pun Log OK Robot On ly Real Mode System Manager Group Window User s Manual 9602 27 ER MicroCIM 2 From the Open CIM Manager window the following Click on the yellow lightning bolt This sends a command to reset INIT all device drivers The run arrow will now turn green Three windows also cascade onto the screen Program View Log View Order View These windows show the status of work in progress they are for viewing only Click on the green run arrow The ll pause button will now turn blue The Leaf View window will now also appear Watch the screen and wait until a box appears with the message CIM PROD HAS BEEN FINISHED Click on Ok Another message appears ORDER HAS BEEN FINISHED 3 Close the Open CIM Manager and all drivers which appear in the Task List 4 Click on MicroCIM System Manager VC2RE MAP A DOS box will appear for a few seconds This will prepare system for on line operation as detailed the follo
9. You will see the other marking Check whether the correct object name is displayed Select ROBOT Automatic Mode Press Enter Make sure you see the ACL prompt in the upper text box See Figure 17 ER MicroCIM 30 User s Manual 9602 Inage Cluster Pattern Options Lookup Table Dahat Mintan Automatic Mode _Identification Figure 16 ROBOTVISIONpro Automatic Mode Screen 7 Templates and Parts Place a plexiglass base on each of the six templates Place the six loaded templates into the six cells on the ASRS rack Make sure the barcode on the template faces away from the robot and the handle faces the robot Fill the parts feeder with the cylinders Make sure there are no parts or templates anywhere in the cell except in the feeder and ASRS rack 8 Pallets and Buffers Place the two pallets anywhere along the conveyor Make sure the arrow on the pallet is facing in the same direction as the movement of the conveyor Make sure the two buffers are empty User s Manual 3l ER MicroCIM 9602 6 User System Operation This chapter provides basic instructions for activating the ER MicroCIM system and running the preprogrammed production sequence 6 1 System Overview Open the User group window See Figure 18 This group contains basic applications required for on line operation of the ER MicroCIM system The following is a brief description of the modules and features which are av
10. pi Lumas p Figure 26 ASRS Report ER MicroCIM 42 User s Manual 9602 8 1 4 Part Definition Report The Part Definition Report shows the names and descriptions of all parts used in the ER MicroCIM It lists parts in all stages of production Open CIM Report Window sd 4 Read Selected Total 7 7 100 ESHED CYLINDER SUP Open CIM Part Definition Report Printed 121495 Type Part Template ID Part Description Supplied 11 0t CYLINDER FROM THE FEEDER PLEXIGLASS SUP Supphed 1 02 PLEXIGLASS SUP FROM THE ASRS PROD Product 21 01 CIM PRODUCTION ERRTMPL Phantom 99 99 ERROR TEMPLATE ERRCIM ERROR PRODUCT PROD Product 22 01 ASRS VISION ASRS BOX Phantom 93 Supplied 2 02 SUPPLIED BOX BAR 8 1 5 Sub Part Report Figure 27 Part Definition Report The Sub Parts Report is a Bill of Material It shows all the sub parts which comprise the finished product Open CIM Report Window m A Bi mi 2 e nesa 100 ESED conoce Open CIM Sub Parts Report Printed 12 14 95 PLEXIGLASS_SUP READC ERRTMPL ONFAIL ASRS CYLINDER_SUP ASSEMBLY VISION 1 ERRCIM O
11. he 43 Sd ASRS LESE ade u ate 43 8 1 4 Definition Report 44 9 1 5 S b Part Report ox ae ah eiut Ruso aen fedem ed 44 8 1 6 45 Sel xat tex deii etate 45 8 1 8 BSerHepOll RR VES S aes xz 46 8 2 Device ID eidem Xo ere dot et eden ax 47 actas 48 8 4 Technical Drawings of Parts lll 51 8 4 1 Plexiglass Base HR eo E IM AO POR 51 8 4 2 Aluminum Cylinders 52 8 5 Barcode Reader Setup 53 8 6 Known Problems nanoa aaa 54 8 6 1 Bug Incorrect Status in Controller for ACL Program RVP 54 8 6 2 Order Limitation 54 9 Maintenance and Repairs 55 9 1 Har OWale cors E hea Bee ee 8 55 9 1 1 CONVEYOR s s ly Sane dosi yea e ob SA oes 55 9 1 2 55 91 3 Pneumatic System ee ee ee 55 9 1 4 Electrical Wiring 55 9 2 5 lt 5 55 9 2 1 OpenCiM 5 55 9 2 2 Vision System
12. 1 VISION 00 00 00 PROD 1 1 ONFAIL 2 TRASHI PROD I 1 TARGET RACKI PROD I 1 NEXT CYLINDER_SUP 1 1 GET CYLINDER_SUP FDR1 ERRTMPL 1 1 TARGET ASRS 1 ASRS 2 TARGET TRASH ERRCIM 1 2 FREE TEMPLET ASRS Figure 29 Aplan Report ER MicroCIM 44 User s Manual 9602 8 1 8 User Report The User Report resembles the Part Definition Report except that it is organized according to the Part ID numbers Open CIM Report Window 08181 PI 5 Sorted by Part ID PLEXIGLASS SUP ESED Open CIM Part Definition Report Printed 121495 Template ID Part Description PLEXIGLASS SUP FROM THE ASRS Box Supplied SUPPLIED BOX BAR CYLINDER SUP Supplied CYLINDER FROM THE FEEDER PROD Product CIM PRODUCTION PROD Product ASRS VISION ASRS ERRCIM Phantom ERROR CIM PRODUCT Phantom ERROR TEMPLATE Figure 31 User Report User s Manual 9602 45 ER MicroCIM 8 2 Device ID The file DEVICE DMC in the SETUP directory contains the device names and ID numbers which you will need when creating or modifying applications The following list and Figure 3
13. 9602 8 6 Known Problems 8 6 1 Bug Incorrect Status in Controller for ACL Program RVP The controller sometimes reports the status for program RVP as PEND response to ACL command STAT When this occurs do the following from the ACL Control Panel Enter the command A to abort all programs Enter the command RUN INITC Enter the command STAT to make sure RVP now has the status DELAY 8 6 2 Order Limitation Only one buffer at the ASRS Assembly Station is available for an assembly task Thus in the Order Definition screen Order Entry icon you must enter 1 one both in the Initial Quantity column and in the Subsequent Quantity column This will enable the system to properly handle a template which is returning to the ASRS Assembly Station with a failed assembly In addition the value in the Total Quantity column should not be greater than 4 four Although the ASRS can handle six parts limiting the quantity to four will enable the system to complete the order even if two parts fail the quality control inspection User s Manual 53 ER MicroCIM 9602 9 1 9 1 3 9 2 9 2 1 9 2 2 Maintenance and Repairs The devices in the ER MicroCIM have few maintenance requirements Preventive maintenance is limited mostly to visual inspection and simple adjustments Hardware Conveyor No preventive maintenance is required For troubleshooting and repair procedures refer to the Programmable Controllers Operation Manual Ro
14. ACL command to turn on the barcode reader RUN BCON Make sure the red light on the rear of the barcode reader 15 lit Make sure the robot has been homed and is free to move to position 15 Enter the ACL commands SPEED 30 MOVE CIM 15 When the robot reaches reaches position 15 take a template which has a barcode sticker and place it in the robot s grasp Enter the ACL commands MOVE CIM 20 SPEED 5 MOVE CIM 10 Make sure you hear the beep when the barcode is read Enter the ACL command to turn off the barcode reader RUN BCOFF Make sure the red light on the rear of the barcode reader goes off Parts Feeder From the Robot Programs WS1 window activate ATS Make sure output 1 is turned off Enter the ACL command SET OUT 1 0 Place at least one aluminum cylinder in the parts feeder chute 3 Enter the ACL command which causes the cylinder to drop down from the chute SET OUT 1 1 Enter the ACL commmand to push the cylinder out of the feeder SET OUT 1 0 As the cylinder is pushed out of the feeder make sure it activates the proximity sensor switch by checking the following The LED near the sensor cable lights up The LED for input 2 on the ACL controller lights up If the switch has not been activated adjust the position of the sensor by turning it If the sensor LED lights up but the input LED does not make sure both the sensor and the controlle
15. PC Connect the braided RS232 cable 40120 to the controller s auxiliary communication card connector Using the braided cable connect COMI from the controller communication card to CON on the Vision PC If COMI on the Vision PC is available use COMI instead of COMO Connect from the controller communication card to cable 40084 Connect this cable to the barcode reader Connect the DC cable from the barcode power supply unit to the round plug on the side of the barcode reader s D type connector Connect the power cord from the barcode transformer to the ACL controller s power outlet If the barcode reader has not been setup by a service technician refer to the instructions in the Section 8 5 Barcode Reader Setup Under the table you will find wires with orange terminal blocks Open the I O Box and connect these terminals as follows Refer to Figure 7 Connect terminal J10 to Input Block C J10 Connect terminal J11 to Input Block C J11 Connect terminal J2 to Output Block A J2 Connect terminal J1 to User Power Supply 11 Connect the camera and the video monitor to the frame grabber card according to the instructions in the ROBOTVISIONpro User s Manual Make the following power supply connections Connect the controller to the AC power supply Connect the conveyor transformer to the AC power supply Connect the computers to the AC power supply Connect the video monitor to the AC power suppl
16. Place window Now make the following selections ER MicroCIM 24 User s Manual 9602 barcode reader A B C D Part ID template 0 template 0 cylinder sup 11 template 0 Source ID asrs 3 barcode 9 feeder 6 assembly buffer 4 Source Index 1 1 1 1 Target ID barcode 9 assembly buffer 4 assembly buffer 4 conveyor 1 Target Index 1 1 1 1 Note 0 0 0 0 OK OK OK OK Robot takes a Robot places the Robot takes a Robot places the template with base template on the cylinder from the loaded template on Result from ASRS rack assembly jig feeder and places it the conveyor and brings it to the on the base 4 From the PLC Control Panel send the loaded pallet to workstation 2 Select Station 1 and click on Deliver Select Station 2 and click on Release The pallet will stop under the camera at the Vision QC workstation 5 In the Vision PC activate ROBOTVISIONpro RVPRO EXE Select OPTIONS Workspace Click on Load Select the file MICROCIM WKS and click on Ok to load the file Select IMAGE ISetup Define Frames Press Snap and watch the video monitor to check the camera s field of view Adjust the position of the camera so that the assembly is within the camera s field of view Select Frame 1 and adjust the size of the frame around the cylinder Select Save to save the frame information in a file Use the name MICROCIM FRA
17. You will see the message Done Close the Order Definition window Click on Start CIM Device drivers will be loaded and the Open CIM Manager screen will appear A small Debug window also opens hidden behind the Open CIM Safety message box which serves to display data which is being communicated 3 From the Open CIM Manager window do the following Click on the yellow lightning bolt This sends a command to reset INIT all device drivers The run arrow will now turn green Three windows also cascade onto the screen Program View Log View Order View These windows show the status of work in progress they are for viewing only They are described in detail in the Open CIM User s Manual Figure 19 shows the Program View window for PROD before the green run button is pressed Figure 20 shows the same window after the button is pressed Note that lines scroll up from bottom to top Click on the green run arrow The ll pause button will now turn blue The Leaf View window will now also appear 4 While the order is being manufactured you can track production by looking at the four different View screens Again refer to the Open CIM User s Manual You can also observe the quality control inspections on the Vision PC monitor Watch the CIM Manager PC monitor and wait until a box appears with the message CIM PROD HAS BEEN FINISHED Click on Ok Another message appears User s Manual 33
18. and others The ER MicroCIM system is a turn key hands on training installation It enables direct user access to each component in the integrated system thus serving to teach the fundamentals of each individual subject The system has been designed for centrally controlled assembly of a cylinder within a base Production orders are defined by the user A machine vision system performs quality control inspections of the cylinders Based on the Open CIM software package the ER MicroCIM system can be expanded to form a larger computer integrated manufacturing CIM system thereby providing a greater number of applications and a more comprehensive emulation of a modern manufacturing environment 1 2 Safety Before installing or operating the ER MicroCIM make sure you have read and understood all safety guidelines and warnings in the user manuals supplied with the robot controller and other system devices Make sure you heed safety warnings at all times To immediate abort all ER MicroCIM activities Press the EMERGENCY button on the ER MicroCIM Control Panel This will abort the PLC and the ACL controller thereby halting all conveyor and robot movement Note The program EMERG which is activated automatically when the software is loaded must be running in the background otherwise pressing the EMERGENCY switch will have no effect See Chapter 5 To immediate abort all robot programs and motion do one of the following Press the
19. 2RED TE 2 WIRED RLI 24BLK RLI 14 pH 500 500 MGCY ND BUS ISTON 1 ISTON 2 Cn c DVD D D O G m Z gt zZ 21516 2 c EE a m o m H gt m m T e to e o z o 3 Lal L 4 0 lt j o zu gt m X ER MicroCIM 46 User s Manual 9602 END1 2 CABLE LENGTH DESCRIPTION SNSR FDR BRN MO CARD J1 12VDC SENSOR CABLE 12 SNSR FDR BLU IO CARD J1 COMMON SENSOR CABLE CONTACOMMON ISNSRFDRBLACK WOCARDJIOIN2 sENSORCABLE NSRRT RED j D40223 RED ISNSRRT WHT 202 O NSRRI GRN T82122 1 040223689 NRSRT BLK 302 D4022 8LK NSRL RED 2 J D40222RED 4 NSRLT WHT 222 D40222WHT_ 9 NSRLT GRN T82232 J D402270RN ISNSRLT BLK 0222 SNSR UP RED 124 J D40223RED ISNSRUP WHT TE242 J NSR UP GRN B25 2 D40223 GRN STA3 AR ID1 NSR UP BLK B32 2 D40223 BLK UP INPLACE NSR DN RED B12 2 D40222 RED SNSR DN NSR DN WHT D40222 WHT ST
20. 3 show the devices defined for the sample application supplied with the system Definition Description CNV1 001 1 Conveyor ASRS 003 3 ASRS Rack ASMBUF 004 4 Assembly Jig BFFR1 005 5 Unloading Buffer FDR1 006 6 Parts Feeder TRASH1 007 7 Trash Bin RACK1 008 8 Palletizing Rack RDR1 009 9 Barcode Reader ROBOT 011 11 Robot VSN1 012 12 Vision System nN s 3 2 4 Z 5 Z 7 Figure 32 Device ID ER MicroCIM 46 User s Manual 9602 8 3 Wiring Figure 34 is a schematic diagram of the system wiring these wires are located within the conveyor The table which follows is a wiring list of the entire ER MicroCIM system This list does not include the communication wiring performed during the installation procedures w104 EOM XTE RED W104 BLK W104 BLK W104 BLK W104 NED dv 31BV3 voa ONNO RED w104 T wos Gat Gat vor far Zor 1 RED 91919990
21. A4 IDO 2 que r Rs NSR DN GRN B27 2 fD40222 GRN STAM AR IDI NSR DN BLK 533 2 jfD40222BLK JDNINPLACE B9 1 WAGO 260 402 9 3 B10 1 WAGO 260 402 11 1 WAGO 2604020 o B11 3 12 1 waco 260 402 B12 3 E B13 3 13 1 14 1 15 4 16 2 B16 4 B17 2 82 jJwaco2600402 PQ Teasa WAGO260402 JJP10 WIRED 4 402268 0 J e4DvC WE2 BLK TB22 FD4022EBLK MRI RED JTBi12 f D40226 RED ADV MR2 BLK TBT 2 FD4022EBLK JPLCOUTO WLIRED f D40226 RED J eMDvVC WL2 BLK TB amp 2 jco MUI RED 26 J ADV VUZ2 BLK 02268 JPLCOUT2 WOI RED 2 f D40226 RED ADV 02 D4022EBLK JPLCOUT3 c c c c c c c CIO K IN IN JE URI 0 co tro User s Manual 49 ER MicroCIM 9602 8 4 Technical Drawings of Parts 8 4 4 Plexiglass Base Figure 34 Plexiglass Base Material PLEXIGLASS 113072 Surf Rough N9 Fillet Rad 0 2 Break Edges 0 2 X 45 Dimensions MM ER MicroCIM 50 User s Manual 9602 8 4 2 Aluminum Cylinders
22. Abort key on the teach pendant or Use ACL command A Enter or Ctrl A or Press the controller s red EMERGENCY button User s Manual I ER MicroCIM 9602 1 3 About this Manual This manual describes the components installation operation and maintenance of the ER MicroCIM system This manual is organized into the following sections Introduction Operation Scenario System Components Installation Preparation for On Line Operation User System Operation Advanced System Operation Technical Data Maintenance and Repairs Suggested Study Topics ER MicroCIM 2 User s Manual 9602 2 Operation Scenario The ER MicroCIM system is preprogrammed to perform the production sequence described below Users can define the parts machining processes and orders resulting in different production sequences Robotic ACL programs can also be added and modified 1 The robot takes a template holding a plexiglass base from the ASRS rack and brings it to the barcode reader 2 The template s identification code is scanned by the barcode reader 3 The robot places the template on the loading buffer Buffer 1 4 The robot takes a cylinder from the parts feeder and inserts it into the base on the template at the loading buffer assembly jig 5 The robot places the template onto a conveyor pallet The pallet carries the template with the assembled product PROD to the vision station 6 Without being removed from the conveyor
23. CIM PROD is scanned by the vision system 7 The vision quality control inspection has either of two results If the side of the cylinder is facing up the assembly passes the inspection The pallet is released from the vision station and the template with PROD is returned to the ASRS Assembly Station If the X side of the cylinder is facing up the assembly fails the inspection As soon as the system determines a failed assembly production of a new CIM PROD begins immediately The pallet carrying the failed assembly is released from the vision station and travels around the conveyor until the robot is free When the robot is free to unload the template the pallet is halted at the ASRS Assembly workstation 8 The robot takes the template from the conveyor and places it on the unloading buffer Buffer 2 9 Depending on the result of the the vision quality control inspection either one of the following will occur If CIM PROD has passed inspection the robot takes the assembly from Buffer 2 to the palletizing finished parts rack If PROD has failed inspection the robot takes the assembly from Buffer 2 to the trash bin 10 The robot returns the empty template from Buffer 2 to the ASRS rack 11 The robot takes a new template with plexiglass base and begins another production cycle if required by the production order User s Manual 3 ER MicroCIM 9602 3 System Components 3 1 Prerequisites To install and
24. CIM PROD7 1 GET PLEXIGLAS ASRS Figure 19 Program View Window for CIM PROD ER MicroCIM 34 User s Manual 9602 Advanced System Operation This chapters provides descriptions and instructions for advanced level operating procedures in the ER MicroCIM system 7 1 System Overview Open the MicroCIM System Manager group window See Figure 21 C2SIMAP OPENCIM Report Start M simulation System Manager VC2REMAP 2 EdiVvC2MAP Help zi Storage Start Start Refresh gt fes Manager Log Not Log OK Figure 20 System Manager Group Window This group contains the modules and features which enable advanced level on line operation of the ER MicroCIM system The following is a brief description of the modules and features which are available in this group Icon OpenCIM Help Machines PartDef Asrs Orders Storage Refresh Description On line help file Defines the machines and processes Defines the materials which will be used and the parts which will be produced Defines the contents of the ASRS Defines the production order Initializes the storage database of the entire system User s Manual 9602 35 ER MicroCIM OpenCIM Reports Start CIM Manager VC2SIMAP VC2REMAP VC2CHMAP Edit VC2MAP PNP Start CIM RVPsi Start CIM RVPma Start CIM simulation Robot Only Real Mode Log OK Log
25. Click on Ok to exit this screen Select IMAGE Setup Image Histogram Select IMAGE Setup Image Histogram Do not do anything Simply let the software automatically adjust the offset and the gain Click on to exit this screen Select IMAGE Binary Binary Level Click on Binarization Move the line cursor on the histogram until you see a clearly defined black and white image of the mark on the cylinder User s Manual 9602 25 ER MicroCIM Select PATTERN Identification Click on Identify and check whether the vision system can identify the v and the X sides of the cylinder Object name QCPASS X Object name QCFAIL Turn the cylinder over Click on Start New Cycle You will see the other marking Check whether the correct object name is displayed Note If the system is unable to identify the v or X do the following Select OPTIONS Image Options Change the value of Min Area to 1000 Change the value of Min Perimeter to 500 Again select PATTERN Identification and click on Identify to check whether the vision system can identify the and the X When successful proceed to save the workspace Save the current workspace Select OPTIONS Workspace Click on Save Select VISION WKS and click on Ok to save the file Exit the ROBOTVISIONpro software 6 Now return to the CIM Manager PC From the PLC Control Panel send the loaded pallet back to workstation 1 Se
26. ER MicroCIM 9602 ORDER HAS BEEN FINISHED 5 To produce additional PRODs do the following Close the Open CIM Manager Click on Storage Refresh Click on Order to open the Order Definition screen Change the total quantity if desired and click on Submit and close the window Click on Manager to open the Open CIM Manager screen Start production as you did previously Eshed OPEN CIM PC Version 1 4 Command YVindow Help Program View Lexel PART ACTION TARGET TPAHAMETUBSTPL P a TopBatch BATCH 1 L PRODA MAKE CIM PRODI 1 1 1 P 1 00 0 PRODA NEXT PRODA PLACE PLEXIGLAS 1 PRODA RENAME PLEXIGLAS PRODA VISION PLEXIGLAS PROD ENDPACK PLEXIGLAS ASMBUF CYLINDER PLEXIGLAS 1 CYLINDER 8 CIM PROD 1 1 BASE TEMPLATE ASMBUF 9 CIM PROD7 1 READC PLEXIGLAS STEMPLATETY 10 CIM PROD7 1 GET PLEXIGLAS ASRS Figure 18 Program View Window for CIM PROD Eshed PC Version 1 4 Command window Help TINTA View Level EBENEN _ SUBPART TARGET PAHAMETERSEETIPZIP3 end BATCH PROD MAKE CIM HOD Ti P 1 00 0 28 PRODA NEXT PRODA PLACE PLEXIGLAS RACK1 PRODA RENAME PLEXIGLAS PRODA VISION PLEXIGLAS PRODA ENDPACK PLEXIGLAS ASMBUF CYLINDER PLEXIGLAS 1 CYLINDER 8 CIM PRODH 1 BASE TEMPLATE ASMBUF 9 CIM PROD7 1 READC PLEXIGLAS STEMPLATETY 10
27. ER MicroCIM User s Manual Second Edition Catalog No 100095 Revision B ESHE Copyright 1996 2000 Eshed Robotec 1982 Limited Catalog 100095 Rev B June 2000 Reprinted PDF version Every effort has been made to make this book as complete and accurate as possible However no warranty of suitability purpose or fitness is made or implied Eshed Robotec is not liable or responsible to any person or entity for loss or damage in connection with or stemming from the use of the software hardware and or the information contained in this publication Eshed Robotec bears no responsibility for errors which may appear in this publication and retains the right to make changes to the software hardware and manual without prior notice User s Manual iii ER MicroCIM 9602 1 Table of Contents Tc IntroducliOl S kuyana s S Qu us h YHP 1 1 1 About ER MicroCIM 1 1 32 A iya det pu Pak Sk iuste Ean SY pak Tun 1 1 3 1 2 2 5 3 3 System 4 Salt PrerequisileS 2 2 Meg K a Me eSI a I S a UQ RM 4 2 DocumernidliOn merce pet Yos S RSU E 4 Oui SONWALE ao dix Se ate hese eger
28. Feeder pneumatic gravity operation 10 plexiglass bases and 10 aluminum cylinders User s Manual 9602 5 ER MicroCIM Vision Station EV681 8 bit frame grabber RS170 video camera Composite RS170 video monitor ER MicroCIM 6 User s Manual 9602 41 4 2 Installation The installation procedures will be performed in the following order Hardware assembly Wiring Software installation Teaching robot positions Stand alone testing and adjustment of devices Unpacking Before installing the ER MicroCIM examine it for signs of shipping damage If any damage is evident contact your freight carrier and begin appropriate claims procedures Make sure you have received all the items listed on the shipment s packing list If anything is missing contact your supplier Setup 4 3 Place the ER MicroCIM table within reach of the power supply and the air supply For personal safety and sufficient access to the ER MicroCIM from all sides a free area of at least 1 meter around the table is recommended Hardware Assembly 4 3 1 Assemble and install the components in the order presented below Refer to Figures 1 and 2 Be sure you comply with all safety guidelines and warnings in the user manuals supplied with the robot controller and other devices Do not make any cable connections unless instructed to do so Wiring procedures appear in the next section Pneumatic Parts Feeder The base of the feeder is p
29. NFAIL TARGET RACKI PLEXIGLASS SUP READC ONFAIL VISION ONFAIL TARGET Figure 28 Sub Part Report User s Manual 9602 43 ER MicroCIM 8 1 6 Order Entry Report The Order Entry Report displays the production order which is currently on the shop floor This order will be put into production whenever the CIM Manager issues a command to start production Open CIM Report Window si d Read Selected Total 1 100 ESED Open CIM Order Entry Report Printed 14 12 95 8 1 7 Aplan Report The file APLAN DBF in the WORK directory is a production task list which is created by the system when an order is submitted It shows the sequence of operations to make each component and or assemble components into a final product Figure 30 Order Report Open CIM Report Window eee Read Selected Total 15 15 15 100 PROD 1 ESED Open CIM Aplan Report Printed 121495 PROD 1 1 4 1 1 P 1 00 00 00 CIM_PROD 1 1 GET PLEXIGLASS SUP CIM PROD 1 1 READC 009000 PROD I 1 ONFAIL 1 ASRS PROD 1 1 BASE ASMBUF PROD l 1 PACK CYLINDER SUP 1 1 PLEXIGLASS 00 00 00 PROD 1
30. Name Priority Status RVP 000005 Delay EMERG 000005 Trigger Close the ACL Virtual ACL Driver window User s Manual 29 ER MicroCIM 9602 5 Senda loaded pallet to workstation 2 Place a template with an assembled part CIM PROD on pallet closest to the vision station Click on PLC to load the PLC Device Driver See Figure 16 Select Station 2 and click on GetFree This will send the pallet to the vision station us s PLC Control Panel Device ID 1 Pallet Destination Status Last Stations Command Buttons ID Station Station 580002 510099 580099 0099 GetFree Sit0099 540099 Release Sit0099 510099 510099 510099 Figure 15 PLC Device Driver Control Panel 6 Prepare the vision station From the ROBOTVISION directory C gt RVPRO in the Vision PC activate ROBOTVISIONpro type RVP Enter Select IMAGE Setup Image Histogram Do not do anything Simply let the software automatically adjust the offset and the gain Click on Ok to exit this screen Select IMAGE Binary Binary Level Click on Binarization Move the line cursor on the histogram until you see a clearly defined black and white image of the mark on the cylinder Select PATTERN Identification Click on Identify and check whether the vision system can identify the v and the X sides of the cylinder v Object name QCPASS X Object name QCFAIL Turn the cylinder over Click on Start New Cycle
31. Not OK Generates reports Loads all device drives including CIM Manager Loads CIM Manager only Produces a listing of all device drivers used in simulation mode and writes it to the file VC2 MAP Produces a listing of all device drivers used in on line mode and writes it to the file VC2 MAP Produces a listing of all device drivers used when workstation 1 is in on line mode and workstation 2 is in either simulation or manual mode and writes it to the file VC2 MAP Opens Notepad for editing VC2 MAP file Generates pick and place reports and writes them to the subdirectory LOG Loads CIM Manager and all device drivers vision device driver is in simulation mode Loads CIM Manager and all device drivers vision device driver is in manual mode Loads CIM Manager and all device drivers in simulation mode Loads CIM Manager and all device drivers in simulation mode except robot device driver which loads in on line mode Generates pick and place reports and writes them to the subdirectory LOG Generates pick and place and database reports and writes them to the subdirectory LOG Complete descriptions of the modules can be found in the Open CIM User s Manual ER MicroCIM 36 User s Manual 9602 7 2 7 2 1 7 2 2 7 2 3 7 2 4 Modes Operation The ER MicroCIM system can be operated in numerous ways Following are five possible modes of operation Total Simulated Production device driv
32. OWS 5 Find the Computer Name of the CIM Manager PC It is defined in the Windows Control Panel Network Computer Name or in the string ComputerName under the heading Network in the SYSTEM INI file in the C WINDOWS SYSTEM directory If the Computer Name does not exist you must create it by editing the SYSTEM INI file User s Manual 15 ER MicroCIM 9602 4 5 2 4 5 3 3 In the files C OPENCIM MICROCIM SETUP MAP change all instances of the string WUSERS to the name of the CIM Manager PC Create two mailslots and send a message from one to the other Make sure only one message is received Refer to the Open CIM User s Manual Note that you must use the format MAILSLOT NAME when creating more than one mailslot on one PC ROBOTVISIONpro Installation Install the ROBOTVISIONpro software according to the instructions in the ROBOTVISIONpro User s Manual and the following Accept the default path C RVPRO as the software directory for the installation When you are prompted for the Robot Type select ACL for ACL controller When you are prompted to run the SETUP program click on No The installation will end and exit to DOS Copy the file C OPENCIM MICROCIM WS2 RVPWKS MICROCIM WKS from the CIM Manager PC to the directory C RVPRO in the Vision PC ACL Controller Configuration From DOS in the CIM Manager PC activate Windows for Workgroups without network drivers Type C gt W Enter Open the
33. Robot Programs WS1 group window See Figure 8 Program Manager Robot Programs Ws1 Hle Window Help m Aw 4 5 Download Download Edit Prolog Download Edit CNV1 Station 1 Report Prolog 98 oc Download En Download EditAsts Download Asrs Edit Barcode IR Dw 2 Download EditRvpcom Download Edit Bffrl Download Edit Asmbuf Barcode Y R Rvpcom Y R Bffr Y R A a fF Figure 8 Robot Programs at Workstation Group Window Click on the ATS icon The ATS main screen will open Press Ctrl F1 to configure Controller A Press Y to confirm the prompt to configure the controller ER MicroCIM 16 User s Manual 9602 You then prompted by a short series of Controller Configuration options See Figure 9 Robot type ER V ER Vplus ER VII OTHER Make sure ER Vplus is selected and press Enter How many axes are installed 8 Type 6 and press Enter Is expanded memory installed Y N Y Press Y or Enter Does the controller have an auxiliary RS232 board Y N N Press Y Working directory is C NopencimWMnicrocimNwslNrobot Is this correct Y N Y Press Y or Enter WARNING ARE YOU SURE Y N N Press Y ATS will now perform the configuration You can ignore the message about the missing SETUP PAR parameter file 4 When gt prompt app
34. ailable in this group gt Open Help Machines amp amp Storage Start Refresh Report Figure 17 User Operations Group Window Icon Description OpenCIM Help On line help file Machines Defines the machines and processes PartDef Defines the materials which will be used and the parts which will be produced Asrs Defines the contents of the ASRS Orders Defines the production order Storage Refresh Initializes the storage database of the entire system OpenCIM Reports Generates reports Start CIM Loads all device drives including CIM Manager Manager Loads CIM Manager only Complete descriptions of the modules can be found in the Open CIM User s Manual ER MicroCIM 32 User s Manual 9602 6 2 Activating the System Make sure you have clicked on MicroCIM System Manager VC2RE MAP and the DOS box appeared for a few seconds From the User group window do the following Click on Storage Refresh A DOS box will appear for a few seconds This serves to clear the buffers pallets and robot of all parts and templates In addition it resets the ASRS cells to the status required for the start of production Click on Order The Order Definition screen will appear showing an order for the PROD cylinder in base assembly Bring the cursor to the Total Qty field and from the keyboard enter the number of items you want to produce Click on Submit
35. and nuts attach the stand to the table User s Manual 9 ER MicroCIM 9602 4 3 6 4 3 7 4 3 8 4 3 9 Attach the barcode reader to its stand using the four screws provided with the barcode reader Make sure the barcode scanner window faces the robot Insert the barcode reader cable through the hole in the table Conveyor Pallets The conveyor is pre mounted on the ER MicroCIM table Place the two pallets supplied with system anywhere along the conveyor with the arrow on the pallet pointing in the direction of movement of the conveyor Templates Apply the barcode stickers to the templates on the side opposite the handle Using 11 4mm and 12 7mm metal pins supplied with the system prepare the six templates for carrying the cylinder in base assemblies Figure 3 shows the arrangement of the pins on a template Make sure the pins are arranged identically on each template Palletizing Finished Parts Rack Using the 10 mm 12 7mm metal pins supplied with the system prepare the palletizing rack for holding the cylinder in base assemblies Make sure the pins are arranged identically for each grid Figure 4 shows the arrangement of the pins on the rack Computers Install the frame grabber card in the Vision PC Follow the instructions in the ROBOTVISIONpro User s Manual The computers may be placed on the shelf under the ER MicroCIM table The CIM Manager PC should be placed to the right of
36. bled Cylinder in Base 8 3 103 113 on Palletizing Rack 8 4 104 114 8 5 105 115 8 6 106 116 Approach In Free At Above Retreat Movement Zone P1 P2 P3 4 Cell 1 3 1 61 71 81 171 Cell 2 3 2 62 72 82 172 Template on Cell 3 3 3 63 73 83 173 ASRS Rack Cell 4 3 4 64 74 84 174 Cell 5 3 5 65 75 85 175 Cell 6 3 6 66 76 86 176 Refer to Section 8 2 Device ID map Cell 1 is on the bottom left side of the ASRS rack ER MicroCIM 20 User s Manual 9602 3 When you have finished recording the positions use the ATS Backup Manager to save the programs positions and parameters to disk Save each item as a separate file Make the following selections and entries Backup directory C opencim microcim ws1 robot Backup Restore ALL File name all Press Enter again Press to SAVE to disk Backup Restore PROGRAMS File name programs Press Enter again Press F3 to SAVE to disk Backup Restore POSITIONS File name position Press Enter again Press F3 to SAVE to disk Backup Restore PARAMETERS File name paramete Press Enter again Press to SAVE to disk User s Manual 21 ER MicroCIM 9602 4 7 4 7 1 Stand Alone Testing and Adjustment of Devices In this part of the installation you will test each device individually to make sure it is functioning properly Turn on the ER MicroCIM power supply The co
37. bot and Controller For maintenance troubleshooting and repair procedures refer to the SCORBOT ER Vplus User s Manual Pneumatic System Make sure air pipes are securely fastened and do not leak Make sure nominal pressure is 5 7 bar Electrical Wiring Make sure cables and wires are securely fastened and do not show signs of abrasion or wear Software and PCs OpenCIM Software For troubleshooting refer to the OpenCIM User s Manual Vision System For troubleshooting refer to the ROBOTVISIONpro User s Manual ER MicroCIM 54 User s Manual 9602 10 Suggested Study Topics The individual devices in the ER MicroCIM can be used for short study units while the entire system itself can provide the basis for an extended course of study Figure 36 MicroCIM Laboratory 10 1 Modules 10 1 1 Robot Robot structure Robot arm movements Teach pendant control of robot arm Point definition Robot programming 10 1 2 Robot Mechanisms Motors Encoders Microswitches Gears and transmissions End effectors User s Manual 55 ER MicroCIM 9602 10 1 3 PID Control Degrees of freedom Open loop control Position and speed control Linear and circular path control PID control parameters Ziglaer Nicholas method of control 10 1 4 Computer Communication Baud rate Data bits Parity Stop bits Flow control Port address Interrupt request 10 1 5 Pneumatic Systems Pneumatic power supply Pneumatic cyli
38. e indes 23 4 7 2 Barcode Header 24 413 Parts Feeder cuu xe 24 4 7 4 Device Drivers 25 47 5 28 User s Manual 9602 5 Preparation for On Line Operation 30 6 UserSystemOOperation 33 6 1 System Overview 33 6 2 Activating the System 34 Advanced System Operation 36 7 1 System Overview 36 7 2 Modes of Operation 38 7 2 1 Total Simulated Production 38 7 2 2 Total On Line Production TIE 38 7 2 3 Production with Simulated Vision 38 7 2 4 Production with User Manual Vision 38 7 25 39 7 3 Stand Alone Operation 40 7 3 4 Stand Alone 5 1 40 7 3 2 Stand Alone Operation Station 2 41 8 Technical Data eios eiue eer en XO NE E e C 42 7 x oboe ome pud Bie al Sr sh petu aw dr xe 3 42 8 1 1 Machine Report 42 8 1 2 Process Report aoaaa ey
39. ears press Shift F10 The ATS Backup Manager screen will open Make the following selections and entries Backup directory C opencim microcim ws1 robot Make sure the path correctly shows the working directory defined during the configuration as shown here Backup Restore ALL Use the arrow keys to highlight ALL and press Enter During Restore ERASE Use the arrow keys to highlight ERASE and press Enter File name all Type all and press Enter Press Enter again Press F5 to RESTORE from disk Press Y to confirm all prompts to overwrite and erase This file named ALL CBU will now be downloaded from the CIM Manager PC to the ACL controller This file contains all programs positions and parameters required for controller operation in the ER MicroCIM environment User s Manual 17 ER MicroCIM 9602 4 6 Teaching Robot Positions In this part of the installation you will adjust the values coordinates of the positions which were downloaded to the controller Note Downloading the ALL CBU file changed the value of controller parameter PAR 52 The default PAR 5220 is changed to PAR 52 4214 Before you record robot positions for the ER MicroCIM you should check the value of parameter 52 by entering the ACL command SHOW PAR 52 1 The teaching of robot positions is performed from Robot Program WS1 ATS 2 Enter the ACL command RUN HOMES Wait until the robot has completed
40. ers operate in simulation mode No equipment is used No product is actually manufactured The procedure for activating this mode of operation is detailed in Section 4 7 5 Stand Alone Testing Manager Total On Line Production device drivers operate in on line mode equipment is used Products are actually manufactured The procedure for activating this mode of operation is detailed in Section 6 2 Activating the System Production with Simulated Vision Robot barcode reader and conveyor device drivers operate in on line mode The vision device driver operates in simulation mode The production takes place normally but when the template reaches the vision station it will stop for a moment and then continues as if it has passed or failed the quality control inspection according to a failure rate which has been predefined in the file RVPRSLINI The procedure for activating this mode of operation is as follows VC2CHMAP Storage Refresh Order Start CIM RVPsi To produce additional PRODs in this mode do the following Close the Manager window Storage Refresh Order Manager Production with User Manual Vision Robot barcode reader and conveyor device drivers operate in on line mode The vision device driver operates in software manual mode The production takes place normally but when the template reaches the vision station it will stop and wait for the user to determine whether the assembly pass
41. es succeeds or fails the quality inspection User s Manual 37 ER MicroCIM 9602 The procedure for activating this mode of operation is as follows VC2CHMAP Storage Refresh Order Start CIM RVPma When the CIM PROD is at the vision station look to see which side is facing the camera From the CIM Manager PC bring up the Virtual RVP Device Driver From RVP Control Panel click on either Success Fail according to the v orX To produce additional PRODs in this mode do the following Close the Manager window Storage Refresh Order Manager From the RVP Control Panel click on either Success or Fail according to the or X 7 2 5 Robot Only Real Mode Loads CIM Manager and all device drivers in simulation mode except robot device driver which loads in on line mode Barcode reader vision and conveyor device drivers operate in simulation mode Only the robot operates on line but without handling any patts Remove an empty pallet from the conveyor and place it at Workstation 1 The procedure for activating this mode of operation is as follows VC2SIMAP Storage Refresh Order Robot Only Real Mode To produce additional CIM_PRODs in this mode do the following Close the Manager window Storage Refresh Order Manager ER MicroCIM 38 User s Manual 9602 7 3 Stand Alone Operation 7 3 1 Each workstation can be operated individually or as a stand alone system Stand Alone Operation Stati
42. f data to controller ER MicroCIM Installation Perform the installation from the DOS environment Software can only be installed to drive C During the installation a file named W BAT is written to drive C If a file of that name already exists rename it before you begin the installation Insert disk 1 of the Open CIM software into the floppy drive of the CIM Manager PC andtype INSTALL Enter You will be prompted to insert the remaining disks When the installation is complete type C N gt W Enter W BAT is written to during the installation This batch file will load Windows for Workgroups without network drivers From the Windows Program Manager select File New Group in order to add seven new groups to your Program Manager Be sure to include the complete path in the Group File field C opencim microcim ws0 ws0 grp manager for system supervisor C opencim microcim ws0 user grp manager for user C NopencimWnicrocimNwslNwsl grp activates workstation 1 C NopencimWnicrocimNwslNwslr grp robot programs at workstation 1 C NopencimWnicrocimNwsl wslsys grp system operation at workstation 2 C opencim microcim ws2 ws2 grp activates workstation 2 C opencim microcim ws2 ws2sys grp system operation at workstation 2 Do not enter any text in the Description field It has already been defined Copy all the files in the subdirectory C OPENCIM WIND to C WIND
43. le Reattach the D50 connector to the cable Controller A Remove the four screws on the controller cover and lift it off Install the auxiliary multi port communication card in the controller according to the instructions in the SCORBOT ER Vplus User s Manual Connect the I O box to the ACL controller as follows Refer to Figure 7 Make sure the ribbon cable is plugged into the connector marked Controller Type A in the I O box Thread the ribbon cable from the I O box through one of the open slots on the controller s rear panel Plug the ribbon cable connector into the I O connector which is located between the controller s power motor switches and transformer Replace the cover of the controller and tighten the screws 5 Place the controller on the shelf under the table 4 3 4 4 3 5 Connect the robot and the controller as follows Connect the robot s D50 connector to the controller Connect the teach pendant to the controller ASRS Four mounting holes for the ASRS are predrilled in the ER MicroCIM table Four screws have been taped to the table next to these holes Align the ASRS rack with the mounting holes on the table Using the four screws provided attach the ASRS rack to the table Barcode Reader Two mounting holes for the barcode reader are predrilled in the ER MicroCIM table Two bolts and nuts have been placed in the holes Align the holes and the barcode reader stand Using the two bolts
44. lect Station 1 and click on Deliver Select Station 2 and click on Release The pallet will stop at the robot workstation 7 Select the Run Pick and Place window at the CIM Manager PC You will now check whether the robot can perform all pick and place unloading operations required in the preprogrammed production sequence In the Run Pick and Place window make the following selections ER MicroCIM 26 User s Manual 9602 G H Part ID template 0 plexiglass sup 1 plexiglass sup 1 template 0 Source ID conveyor 1 buffer 5 buffer 5 buffer 5 Source Index 1 1 1 1 Target ID buffer 5 rack 8 trash bin 7 ASRS 3 Target Index 1 1 1 1 Note 0 0 0 0 OK OK OK OK Robot takes template Robot takes Robe eae assembled part from empty template to from conveyor and assembled part from buffer to finished Cell 1 in ASRS places it on buffer buffer to trash bin parts rack 8 Close the Virtual ACL Driver window This will close the ACL Control Panel Close the Virtual PLC Driver window This will close the PLC Control Panel 4 7 5 CIM Manager The modules and functions in the CIM Manager are explained in Chapter 7 Advanced System Operation 1 From the MicroCIM System Manager window do the following Click on VC2SIMAP A DOS box will appear for a few seconds Click on Storage Refresh A DOS box will appear for a few seconds
45. nder and piston Pneumatic logic control 10 1 6 Sensors and PLC Control PLC digital input and output Magnetic infrared and distance sensors DC motor control Step motor control Ladder diagram design PLC control of pneumatic system 10 1 7 Identification Systems Binary to decimal code Decimal to binary code Magnetic code Barcode ASCII and binary data transmission on RS232 channel CIM template and pallet identification system ER MicroCIM 56 User s Manual 9602 10 1 8 Vision and Quality Control Lighting and optics Image acquisition Image processing Pattern recognition Applications product identification inspection robot guidance 10 1 9 Manufacturing Software Part definition Order entry Machine definition Storage management Logs 10 2 Courses Eshed Robotec has developed a method for teaching modern manufacturing technologies known as AMT Advanced Manufacturing Technology Laboratory is four semester academically based program designed to provide high school students with a broad based competency in modern manufacturing technologies The program is designed with a modular and flexible curriculum which systematically covers a variety of subjects and develops the students knowledge and experience in these areas Each subject or module can be covered in 16 classroom hours Students are divided into groups which concurrently study the various subjects and simultaneously rotate to the next module An i
46. nstructor managment system ensures that all students complete all material by the end of the semester Each semester begins with a 2 4 hour introductory presentation and concludes with a 6 8 hour final project 10 2 1 AMT Semester Introduction to the ER MicroCIM system components stations software Introduction to CAD when included in installation Introduction to CNC when included in installation Materials Testing and Evaluation Pneumatic Hydraulic Systems Introduction to Robotics User s Manual 57 ER MicroCIM 9602 10 2 2 AMT Semester II Introduction to CAD when included in installation Sensors and PLC Control Mechanical Measurement and Quality Control Pneumatic Hydraulic Systems Robot Mechanisms and Computer Communication 10 2 3 AMT Semester IlI Manufacturing Software Vision and Quality Control Introduction to FMS when CNC included in installation Identification Systems PID Control 10 2 4 AMT Semester IV Guided Project Based on a set of projects developed by Eshed Robotec the student will consider engineering industrial and economic factors and will design and produce several products 30 hours Final Project The student will be encouraged to take an entrepreneurial approach to design and produce an item 60 hours ER MicroCIM 58 User s Manual 9602
47. nveyor will move for 60 seconds and then stop If the Auto Manual button on the conveyor s control panel is set to Manual when power is turned on the conveyor will not move Check the following Make sure all devices are turned on Make sure there is no movement of any other device in the system You may now proceed to check the devices in the following order Conveyor Refer to Figure 12 4 Switch the Auto Manual button on the 9 conveyor s control panel to Manual Then press Start Check the following The conveyor is moving clockwise The pistons at both stations on the conveyor extend and stop the pallets and then retract and release the pallets The conveyor stops when you press Stop and restarts when you press Start I Stop and start the conveyor several times Figure 11 Control Panel Make sure the Auto Manual button on the conveyor s control panel to Manual Then press Start While the conveyor is moving press the emergency button and check the following The emergency button remains locked The LED for input 1 on the ACL controller is lit The conveyor stops Release the emergency button and check the following The LED for input 1 on the ACL controller turns off The conveyor restarts or can be restarted ER MicroCIM 22 User s Manual 9602 4 7 2 4 7 3 Barcode Reader From the Robot Programs WS1 window activate ATS Enter the
48. on 1 Open the Open CIM Station 1 group window See Figure 22 Elopen Station 1 Start Station 1 Figure 21 Workstation 1 Group Window This group contains the modules and features which enables students to operate Workstation 1 as a stand alone system Workstation 1 contains the following elements Robot Parts Feeder Barcode Reader Conveyor PLC The procedure for activating this mode of operation is as follows See Figure 23 Double click on Start Station 1 The ACL Control Panel and the PLC Control Panel will open In the ACL Control Panel enter the ACL command RUN HOMES Wait until the robot has completed the homing twice Click on Enter P P The Run Pick and Place window will open All robot operations can now be activated from the Run Pick and Place window The PLC Control Panel monitors and controls the movement of all pallets on the conveyor User s Manual 39 ER MicroCIM 9602 us 3 m Virtual ACL Device Driver 11 Actions Run Pick and Place Part ID T ACL Control Panel Device ID 11 Control Mode On Line Mode Connected OK Send to Controller Sowce ID Target ID 3 Source Index 1 6 l e 1 6 Target Index 2 s Open Cim Safety Task History PP PCPLC ID 110000 0 3 1 3 2 0 Complete from File 0 Pick and Place Commands Save Cmds Clase PIP File
49. operate the ER MicroCIM system your facility must provide the following items CIM Manager PC Hardware Requirements 486 66MHz with at least 16MB at least 30MB available disk space VGA display adapter 2 RS232 ports BUS mouse Software Requirements DOS 6 2 or later Windows for Workgroups 3 11 English versions recommended Vision PC Hardware Requirements 486 33MHz with at least RAM at least 4MB available disk space display adapter 2 RS232 ports Software Requirements DOS 6 2 or later 2 Monitor Keyboard Desks one desk must be large enough for two monitors the Vision PC monitor and the video monitor Compressed Air supply 5 7 bar 6mm inlet AC Power supply and power outlet strip with on off switch and 6 outlets Make sure the voltage settings on the ER MicroCIM equipment match your power supply To ensure proper functioning of the CIM and vision software be sure your PCs do not contain any additional expansion cards particularly multimedia sound and communication cards 3 2 Documentation A number of publications are provided with the ER MicroCIM system The following is the list of publications you will need for working with the system ER MicroCIM User s Manual Catalog 100095 Open Cim User s Manual Catalog 100094 SCORBOT ER Vplus User s Manual Catalog 100016 ACL for Controller A Reference Guide Catalog 100083 ATS for Controller A Reference Guide Catalog 100084 ACLoff line U
50. r input are operating in the same logic mode PNP or NPN User s Manual 23 ER MicroCIM 9602 4 7 4 OpenCIM Device Drivers and Vision 1 Open the System Station 1 group window See Figure 13 Program Manager System Station 1 CIM g E M ais Station Terminal acl Notepad Lss ple Robot com2 vc2 map omron Robot ma si PLCsi Manual BarCode BarCode si Figure 12 System at Station 1 Group Window This group allows you to operate each of the ER MicroCIM device drivers in each of three modes except for the barcode which has two modes Real Mode on line operation Manual Mode off line step by step software operation the item description has the suffix ma Simulation off line software operation the item description has the suffix si You will now activate the device drivers in Real Mode and check whether they actually operate the devices 2 Click on the PLC icon to load the PLC Device Driver From the PLC Control Panel send an empty pallet to workstation 1 Select Station 1 and click on GetFree 3 Make sure there is a template with a plexiglass base in Cell 1 of the ASRS Make sure there is at least one cylinder in the parts feeder Click on the Terminal ACL icon to load the ACL Device Driver You will now check whether the robot can perform all pick and place operations required for assembly and loading in the preprogrammed production sequence Click on Enter to open the Run Pick and
51. re mounted on the ER MicroCIM table Four screws have been placed in this base Attach the feeder chute to the base by means of the four screws As you tighten the screws adjust the spacing between the two sides of the chute to allow the aluminum cylinders to fall freely into the base User s Manual 7 ER MicroCIM 9602 VISION PC 1 0 BOX POWER CONIROLLER A SUPPLY Figure Installation Layout Side View VISION CAMERA ASSEMBLY BARCODE READER ASRS RACK PARTS FEEDER 000000000 0115 STATION 1 e PALLET CONTROL PANEL CONVEYOR UNLOADING BUFFER REJECTED PARTS PALLETIZING RACK ROBOT Figure 2 Installation Layout Top View ER MicroCIM 8 User s Manual 9602 4 3 2 4 3 3 SCORBOT ER Vplus Robot Six mounting holes for the robot are predrilled in the ER MicroCIM table Bolts and nuts have been placed in these holes Mount the robot on the ER MicroCIM table according to the installation instructions in the robot s SCORBOT ER Vplus User s Manual Position the robot with its cable facing towards the hole in the table Remove the D50 connector from the end of the robot cable Insert the cable through the hole in the tab
52. ser s Manual Catalog 100051 ROBOTVISIONpro User s Manual Catalog 100062 ER MicroCIM 4 User s Manual 9602 SLC 500 Module Hardware Style Installation and Operation Manual Allen Bradley U S A only or COMI Programmable Controllers Operation Manual OMROM all countries except U S A 3 3 Software The ER MicroCIM system contains the following software ER OpenCIM version 1 4 Six 3 5 1 44MB diskettes including ATS and ACLoff line software HASP 3 DEOAX white software protection plug ROBOTVISIONpro version 2 4 One 3 5 1 44MB diskette Gray software protection plug 3 4 Hardware The ER MicroCIM system contains the following hardware Conveyor Closed loop monorail conveyor Pallet tracking devices magnetic sensors and pneumatic pistons for halting and releasing pallets at station Programmable Logic Controller PLC 2 Pallets Robot Station SCORBOT ER Vplus robot Controller A Advanced Control Language ACL version 1 44 command environment programmed onto EPROM within the controller Equipped with auxiliary RS232 communication card Teach pendant connected to the controller for immediate hand held access to the controller especially useful for teaching positions 2 Buffers Buffer 1 serves as an assembly jig ASRS Rack with 6 cells 6 templates Palletizing Rack for assembled parts Trash Bin for rejected assemblies Barcode Reader for template identification Parts
53. t C User Report 2 C AS RS Report C User Report 3 Figure 23 Report Generator Menu 8 1 1 Machine Report The Machine Report lists the names of all machines in the ER MicroCIM environment Report Window ESLIED Open CIM Machine Report Printed 12 1495 Cost Per Hour Figure 24 Machine Reports User s Manual 41 ER MicroCIM 9602 8 1 2 Process Report The Process Report shows the user defined name Process Name field of each machines and the process performed by the machine Report Window Est 4 5 or 2 ut LT ESED NEN Open CIM Process Report Printed 12 14 95 4 Machine Name Process Name ProcessType Program File Name a ETE VENI VISION gg Figure 25 Process Report 8 1 3 ASRS Report The ASRS Report shows the contents of the ASRS automatical storage and retrieval system E Open CIM Report Window m 4 v a 2 Read Selected Total Z Page 600 6 600 10011 of 1 ESED Open CIM AS RS Report Printed 12 1895 Name Index PartName PartID Siatus Template Number PLEXIGLASSSUP 0 Parton Template 010001 PLEXIGLASS SUP 0 Parton Template 010002 PLEXIGLASS 0 Paton Template DDD PLEXIGLASS SUP 0 Parton Template 010004 PLEXIGLASS SUP 0 PatonTemplte 010005
54. the ACL controller and the Vision PC should be placed to the left of the controller Make sure the cables from the equipment on the ER MicroCIM table can reach the computers Make sure the cables from the monitors and the inputs devices can reach the computers Connect the monitor keyboard and mouse for each computer 4 3 10 Vision 1 2 Three mounting holes for the camera stand are predrilled in the ER MicroCIM table Three bolts and nuts have been placed in these holes Align the holes and the base of the camera stand and attach Attach the lens to the camera ER MicroCIM 10 User s Manual 9602 3 Attach the camera to the stand 4 Place the video monitor on the desk next to the Vision PC monitor DIA FIXING MM DIA FIXING PINS x36 Figure 4 Layout of Pins on Palletizing Rack User s Manual 11 ER MicroCIM 9602 44 Wiring 10 11 Refer to Figures 5 6 7 Refer also to Section 8 3 Wiring for additional technical data Connect the HASP 3 white software protection plug to the parallel port on the CIM Manager PC Below the ER MicroCIM table you will find the RS232 cable from the PLC Connect the D25 female connector to COMI on the CIM Manager PC Connect the RS232 cable ER40035 to the ACL controller s RS232 port and to COM2 on the CIM Manager
55. the homing twice 3 positions used in the ER MicroCIM belong to the vector CIM 200 To teach the robot the positions required for the application you must attach this vector to the teach pendant Enter the ACL command ATTACH CIM 3 Figure 10 and the following Positions Table show the numbers of the positions which must be recorded before the assembly operation can be executed ABOVE LOCATIO PI 10 P1 is dways the positions in at on the device APPROACH POINT PI 20 Part ID group IN FREE MOVEMENT ZONE 110 20 BARCODE 10 15 GET PART 40 PUT PART 2140 PID ABOVE 10 OO0O0000O00O000 SOSOSOSO SOD 80000000000 000000009500 00000000000 090000090 00000000 GET PART 204 PUT PART 120 ABOVE 08000508 ABOVE LOCATION P1 10 Figure 9 Part Positions ER MicroCIM 18 User s Manual 9602 Note the following part ID numbers The plexiglass base part ID number is 1 The cylinder part ID number is 2 The part ID numbers PID in Figure 10 determine the name number of the various positions in the ER MicroCIM cell Figure 11 illustrates the order in which positions sho
56. uld be taught P2 P1 P2 172 173 174 1 5 176 82 83 84 85 86 72 73 74 75 76 62 63 64 65 66 GET PUT ASRS TEMPLATE ON WAY TO BARCODE READER TEMPLATE IN FRONT OF BARCODE READER GET PUT TEMPLATE AT ASSEMBLY BUFFER Cx E cc PUT CYLINDER P2 P1 P2 P1 Part Number Part ID Group IN PLEXIGLASS BASE TEMPLATE GET PUT CONVEYOR TEMPLATE GET PUT BUFFER EF IF PASS QC 31 FINISHED PARTS RACK 168 Y 111 112 113 114 115 116 21 PROD 106 5220 gt 52 4214 IF FAIL 91 101 102 103 104 105 TRASH 90 cc utem 1 2 3 TEMPLATE ON PALLET SENSORS P2 TAKE CYLINDER P1 FROM FEEDER IN PLACE ARRIVING 100 ID 1 DIRECTION OF MOVEMENT Figure 10 Position Teaching Sequence User s Manual 9602 19 ER MicroCIM ER MicroCIM Positions Above Above Description of Position Device Device GET GET PUT PUT ID Index P1 P2 P1 P2 Template on pallet at workstation 1 1 1 11 1 11 Template in front of barcode reader Movement between position 10 and 9 1 10 20 10 20 position 20 must cross the laser beam Template on buffer 5 1 2 12 2 12 Template on buffer jig 4 1 3 13 3 13 Cylinder in base on template on 4 1 142 152 buffer jig Plexiglass base on template on buffer 5 1 21 31 Feeder 6 1 92 93 Trash Bin 7 1 90 91 8 1 101 111 8 2 102 112 Assem
57. wing chapters Open Cim Safety Eshed Version 1 4 Virtual PLC Device Driver 1 Virtual LSH Device Driver 9 Virtual RVP Device Driver 12 MAP VC Program Manager Micro CIM System Mana Virtual ACL Device Driver 11 Figure 14 Open CIM Manager ER MicroCIM 28 User s Manual 9602 5 Preparation for On Line Operation At the start of every on line work session the following procedures must be performed 1 Turn on the power supply Make sure all devices computers and the controller are turned on and ready for operation 2 Activate the Open CIM software On the CIM Manager PC do the following From the DOS prompt type w Enter This is the same as activing Windows by means of the command WIN n Open the Program Manager System Station 1 group window Click on Terminal ACL to load the ACL Device Driver 3 Home the robot Make sure the controller is in the CON state Control Enabled From the ACL Control Panel enter the command CON Using the teach pendant bring the robot to the area above the buffers Free Movement Zone so that the homing operation can safely begin Home the robot From the ACL Control Panel enter the command RUN HOMES Make sure the teach pendant is set to Joint Mode 4 Check controller status Maximize the the Virtual ACL Driver window From the ACL Control Panel enter the command STAT Make sure the system displays the response Job
58. y ER MicroCIM 12 User s Manual 9602 TABLE SURFACE BARCODE READER CAMERA TERMINAL BAR VIDEO MONITOR 25 MALE TO 9P FEMALE 420110 w E 2 MANAGER COMPUTER PARALLEL COM2 COM1 wx e use PLUG WHITE 40231 FOR ALLEN BRADLEY 140230 140035 CONTROLLER A RS232 5 TO ROBOT ILA 5 TO POWER SUPPLY 220V TO FEEDER SENSOR O BOX FRAME GRABER PARALLEL COM2 COM1 40084 q 40035 40229 PLUG GRAY BARCODE SUPPLY Figure 5 ER MicroCIM Wiring ER MicroCIM 13 User s Manual 9602 RS 170 VIDEO MONITOR FRAME GRABBER CARD Figure 6 Vision System Cable Connections

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