Home

ER-CIM - intelitek

1. MOVED CIMB 90 SET OUT 9 0 GOSUB OGRIP SPEEDA 10 SPEEDB 2 OVE CIM 94 OVE CIM 98 MOVE CIM 99 MOVED CI 100 MOVED CIMB 100 GOSUB CGRIP SET OUT 2 l open chuck DELAY 300 ET OUT 2 0 close chuck OVED CIMB 90 MOVE CL 99 MOVE CI 98 MOVE CIM 94 MOVED CIM 93 SET OUT 10 1 close door OVE CI 90 SET OUT 10 0 ENDIF END PROGRAM TOM1 take part insert in machine 1 open close door GOSUB ID IF ID 1 do only if part is alum rod SPEED 25 SET OUT 9 1 open door MOVE CIMB 90 MOVE CIM 90 MOVE CIM 93 MOVED CIMB 90 WAIT IN 12 1 door opened SET OUT 9 0 SPEEDA 10 SPEEDB 2 MOVE CI 94 MOVE CIM 98 MOVE CIM 99 MOVED CI 100 MOVED CIMB 100 SET OUT 1 1 close chuck DELAY 300 SET OUT 1 0 GOSUB OGRIP DELAY 20 ER CIM USER S MANUAL Station Application Programs 9 23 9211 9502 MOVED CIMB 99 GOSUB CGRIP SET OUT 2 l open chuck DELAY 300 SET OUT 2 0 OVED CIMB 100 SET OUT 1 1 close chuck DELAY 300 SET OUT 1 0 GOSUB OGRIP OVED CIMB 90 OVE CI 99 OVE CI 98 OVE CI 94 OVED CI 93 SET OUT 10 1 close door DELAY 100 SET OUT 10 0 WAIT IN 11 1 door closed ENDIF END CNC Lathe Station Application Positions This listing does not include the positions for the default template manipulation programs Refer to the section Positions for
2. ER CIM USER S MANUAL CIM Main Menu 2 1 9210 9502 F2 F3 F4 F5 F6 F7 FS F9 Activates PROD Software PROD is used to download production orders to the central CIM controller and to activate CIM production Activates ASRS Software When this option is selected the software attempts to connect to the ASRS station controller Following this connection the ASRS Software is loaded ASRS Software is used as an interface to the ASRS controller Activates MRP Software MRP Software is used to manage the raw material requirements of the CIM cell Activates Reports Software Used to monitor the status of the cell during production Activates Graphics Menu Used to provide an on line graphic representation of the working CIM cell Activates the Communication Menu Used to access and connect the various elements within the RS232 communication network Activates the Setup Menu Used to define the elements at each station initialize controllers activate ATS and perform backup and restore functions Exit to DOS Exit to the DOS environment Activating CIM System Programs Selecting options F1 through F5 in the CIM main menu directly accesses the detailed ER CIM programs Refer to the User Guide chapters in this manual which describe the CIMDEF PROD ASRS and MRP software in detail 2 2 CIM Main Menu ER CIM USER S MANUAL 9210 9502 Graphic Tracking Menu Select F6 in the Main Menu to act
3. The sequential number of the subprocess The station at which the subprocess takes place The machine which performs the subprocess The task which is performed by the machine in the subprocess The current activity being performed on the material other than a subprocess The possibilities are RELEASE UNLOAD UNLOAD FOR ASSEMBLY In the example shown here the piece a component of assembled part 21 is released undergoes two subprocesses and is then unloaded Press lt Esc gt to remove the Process Table from the screen display ER CIM User s Manual 9209 9502 REPORTS 10 9 ASS Y PCS The number of different pieces need to assemble one part This information will appear only on lines which contain assembled parts PCS QTY The amount of each type of piece which needs to be processed in order to assemble one part For example Part 21 is an assembly which requires 2 pieces of materal 1 line 4 and 1 piece of material 11 line 5 The last three columns relate to the actual production status IN PRODUC The number of parts ordered which are currently in the production process FINISH The number of processes which have been completed STATUS The status of the current line in the order The options are READY The amount of materials ready for release into the production cycle At most two can be ready for release WORKING Indicates that two materials are in production No materials can be released u
4. The same procedure may be used to delete a station however this message will appear Remove station are you sure Y N Entering N removes the message entering Y removes the element and displays Done on the screen for a few seconds Warning You can only delete an empty station a station that does not contain any machines If you attempt to delete a station that contains machine s by entering Y in response to the above message the following message will appear on the screen for a few seconds Station not empty can t remove If you want to delete a station that contains machine s you must first delete all of the machines and then delete the empty station Saving Configuration Changes To return to the On Line screen from the Configuration screen press lt Esc gt If you have made changes to the configuration this message will be displayed on the screen Save new RS232 configuration Y N Entering N returns you to the On Line screen without saving the changes entering Y saves the new configuration and returns you to the On Line screen 4 12 RSNET ER CIM USER S MANUAL 9204 9502 Using RSNET for Communication within a Station RSNET may be used to define and modify the communication paths within a station by running the program from the station computer The communication paths run from the station computer to the station elements hence the station name should ap
5. STATION 2 STATUS IN MACHINE DONE MACHINE 1 WORKING ROBOT PALLET x NO PALLET x 1 2 station number to show PgUp PgDn previous next station F9 F10 SCROLL Fi TRACK F2 PALL F3 ORDR F4 STAT FS BUFF F6 CONU Esc MAIN Figure 9 The BUFFERS Report Screen The STATION is shown at the top of the screen To view the buffers for different stations press the corresponding number key For example to view the status of the buffers at Station 3 press 3 Or use the lt PgUp gt and lt PgDn gt keys to scroll through the stations MACHINE The number of the machine at the station BUFFER The number of the buffer at that machine TEMPLT The number of the template which is currently on the buffer 0 indicates empty PART The number of the finished part on the template which is currently on the buffer ER CIM User s Manual REPORTS 10 17 9209 9502 RAW The number of the raw material on the template which is currently on the buffer 0 indicates a finished assembly SUBPRO The total number of the subprocess to be performed or currently being performed on the part on the template which is on the buffer INFO Optional user defined variables defined in the station programs For example you can create the following definitions 1 indicates part which is flawed defective but accepted 2 indicates part which requires retooling 3 indicates part which has failed inspection part rejected If a sta
6. Similar to WTM1 but activates machine number n if present at the station Uses the variable TASKn More than one WTMn program may run on the controller at the same time For example if a station contains two CNC machines both may be run simultaneously to process two parts Removes part from machine number 1 When CNC machines are used this program commands activities such as door and vice opening Similar to FM1 but removes part from machine number n if present at the station Since this program operates the robot only one FMn program may run on the controller at any one time ER CIM USER S MANUAL 9211 9502 Station Application Programs 9 11 Programs Required for Assembly and Other Advanced Tasks The following programs are required only for assembly tasks and other advanced ER CIM applications For a better understanding of the more advanced ER CIM station application programs refer to the sample application programs in the file USERASSM SMP given in the section Sample Application Programs ASMBL Assembles a part from its components GETP Takes an assembly part from the assembling surface to a transfer point or takes a part from a local feeder to a transfer point The following programs are used during automatic downloading of programs to the CNC machines using the program AutoCNC LMODn Puts CNC machine n at station in Load mode before downloading a n 1 4 program AMODn Returns CNC machine n
7. Feeders at Level 1 CIM 71 81 91 Feeders at Level 2 CIM 72 82 92 Feeders at Level 3 CIM 73 83 93 The positions should be recorded at the following locations for each level respectively Positions in front of ASRS for CIM 71 72 73 feeder access Inside ASRS at feeder CIM 81 82 83 positions for grasping part Inside ASRS above feeder CIM 91 92 93 positions for removing part ER CIM USER S MANUAL Station Application Programs 9 17 9211 9502 ASRS Carousel Positions The 18 circular positions of the carousel are defined in the Group B position vector SRSP 18 Carousel position of Cell 1 SRSP 1 Carousel position of Cell 18 SRSP 18 The user needs only to set SRSP 1 All other carousel positions are set relative to this position with an offset between cell locations of 1706 66 encoder units Cell 1 on the carousel is labelled The numbering of the rest of the cells proceeds in a counter clockwise direction To move the carousel use the teach pendant keys that control Axis 7 Then use the teach pendant to record SRSP 1 To set the rest of the positions automatically run the program MKSRS from the ASRS station PC Alternatively you can run program 10 from the teach pendant ER CIM Sample Applications The positions listed here illustrate a possible ER CIM application using the following raw materials aluminum rod Processed by a CNC lathe to make a chess piece per
8. Fl Activates RSNET Software Refer to the RSNET Software User s Guide chapter F2 Activates ATS to the central CIM management controller F3 Activates ATS to the ASRS station controller attempts to connect the central CIM computer to the ASRS controller and then load ATS for direct user communication 2 4 CIM Main Menu ER CIM USER S MANUAL 9210 9502 F4 Activates ATS to a specific station controller attempts to connect the central computer to the specified station controller and then load ATS for direct user communication A Select Station menu will be displayed Up to six stations can be selected depending upon the number of stations defined in the Setup menu Station Controller Setup Communication menu RSNET Activate ATS to central controller Fe Activate ATS to ASAS controller to station controller ATS Select station Activate AUTOCNC Station RSDNL Station External user defined program 1 Station External user defined program 2 Station FS Activates ATS without performing any new network connections Usually this option will be used for communications with a previously connected station or after the connection path has been selected using RSNET F6 Enter the AutoCNC software to activate automatic downloading of CNC programs from a CNC station PC or the central CIM computer to a CNC machine over the switched RS232 network during production F7 Enter the RSDNL software to download a file
9. NEW STATION Name Alt name Number of ports 5 El Station number 0 Description Station port connected to center _0 Control character lt Ctrl gt T Delay before disconnect Choosing the Station option displays a station definition window on the Configuration screen as shown in Figure 3 Figure 3 Station Definition Window This is a description of a station All stations are connected directly to the central CIM network switcher ER CIM USER S MANUAL RSNET 4 5 9204 9502 The following fields must be entered Name Alt name Number of ports 5 9 Station number Description Station port connected to center Control character lt Ctrl gt T Delay before disconnect 0 Name of station up to 8 letters Alternate station name up to 8 letters If AutoCNC software will be used be sure to use the required names as specified in the chapter AutoCNC Software User s Guide Switchers may have 5 or 9 communication ports depending on the number of elements to be connected Usually the Central CIM Network switcher has 9 ports and the station switchers have 5 ports Stations are identified by a number up to 8 stations allowed This is also the number of the Central CIM Network switcher port at which this station is connected Two line description of the station This text is displayed in upper left corner of the screen when this element is selected highlighted The number of
10. The first option is to satisfy the minimum stock quantity The raw material database contains the minimum stock quantity for each raw material while the ASRS files contain the available stock quantity The amount ordered is the larger of these two quantities e twice the minimum stock quantity minus the available stock quantity e the supplier s minimum order quantity When the satisfy minimum stock quantity option is chosen the following window appears on the screen Report Destination Screen Printer You are asked to specify whether the purchase order is printed to the screen to a file or to the printer 7 8 MRP ER CIM USER S MANUAL 9204 9502 When the printer is chosen this message appears Make sure printer is e Pr lt Enter gt to continue To continue printing press lt Enter gt To abort the print command press lt Esc gt This will return you to the previous window If you choose to send the report to a file you will be prompted for the file name Enter file name without extension raw Enter a name with up to eight characters Do not add any extensions the program automatically adds REP to the name entered If this file already exists you will receive the following message File raw rep You can either write over the previous contents of the file or enter a new file name When the purchase orders are written to a file the program will report the number of purchase order
11. it it n controller port connected to SQC computer INCLUI DE CI MSYS ST PORTn INCLUI DE CI MSYSASTA sqc dme DMC Add the following lines to the WTMn file following the lines previously added from Step 2 SET SET GOSUB In the SQC software program define the following NSIZE 5 NSEND HGRES SENDL 3 digits to left of decimal point 2 digits to the right of point ID not used number of samples 1 XXVi ER CIM version 1 84 UPDATE ER CIM USER S MANUAL 9407 9502 Laser Scan Micrometer 1 Connect the LSM to a controller port n 2 In the USERn DNL file make the following changes e Add the following lines at the beginning of the file INCLUDE CIMSYS ST PORTn DMC INCLUDE CIMSYS ST LSM DMC n station controller port number INCLUDE is an ACLoff line command e You must add the program START PROGRAM START which must contain the line GOSUB LSTRT e In program WTMn include the following GOSUB LMES1 or GOSUB LREAD read IF LRES lt minimum ORIF LRES gt maximum SET RESn 1 reject ENDIF 3 OPTIONAL To also use SQC statistical software program e Add the following lines at the beginning of the USERn file preceding the INCLUDE lines from Step 2 INCLUDE CIMSYS ST PORTn DMC INCLUDE CIMSYS ST SQC DMC n controller port connected to SQC computer
12. 99 Part in the machine CIM 100 Slightly outside the machine CIM 95 Pushing the part exactly in place CIM 96 Linear Slide Base Positions Group B Near the CNC machine CIMB 90 CNC Mill Station I O Outputs Door open OUT 2 1 Door close OUT 2 0 ER CIM USER S MANUAL Station Application Programs 9 29 9211 9502 Cycle start Vice open Vice close Inputs Door opened Door closed Machine cycle started OUT 11 pulse OUT 3 pulse OUT 4 pulse IN 10 1 IN 9 1 IN 13 1 Assembly QC Unloading Station Programs USERASSM SMP This station can perform the following applications e quality control using robotvision e assembly using the palletizing racks as a buffer to store the components required for the assembly and an electric vice to hold the parts during assembly e unloading to two palletizing racks grills The application given here does not support the use of the palletizing rack for both assembly and unloading The palletizing racks use a last in first out scheme for storing or retrieving parts No more than eight pieces can be stored in each rack GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL GLOBAL ID Pl P2 P3 P4 P5 PNT1 PNT2 1TSK LINE 9 30 Station Application Programs ER CIM USER S MANUAL 9211 9502 PROGRA
13. Note If the CNC programs will be downloaded to the machines from the central CIM computer over an Ethernet link do not add the modifier CNC when initializing the CNC station computer refer to the chapter Initialization and Setup Procedures CNC Program Names Extensions and Suitability CNC programs must be written in a format suitable for the machine that will use them The CNC program used to perform a specific manufacturing activity appears in the CIMDEF definitions as the task used in a specific subprocess as in the example shown in Figure 1 Here task 2 references a CNC program that mills a hole Process Definition Process 2 Name Make Lamp Base Number of subprocesses Remarks mill threaded center hole and finish surface rocess Definition Subprocess Subprocess name Center hole Station Station name Machining Using a machine i Machine 1 Name ACME 100 Expected processing time Remarks Mi11 16 5 mm diam hole in center of block Fil Previous subprocess Shift F1 10 subprocesses back F2 Next subprocess Shift F2 10 subprocesses forward Esc Processes Definition Figure 1 Example of a Task Number in a Subprocess Definition The AutoCNC software contains tables of the correspondence between task number and CNC program file name A separate table is defined for each machine at each station 12 4 AUTOCNC ER CIM USER S MANUAL 9204 9502 The extension of the file
14. e In the SQC software program define the following 4 digits to left of decimal point 3 digits to the right of point ID 4 digits samples 5 e Inthe WTMz file do not use the GOSUB line s from Step 2 Instead add the line GOSUB LMES 75 samples ER CIM USER S MANUAL ER CIM version 1 84 UPDATE XXV 9407 9502 SCORBOT ER Ill Controller for I O Expansion 1 Connect the ER III controller RS232 port marked computer to an ACL controller port n 2 In the USERn DNL file add the following lines at the beginning of the file INCLUDE CIMSYS ST PORTn DMC INCLUDE CIMSYS ST ER DMC n station controller port number INCLUDE is an ACLoff line command 3 Include the following lines at the appropriate locations in your ACL station programs SETOUT ns FINPUT ns additional lines ENDIF n 1 8 number of input output s 0 1 status 0 off 1 on Note that the period before SETOUT and IFINPUT indicate that these are macro commands SETOUT alters the state of the ER III outputs and IFINPUT reads the state of the ER II inputs xxviii ER CIM version 1 84 UPDATE ER CIM USER S MANUAL 9407 9502 ROBOTVISIONpro ER CIM Interface Install the ROBOTVISIONpro hardware and software according to the instructions in the ROBOTVISIONpro User s Manual but do not perform the ACL Controller Setup In the USERn DNL file make the following cha
15. line er part number line 28 part number line 29 part number line 30 part number Order 11 Empty order Order 30 OK Order 31 OK Order 45 line 1 part 1 is a raw material Order 55 OK Order 67 PgDn PgUp Move Page 1 1 Move Line Home End Start End Esc Quit Figure 6 Production Order Validity Report Inventory Report This request produces a short report of all parts and empty templates stored in the ASRS Report Destination Screen Printer When this option is chosen the following window requests the destination of the report 7 14 MRP ER CIM USER S MANUAL 9204 9502 If the file option is chosen you must specify a file name with up to eight characters and no extensions An example of an inventory report is shown in Figure 7 Report Inventory Report Quantity In feeder s Part 6 Raw Part 10 12 Part 12 14 Part 14 Empty Templates Template type Quantity PgDn PgUp Move Page 1 1 Move Line Home End Start End Ese Quit Figure 7 Example of an Inventory Report Raw Material Production Requirements Queries This request produces a report describing the quantities of raw materials required to manufacture a specified range of orders The specifications include e arange of order numbers e all orders e all orders satisfying a date range e all orders satisfying an order priority range ER CIM USER S MANUAL MR
16. 9 26 CNC Mill Station Positions 2 ear bog A AD el ea ed 9 29 Robot Positions Group A a a 02 ee 9 29 Part from Family 2 Perspex on Buffer 022 9 29 CNC Machine Tending Positions 9 29 Linear Slide Base Positions Group B 24 9 29 CNC Mall Station Ors 2 9 o Be ae Se eee A lee Ge a A R 9 29 CIUIPUIS Laca to ade gent a th gk he ay Bi ode Beta ae 9 29 DUS di 8 ode ho a SO oe eS o de OK 9 30 Assembly QC Unloading Station Programs USERASSM SMP 9 30 Assembly QC Vision Station Positions 00 9 36 Parton Template aa a RS eee Shs 9 36 Vision POSIONS lt o t ssia e e o a RS 9 37 Palletizing Rack Positions 9 37 Assembly Positions e ghee abd Ye a e 9 37 Assembly QC Vision Station VO o a a e 9 38 OUTPUTS acuso es a Be yee Bence a LA ees 9 38 OPUS e de e AA a e A AA a N 9 38 CHAPTER 10 REPORTS Software User s Guide 10 1 IMtoduchon Le ao dr a o e hy Go etd A ae ee ee Oe od 10 1 Activating REPORTS 2 sia ae a a E 10 1 User nterface fe Ao ee 2 Be ae e a A et Be i Pes 10 2 xX ER CIM USER S MANUAL 9502 Frack E tg slp a a lS aoe Ae inst Ge Wc ce lt 3 Sank Se aha ats amp Gate S 10 2 Tracking SSP a wR BE GA a ecg ee RE a i ak 10 3 SETUP SOCIE s ag al ddd UA E ay a RAS 10 3 SETUP Fil ged D a don A 28 e ee Gere Kn He ps A A 10 5 SETUP Printer ed A ras Sa at 4S 2 ee 10 6 Trackine Display O ia a ol
17. 9211 9502 put template on buffer BFR BFR 10 PROGLNS MOVED CIMB BFR B1 BFR PROGRAM TOBFR DEFINE B1 SET B1 SPEED 406 OVED CI SPEEDA 5 OVELD CI GOSUB OGRIP SPEEDA 10 OVELD CI END Optionally you may substitute your own template manipulation programs using the above names in the USERn DNL file for the station These programs will replace the system s default programs when the files are downloaded during station installation Positions for Default Template Manipulation Programs To use the default programs you must first properly record the default positions these are the positions at which the robot holds the template on the buffer and on the pallet These positions must be defined at each station The CIM application programs use two position vectors CIM 500 CIMB 100 Positions for robot group A Positions 1 through 19 are used by the default template manipulation programs Positions for group B linear slidebase for example positions 1 through 9 are used by the default template manipulation programs When the station controller is turned on the AUTO program attaches these vectors to the teach pendant Positions recorded from the teach pendant will be automatically assigned to these vectors 9 8 Station Application Programs ER CIM USER S MANUAL 9211 9502 Robot Positions Template on buffer 1 CIM 1 Template on buff
18. Destination Source Define where a part or empty template will be taken to when retrieving or where it will be taken from when storing There are 2 options Buffer 1 Buffer 2 Buffer 2 is not currently available ER CIM USER S MANUAL ASRS 6 11 9204 9502 Type of object What to retrieve or store Again there are 2 options Part on a template A part on a fitting template Empty template A template without a part on it Part Template type Enter the number of the part or the template type number After you press Y yes to confirm the verification message the system will perform the requested action While the action is being performed you can abort it by pressing lt Esc gt Search Algorithm Used in Store Retreive The carousel automatically rotates to a holding position after every store or retrieve operation In this position cell 9 is directly across from the robot When a store or retrieve operation is initiated the program searches for the cell with the required contents or an empty cell in the case of a store operation that is nearest to cell 9 The object is to minimize the carousel rotation that will be required to bring the selected cell across from the robot The algorithm first checks the contents of cell 9 on each level starting with A and ascending to C If no suitable cell is found the algorithm checks cell 10 on each level then cell 8 on each level and so on until a suitable cell
19. Note that the color of the option line matches the color of the elements displayed on the conveyor PALLET ID TEMPLATE TYPES RAW MATERIALS PARTS Shows all pallets currently on the conveyor whether or not they are empty When this option is selected the pallet numbers appear in magenta characters in the sector boxes Shows all templates currently on the conveyor whether or not they are empty When this option is selected the template type numbers appear in red characters in the sector boxes Shows the type of raw material currently on the conveyor When this option is selected the raw material type numbers appear in blue characters in the sector boxes Shows the ID of the finished parts currently on the conveyor When this option is selected the part numbers appear in black characters in the sector boxes 10 12 REPORTS ER CIM User s Manual 9209 9502 Pallets The Pallets Report screen reflects the status of the pallets which are on the conveyor PALLET TEMPLT 0 0 2 2 AN Om Rh WN E 0 0 35 21 SUBPROC INFO 0 0 0 0 1 0 2 0 0 0 32 MOVING NOT IN USE 0 0 1 STOPPED 11 2 12 MOVING NOT IN 11 3 20 MOVING NOT IN NOT IN NOT IN NOT IN NOT IN NOT IN NOT IN NOT IN NOT IN F9 F10 SCROLL F1i TRACK F2 PALL F3 ORDR F4 STAT FS BUFF F6 CONU Esc MAIN PALLET TEMPLT PART RAW Figure 7 The PALLETS Report Screen The pallet s ID number 1 15 as determined by the
20. SET 1TSK TASK END PROGRAM FM1 take part from vision application IF TASK lt 900 GOSUB ID IF ID 1 SET P3 87 SET P4 88 SET P5 89 ELSE SET P3 97 SET P4 98 SET P5 99 ENDIF SPEEDA 40 MOVE CIM P3 MOVE CT P4 GOSUB OGRIP SPEEDA 5 MOVED CI P5 GOSUB CGRIP SPEEDA 10 MOVE CI P4 SPEEDA 40 MOVED CIM P3 ENDIF END PROGRAM WTM1 performs vision application IF M1TSK lt 900 do this if task is not unloading SET OUT 16 l start vision WAIT IN 16 l wait for input from vision quality is ok SET OUT 16 O end vision Note additional inputs can be ENDIF checked if desired END PROGRAM ASMBL put rod into base SET ID 2 GOSUB FG remove base from palletizing rack SPEEDA 70 MOVE CI 94 MOVE CI 93 SPEEDA 10 MOVED CIM 92 GOSUB OGRIP MOVE CI 91 MOVED CIM 90 9 34 Station Application Programs ER CIM USER S MANUAL 9211 9502 SET OUT 1 1 close electric assembly vice MOVE CIM 93 SPEEDA 50 MOVED CIM 94 SET ID 1 GOSUB FG remove rod from grill SPEEDA 70 MOVE CIM 84 MOVE CIM 83 SPEEDA 10 OVE CIM 82 OVED CIM 81 SPEEDA 5 SET OUT 1 0 open vice so that the base will be free to move DELAY 100 while the rod is inserted MOVELD CIM 80 put rod into hole in base GOSUB OGRIP SET OUT 1 1 close vice MOVE CI
21. Station with Controller B 2 2 a C 10 EMCO 120P Machine SSP e ios Ge eee BG a eG C 10 Software Configuration Parameters 4 C 11 Hardware Preparations bl ac Gis Genel Oe a E C 11 APPENDIX D CIM Controller Management Programs D 1 Controller Sep e s ea Ga ee ee a ER O SR RS D 1 Central Controller Setup 2 0 idea e BO we e D 1 Station Controller Setup ta e ede Ee ate gt AR A KS D 2 Controller Backup e oe ana el Ol Siw e Soe RS ee A D 3 CIM ACL Station Program Backup 0 D 3 Position Backup Lala A ew oe Oe etl ey D 4 APPENDIX E Preparing the LS 6x20 Bar Code Scanner for Operation E 1 APPENDIX F CIM ACL System Program Listing lt lt F 1 Central Controller Program Listing 2 044 F 2 Station Controller System Programs 0 0040 F 48 ASRS Station Program Listing 25 02 2054 4 24 o F 92 ER CIM USER S MANUAL xiii 9502 This page intentionally left blank xiv ER CIM USER S MANUAL 9502 Software UPDATE ER CIM version 1 84 Installation Prerequisites Software Plug Software protection plugs are no longer required for any part of the ER CIM software Drive H Before installing the ER CIM software be sure the central CIM computer can access drive H This can be achieved by means of one of the following e Using a LAN such as NOVELL e Including the line LASTDRIVE H or greater in the CONFIG
22. The STATIONS Report screen shows the status of production activity at each station 1 COMMUNICATION O K RELEASING MATERIAL FOR PART 12 2 COMMUNICATION O K 3 COMMUNICATION O K F9 F10 SCROLL F1i TRACK F2 PALL F3 ORDR F4 STAT FS BUFF F6 CONY Esc MAIN Figure 8 The STATIONS Report Screen STATION The station number LOCAT The conveyor sector number at which the station is located STATUS Checks and reports on the status of both RS232 communication and T O signals between the station controller and the central controller Current communication status at the station The possibilities are NOT ACTIVE There is neither RS232 nor I O communication with the station RS232 ERROR I O ERROR COMMUNICATION O K Both RS232 and I O communication are functioning properly ER CIM User s Manual REPORTS 10 15 9209 9502 PALLET The ID number of the pallet currently at the station or which has just left the station The pallet number will change as soon as the next pallet arrives at the station REMARKS Describes the current activity at the station The possibilities are RELEASING MATERIAL FOR PART ASSEMBLING PART NEED TEMPLATE FOR PART Request for an empty template to put part on RELEASING TEMPLATE In response to a request for a template RELEASING PART Indicates part is completed 10 16 REPORTS ER CIM User s Manual 9209 9502 Buffers The Buffers Report screens show the status of the buffers at each station
23. The following options are available to exit the window lt Fl gt Save the new station description print DONE on the screen and return to Configuration menu The new machine will be added to the graphic display lt Esc gt Return to the Configuration screen without saving the changes When lt Esc gt is pressed the following message is displayed on the screen Quit with no update are you sure Y N Pressing N removes the above message pressing Y removes the New Machine window from the Configuration screen Modifying an Element This feature allows you to modify the description of an existing element in the configuration Pressing lt Enter gt when a station is highlighted on the Configuration Screen the ASRS station for example displays the Modify Station window shown in Figure 6 MODIFY STATION Name ASAS Alt name STATION1 Number of ports PE 9 Station number 1 Description Automatic Storage and Retrieval System Station port connected to center _1 Control character lt Ctrl gt T Delay before disconnect Figure 6 Modify Station Window 4 10 RSNET ER CIM USER S MANUAL 9204 9502 The gt lt TI keys are used to move between fields All changes must be followed by lt Enter gt or they will not be saved once you move to the next field Note that you cannot change the station number from this screen Pressing lt Enter gt when a machine element is highlighted on the C
24. The station contains a controller a PC computer a carousel a robot buffers templates parts and feeders These devices have the following functions the controller handles requests from the central CIM controller the station PC and the central CIM computer while controlling the movement of the carousel and the robot the PC with its ASRS software interfaces between the user and the controller the carousel a multi level rotating warehouse stores parts templates and feeders the templates hold parts the feeders serve as magazines for raw materials the buffers temporarily store templates the robot transfers parts and templates between the carousel the buffers and the conveyor The ASRS Software The ASRS software serves as a user interface to the ASRS controller The program s simple user interface makes it easy to learn to operate the ASRS software The ASRS software provides the following features Real time graphic display of the ASRS cell contents On line updating of ASRS cell contents Storage and retrieval of selected parts or templates Automatic verification of template identity using a barcode scanner ER CIM USER S MANUAL ASRS 6 1 9204 9502 e Separate backup and restore of ASRS cell contents and template correspondence data e Off line mode for creating or modifying ASRS contents and template data using the graphic display For a listing of robot and carousel positions used by ASRS programs
25. materials production sequences etc Used for selecting and downloading production orders to the main controller and activating the manufacturing process Can only be activated at the central CIM management computer ER CIM USER S MANUAL 9210 9502 CIM Main Menu 2 13 ASRS DOWNLOAD SEND CENTER REPORT STATION Activates the ASRS automatic storage and retrieval system software Can be activated at the central CIM management computer and at the ASRS station computer Downloads ACL Off Line programs to the various controllers Sends a command to an ACL controller Enters the directory containing the programs for initializing the main controller DNL Initializes the central CIM controller and loads system programs Can only be activated at the central CIM management computer Activate the REPORT software for a complete on line display of the production status of all the CIM elements Enters the directory containing the programs for initializing the station controllers INITST Defines the types of robots and peripheral equipment at each station DNLST Loads system programs to station controllers BACKST Performs backup of entire contents of station controller BACKSTP Performs backup of station controller positions only RESTST Restores entire contents of station controller RESTSTP Restores station controller positions only Refer to the chapter CIM ACL System Program Management for
26. refer to the section ASRS Station Positions at the end of this chapter All programs necessary for ASRS control and operation are included in the CIM ACL system programs and in the ASRS software For a listing of the ACL ASRS programs refer to the ASRS section of the appendix CIM ACL System Program Listing For information on setting up the barcode scanner s internal programming refer to the appendix Preparing the LS 6x20 Barcode Scanner for Operation Activating the ASRS Program Getting Started For the ASRS program to function correctly the ASRS controller must be loaded with 1ts own specific software This initialization is usually done only when the entire CIM system is installed To activate ASRS in on line mode do one of the following From the ER CIM Main Menu select F3 e At the central CIM computer s H gt prompt type ASRS and press lt Enter gt At the ASRS station s DOS prompt type ASRS and press lt Enter gt The ASRS program will first try to establish communication with the ASRS controller Figure 1 Communicating with controller Status Window 6 2 ASRS ER CIM USER S MANUAL 9204 9502 If the ASRS program fails to communicate with the controller the following message is displayed Error Controller not responding How to continue Retry Abort Ignore Offline mode Figure 2 Controller Not Responding Message If this happens you should check t
27. ve O Q RAM FB take part from template on buffer BFR GOSUB ID SPEEDA 60 MOVED CIM 150 SP S PEEDA 40 PEEDB 40 E CIM P2 OVED CIMB BFR SUB OGRIP SPEEDA 10 MOVELD CIM P1 GOSUB CGRIP OVELD CIM P2 PROGRAM TOB put part on template on buffer BFR 9 26 Station Application Programs ER CIM USER S MANUAL 9211 9502 SPEEDB 40 E CIM P2 ED CIMB BFR SPEEDA 10 MOVELD CIM P1 GOSUB OGRIP MOVELD CIM P2 ea Z U TU ROGRAM WIM1 ET ouT 11 100 ouT 11 0 IN 13 1 working IN 13 0 stopped 1 start machine Aw el Hoe D K H H HOH A Ef Gio Oa SM Z U PROGRAM FM1 GOSUB ID IF ID 2 SPEED 25 SET OUT 2 1 open door CIMB 90 CIM 90 WAIT IN 10 l wait for signal that door is open OVED CIMB 90 ET OUT 3 0 ET OUT 4 0 ET OUT 3 l open vice OVE CIM 97 ED CIM 95 JAW 34 no room to open gripper use JAW to open partially SPEEDA 10 MOVELD CIM 100 GOSUB CGRIP SET OUT 3 0 OVEL CIM 99 OVEL CIM 98 OVE CIM 97 MOVED CIM 90 SET OUT 2 0 close door ENDIF Bi B iS O lt mi T END PROGRAM TOM1 take part to machine 1 open close doors insert GOSUB ID IF ID 2 do this only if part is perspex base ER CIM USER S MANUAL Station Application Programs 9 27 9211 9502 E z
28. 3 CNC Note If the CNC programs will be downloaded from the central CIM computer over an Ethernet link do not add the modifier CNC when initializing the CNC station computer 3 When installation is completed remove the diskette from drive A 4 Turn off the computer and then turn it on again Additional Installation Procedures Loading USERn DNL Files After computer programs have been installed you can load previously prepared station programs contained in the USERn DNL files n is a station number The following procedures must be executed in sequence 1 At the central CIM computer type CIM followed by lt Enter gt This will log into the H CIM drive You will be prompted to enter a name name Type USER followed by lt Enter gt You will be prompted for a password password Do not type anything simply press lt Enter gt The CIM Main Menu will be displayed To perform the following step press F9 to exit the Main Menu You will receive the DOS prompt H gt ER CIM USER S MANUAL Installation 1 5 9308 9502 Type STATION and press lt Enter gt This will bring you into the directory H CIMSYS ST This directory contains the sample ER CIM application USERx SMP files x LATHE MILL or ASSM Refer to the chapter Station Application Programs in this manual for further explanation and a listing of these files Create the USERn DNL files and save them in the H CIMSYS ST directory
29. 71 72 73 feeder access Inside ASRS at feeder CIM 81 82 83 positions for grasping part Inside ASRS above feeder CIM 91 92 93 positions for removing part ASRS ER CIM USER S MANUAL 9204 9502 ASRS Carousel Positions The 18 circular positions of the carousel are defined in the Group B position vector SRSP 18 Carousel position of Cell 1 SRSP 1 Carousel position of Cell 18 SRSP 18 The user needs only to set SRSP 1 All other carousel positions are set relative to this position with an offset between cell locations of 1706 66 encoder units Cell 1 on the carousel is labelled The numbering of the rest of the cells proceeds in a counter clockwise direction To move the carousel use the teach pendant keys that control Axis 7 Then use the teach pendant to record SRSP 1 To set the rest of the positions automatically run the program MKSRS from the ASRS station PC Alternatively you can run program 10 from the teach pendant ER CIM USER S MANUAL ASRS 6 19 9204 9502 This page intentionally left blank 6 20 ASRS ER CIM USER S MANUAL 9204 9502 CHAPTER MRP Material Resource Planning Software User s Guide Introduction The MRP Material Resource Planning software aids the user in managing the raw material requirements of the ER CIM cell The program accesses the CIMDEF and ASRS database to create reports and raw material purchase orders according to the user s specificatio
30. A Ww NBS AHWR UWN WAN WR 00000000 Of 00000000 ok 1 1 select line Enter show process table F9 F10 SCROLL F1 TRACK F2 PALL F3 ORDR F4 STAT FS BUFF F6 CONY Esc MAIN Figure 5 The ORDERS Report Screen LINE The line number in the production order PART The ID number of the part to be be processed If a part is a processed material it appears as one line in the order For example Parts 2 and 12 lines 1 and 2 are processed materials If a part is an assembly it will appear on several lines The first line contains the part number and the following lines which do not display a part number represent the pieces which comprise the assembly For example Part 35 in line 6 is an assembly Lines 7 10 describe the four pieces which make up the assembly 10 8 REPORTS ER CIM User s Manual 9209 9502 QTY The number of parts with this part number or the number of pieces in an assembly that are currently on order RAW MATER The ID number of the raw material used SUBPR The total number of subprocesses to be performed on this specific raw material in order to create the part A breakdown of the different subprocesses for each part can also be viewed Use the 4 down and 7 up arrow keys to highlight the line you want to view and press lt Enter gt e HPART 1 a 2 i 3 21 4 4 21 kas Another frame appears on the screen SUBPR STATION MACHINE TASK REMARKS 0 1 1 1
31. A a ae 4 The RSNET On Line Screen ceca o he oe awe a AA 4 2 Activating a Communication Path 2 2 en 4 3 Changing Configuration 2 3 e E E ee aS ee OS eA 4 3 Inserting Elements ocean a ER ee es 4 4 Ins rtino A SAO ate ak e Se ete e ra KS 4 5 Inserting a Machine see ae 4 Swe oe RR Re DIS ews 4 7 Modifying an Element iy a6 a a Se ee SRS 4 10 Deleting Elements 5 2 lt 4 0 2 s 6 4 ee a a 4 12 Saving Configuration Changes 2 a o eo 4 12 Using RSNET for Communication within a Station 4 13 RSNET Configuration Data Files 4 4 rr a e 4 14 Command Line Options 20 00 0000 0000004 4 15 Activating a Communication Path 2 en 4 15 Defining the Communication Port a a a a a 4 16 CHAPTER 5 PROD Software Users Guide noanoa 5 1 ntrod tion s a io os ooi ee o ed BRE eee a e ae 5 1 Orders and Downloading a 5 1 Activating the PROD Program a 5 2 Getting Started 3 2 La a a e a a AA a N 5 2 Production Setup 26 204 2306008 bee aa aoa ARA 5 3 Select Production Order 46 22 YS SAL a e 5 4 Download Production Data a a a a a o 5 6 CIM Prod cti n e s s ss soas a Gee meh a opok e ee s ao 5 8 Reset CIM Cell lt 5 405 5 Sie de a Be e ED AAA 5 8 Order Entry i a pk ee ee RA ae ae IS ER es 5 9 Selects a ala we eA Se RR I uh ee oe ae oar a a ae 5 9 Order Entry Screens ld ae ES we ee ee a 5 9 SAVE a sh dah Shown ce Soe Be ee a
32. ACL program RORD as described in the chapter CIM ACL Report Update Programs A function key menu is displayed on the bottom of the screen F2 Activate ATS for direct access to the Central CIM controller F9 Return to the CIM_CELL screen The functions of the remaining keys lt F1 gt lt F5 gt lt F8 gt will not be covered here The Second Function Key Menu Pressing F7 from the CIM_CELL screen displays the second function key menu on the bottom of the screen F2 Activate ATS for direct access to the Central CIM controller F3 Use the TRACE facility for debugging purposes This displays all messages sent to and from the Central CIM controller on the screen F4 Run the CIM ACL system reset program to reset the cell The functions of the remaining keys F1 and F5 through F8 will not be covered here ER CIM USER S MANUAL Graphic Tracking 8 9 9207 9502 Defining the Graphic Layout and Conveyor Type The graphic tracking program takes the layout information from files stored in the directory H WIZCON at the central CIM computer Additional information is contained in files that specify the shape of the conveyor square or oval To set the layout and conveyor shape used in the graphic display do the following 1 Enter the H WIZCON directory at the central CIM computer 2 Type the following CHANGE shape type where shape is one of the following SQ a square conveyor OV an oval conveyor and type is the na
33. ASRS elas te Sy tl de ls BP oS a o e ll aa xvi ASRS SACL Files a er a es a o A A a AaS xvi Retrieve Store Part 4 dla ESAS amp ee ee we te SS xvii REPORTS co canas A ri a y de a BS xvii AUTOCN CG eeu al o be De e gee aae De aA xvii Graphic racking co as A A EE A aa N xvii NIEMEBAT ia So nS a e Ronee we a a aae RS ee es xvii Station EIES ig se rn igs Wx he A a E Ws OD Ee De xviii WISE RSI D e ea n tran dy os el By A E e ri Be RA A ds xviii POINTA CBU io an feta doen aise oe a e ae E A ee e oY xix STATIONA CBU 2d a o a a Se we LA BO s X1X PARA CRO a tt oe te ee Bo A a Re e Gee ES BE eo wd xix CONE AC saia bis he ala Ye a a ZY oe ged amp XX REPORT DISD 0 04 bin Ghats ao sO Ss ore Ge Go Pa we thos Se ke as i XX Sample CSMPY Bl o see 2 a Be yadinda eee de E eon XX ACL Central CIM Controller 4 8 4 da We a BR ES xxi New Variables 2 sas ho fe ea Be ee el By Go tee He AS amp dS xxi ACL Station Controller a ui a a a a xxi N w Variables eein A A A SE xxi For program WTMn aoaaa AAA xxi For program FB and RJCT oaaae xxi For non robot assembly program ASMNR aaa xxii For program START 0 aaa e xxii New Programs a ene e AE ra A xxii RSKBD sc Se Bo ee o rs Boe A a a ES a Bod xxiii Device Installation s ana an e GOES A AS POE a ES xxiii Using SQC Software Goa E a ERA RA et SSS XX1V Hesht Gace a E A ee rr we eee e ee eS XXV Laser Scan Micrometer we ss Bale He eR eee ae Ba I aS xxvii SCORBOT ER HII C
34. AutoCNC File Handling Screen The CNC program files must be located in the proper downloading directories on the CNC station PC in order to be downloaded automatically When CNC program files are found in another location such as on a diskette or in a CAD program directory on the CNC station PC this location is referred to as the source The File Handling screen lets you copy CNC files from a source directory to the specified downloading directory as well as other file handling tasks Note This screen only allows you to list copy or delete specified files It does not allow you to specify the file that will be downloaded The file that will be downloaded is specified by the task number in the CIMDEF subprocess definition for the part under production the task to file name correspondence information entered in AutoCNC and the file extension and location defined in the option file used by RSDNL The file handling screen is divided into three sections The top section defines the source directory and the files to be handled the left side of the screen gives six utilities and the window on the right displays the files requested by the various utilities ER CIM USER S MANUAL AUTOCNC 12 9 9204 9502 The top line on the screen lets you define the source directory The next field lets you select the station and machine number CNC file name and file extension The utilities available are Get from source lt F1 gt Save to source l
35. CIM 94 OVE CIM 98 OVE CIM 99 MOVED CIM 100 MOVED CIMB 100 GOSUB CGRIP SET OUT 2 DELAY 300 SET OUT 2 MOVED CIMB 90 MOVE CIM 81 MOVE CIM 82 MOVE CIM 83 return part to template on buffer BFR jactivate machine 1 and wait for it to finish 1 start machine pulse duration 0 l machine working O machine stopped 1 OBOT 1 open door 1 0 close door l open chuck ER CIM USER S MANUAL 9211 9502 Station Application Programs 9 21 MOVED CIM 84 MOVED CIMB 100 SET OUT 1 1 close chuck DELAY 300 SET OUT 1 0 GOSUB OGRIP DELAY 20 MOVED CIMB 99 GOSUB CGRIP SET OUT 2 l open chuck DELAY 300 SET OUT 2 0 MOVED CIMB 100 SET OUT 1 1 close chuck DELAY 300 SET OUT 1 0 GOSUB OGRIP OVED CIMB 90 MOVE CIM 83 OVE CIM 82 MOVE CIM 94 MOVED CIM 93 SET SBUSY 0 POST 1 TO ROBOT SET OUT 10 1 close door DELAY 100 SET OUT 10 0 WAIT IN 11 1 door closed SET OUT 3 l start machine DELAY 100 SET OUT 3 0 WAIT IN 10 1l working WAIT IN 10 0 stopped END PROGRAM FM1 remove part from machine 1 GOSUB ID IF ID 1 do this only if part is alum rod SPEED 25 SET OUT 9 1 open door MOVE CIMB 90 MOVE CIM 93 WAIT IN 12 l wait for signal that door is open MOVE CIM 94 9 22 Station Application Programs ER CIM USER S MANUAL 9211 9502
36. Computer or a Station Computer 2 11 DOS Commands for Activating System Programs 2 13 Disk Structure for ER CIM System 028 2 15 CHAPTER 3 CIMDEF Software User s Guide 2 2 002 2 eee eee 3 1 Iniroductious 1 2 a ee oa ee ee a a ee ee Sc ee Ok ee GY 3 1 Stations and Machines ig 54 5 e Sone GAG Se ek Boks GOR Sa dese 3 1 Processes and Subprocesses 2 1 1 ee ee 3 1 Materials s te ox ie ee gn a OE hn ae So PGS SR oA 3 1 Orders Han Bea hs A GP Bede Guna Ee GRE Bee Wi ee Ag ok A es Sk ee Age 3 2 Activating the CIMDEF Program 4 3 2 Getting Started rra ee ects oe a ao a Bee De A ek 3 2 COMMON Features sessi a cg Dd SS AW o a GS GB ae Os 3 3 REPORT Sat oho okt Ms ake eA a Ue Se He as Ei panie aS 3 3 AVC A Be Rs Bk eR Se oe AA es Se Ge Ge Sa Ea A 3 4 Select a eh E ea Se IS he ek ae Da ae SL ae a 3 5 Delete z od a A BOER ae eS SY SOE eS 3 5 Station Definition s s a s ao go de a Be A aE eee Eke ed 3 5 Process Definitore 2 5 g iui a A A a GG A 3 7 vi ER CIM USER S MANUAL 9502 Material Assembly Definition o o 3 9 Order BA soane foi ER E AA a O RE on A A He che 3 12 PU MADABEE Le a o A AR a ta A AR A a are 3 14 Command Line Options Gl o Spee a A 3 15 CHAPTER 4 RSNET Switched RS232 Network Software User s Guide 4 1 Inteoducton ne Ge a e o o e de E A EE AA AA 4 1 Accessing the Software y luto 2 ee de Be oR a amp
37. Default Template Manipulation Programs Robot Positions Group A Part from Family 1 on Template Part from family 1 on buffer 1 CIM 31 Part from family 1 on buffer 2 CIM 51 Above 31 CIM 41 Above 51 CIM 61 Access point between 6x and 4x CIM 150 CNC Machine Tending Positions Out of the machine CIM 93 Near the machine CIM 94 98 99 9 24 Station Application Programs ER CIM USER S MANUAL 9211 9502 Ready to enter the chuck Outside of chuck Rotate roll the part 180 Return to chuck with rotated part Linear Slidebase Positions Group B CNC Machine Tending Positions Outside the chuck Inside the chuck Access point near CIMB 100 to push the part exactly in place CNC Lathe Station I O Outputs Door open Door close Cycle start Chuck open Chuck close Inputs Door opened Door closed Machine cycle started CIM 100 CIM 8 1 CIM 82 83 CIM 84 CIMB 90 CIMB 100 CIMB 99 OUT 9 pulse OUT 10 pulse OUT 3 pulse OUT 2 pulse OUTT 1 pulse IN 12 1 IN 11 1 IN 10 1 ER CIM USER S MANUAL 9211 9502 Station Application Programs 9 25 CNC Mill Station Programs USERMILL SMP GLOBAL 1D GLOBAL P1 GLOBAL P2 PROGRAM ID calculate part family ID intermediate pos SET ID RAW 10 SET ID ID 1 SET Pl BFR 20 P1 20 BFR ID 10 SET P1 P1 10 SET P1 P1 ID SET P2 P1 10 END PROGRAM OGRIP PROGRAM CGRIP BE f E O n ea U
38. I O connections are used for interfacing the robot station controller and its various peripherals CNC machines and the pallet tracking sensor The I O connections are used for communication with the pallet conveyor s Programmable Logic Controller PLC and for direct control of the pallet sensors and stop stations For complete details of I O connections refer to the appendix CIM I O Connections Point to Point RS232 Connections Point to point connections link the central controller directly to each station controller Through these connections the central controller transmits data such as part ID task to perform machine to use When production starts the central controller also uses point to point connections to give commands to the ASRS for raw material inflow station During production each of the station controllers communicates with the central controller for real time on line production commands and updates RS232 peripherals such as the barcode unit may also be connected in this manner for immediate on line communication ER CIM USER S MANUAL Communication Network A 1 9204 9502 For complete details of RS232 connections refer to the appendix CIM RS232 Connections Switched RS232 Network The switched RS232 network allows the operator from one computer to fully interact with any station or machine in the CIM cell This communication network links all elements of the cell starting from the
39. It allows the user to create view or modify the following information e minimum stock quantity definition e unit price e minimum order quantity e delivery time e supplier information This information is used by the MRP software to generate queries reports and raw material purchase orders 7 4 MRP ER CIM USER S MANUAL 9204 9502 Choosing the Raw Material Information option from the main MRP menu displays the selection screen shown in Figure 2 Raw Material Information Raw material ID Enter Select current F5 Report Esc Previous menu Figure 2 Raw Material Information Selection Screen From this screen you can view the information on a particular raw material or issue a report on all or a selected range of raw materials If you choose to generate a report from this screen by pressing lt F5 gt you must then specify the report type full or partial the range of raw material part numbers for a partial report and the report s destination screen file or printer To view the information on a particular raw material enter its part number and press lt Enter gt Part numbers from 1 to 1000 may be entered If there is no part defined for this number you will receive the following message Error Part does not If the number entered does not correspond to a raw material part this message will appear on the screen ER CIM USER S MANUAL MRP 7 5 9204 9502 Once you have typed
40. OV 103A where OV or SQ is the shape of the conveyor and 103A is the graphic layout for one of the ER CIM configurations If you type VIEW OV or VIEW SQ without specifying the specific graphic a list of graphics for you to chose from will be displayed ER CIM USER S MANUAL ER CIM version 1 84 UPDATE XVii 9407 9502 Station Files USE All the files for each specific station are now located in individual station subdirectories accordingly named 1 2 3 4 5 and 6 within the H CIMSYS directory Each directory contains the following files USERn DNL station programs n station number POINTn CBU station positions created during backup STATIONn CBU station controller contents created during backup PARxx CBU all parameters for robot gripper and accessories at specific station xx the type of robot CONFIG ACL station controller configuration REPORT DLD log of last controller initialization During the installation upgrade procedure the station specific files USERn DNL and POINTn CBU are moved to the appropriate station directories and removed from the CIMSYS ST directory Rn DNL This is a user file which contains the programs for the specific station It is created and edited during ER CIM installation and modification This file is used by Station Setup Initialize controller menu option From the H gt prompt at the central CIM computer type STATION to change the current directory
41. Resource Planning analysis The table in this screen provides the following information Line Part ID Part name Quantity The number of line in the order The number of the part you want to order Updated automatically according to the Part ID field The amount of parts of Part ID you want to order PROD ER CIM USER S MANUAL 9204 9502 Save To keep the changes you have made after defining or modifying an order and before exiting the screen use the Save option This will save your changes to disk Press F2 Note that you are always prompted to save your changes Figure 14 Save before exit verification Window Delete To cancel the currently selected order press F3 This will delete from disk the file describing the order Note that deleting unnecessary files frees disk space Report The Report function lets you receive information on a range of orders Activate this ontion bv pressing F5 Tupe Figure 15 Type of report Window Two types of reports are possible Partial A report of a range of orders You are prompted to define the requested range For example a report of orders 4 to 15 Tupe of report Partial Full Enter order range From 4 To 15 Figure 16 Range of report Window Full A report of all the orders defined After selecting the type of report select where to direct the report ER CIM USER S MANUAL PROD 5 11 9204 9502 Report destination Fi
42. S MANUAL 9407 9502 ER CIM version 1 84 UPDATE XXi For non robot assembly program ASMNR PARTA ID number of part to be assembled For program START ACOFF New Programs LIGHT RJCT ASMNR ATACH GTROB FRROB If AUTOCNC is not used this variable may be set to a non zero value thereby permitting use of COM2 normally reserved for AUTOCNC for user programs Station light control by default turns on output 1 green light on if a template is on any buffer turns output 1 off red light on if all buffers are empty At ASRS station also turns on output 1 green light on if ASRS safety lamp is on Takes part being held by robot to rejection bin can use variables PART RAW RAWN TASK SUBP INFO RESUL as in program FB When assembly does not require robot use this program instead of program ASMBL this program uses variable PARTA Attaches user position vector to group B If slidebase is defined in the setup the command ATTACH CIMB is executed by default If slidebase is not defined program is empty Starts using robot Finishes using robot To use robot in WTMn program user commands for the robot must be preceded and followed by these two commands GOSUB GTROB user commands for the robot GOSUB FRROB This ensures that no other programs are using the robot at the same time XX ER CIM version 1 84 UPDATE ER CIM USER S MANUAL 9407 9502 RSKBD A new progr
43. additional descriptions of these commands CIM Main Menu ER CIM USER S MANUAL 9210 9502 Disk Structure for ER CIM System H r ROBOT ACL ATS Program DOWNLOAD Program SEND Program Standard Parameters CIMSYS CIMP CIM Menu CENTER Main Controller ACL CIM Programs DNL Program ST Station Controller ACL CIM Programs INITST Program DNLST Program BACKST Program BACKSTP Program RESTST Program RESTP Program aii Si PAR7 CBU PAR7 CBU CNC RSDNL Program RSDNL Data files AutoCNC Program 1 M1 CNC Programs G code M2 CNC Programs G code S6 M1 CNC Programs G code M2 CNC Programs G code ER CIM USER S MANUAL CIM Main Menu 2 15 9210 9502 REPORT REPORT Program REPORT Configuration Files RSNET RSNET Program RSNET Configuration files RSNET1 RSNET Configuration files for station 1 RSNET6 RSNET Configuration files for station 6 WIZCON a WIZCON Program Graphic Display WIZCON Working Data Files Data WIZCON Data Files OV Layout Data for Oval Conveyors so Layout Data for Square Conveyors CIMDEF al CIMDEF Program PROD Program MRP Program CIMDEF Data Files ASRS ASRS Program Data Files PLC PLC Program J Batch files for program activation H is a virtual disk name wh
44. computer and any of the CIM elements e a station computer and a CIM element at that station Unless otherwise stated the descriptions in this chapter refer to the first function The RSNET software allows the user to activate or deactivate a communication path and to change the communication configuration by adding deleting or modifying elements CIM elements include station robot controllers CNC machines vision systems computers and other devices Accessing the Software To access the Switched RS232 Network software select the Communications Menu F7 from the CIM Main Menu then select RSNET F1 Alternately type RSNET at the DOS prompt You will see the On Line screen ER CIM USER S MANUAL RSNET 4 1 9204 9502 The RSNET On Line Screen Figure 1 shows the On Line screen Single frame squares represent machine elements such as a lathe or controller while double frame squares indicate stations such as quality control The connecting lines show possible RS232 communication connections between the elements CONTROL 7 ER Uplus cont ROBOT ER Vplus Central CIM Station CNC BI PROJEC UNLOAD ple CONTRO CONTRO CONTRO CONTRO COMPUT LATHE LATHE COMPUT COMPUT COMPUT MILL MILL COMPUT lt lt ON LINE gt gt gt use lt 1T7 gt to Select lt Enter gt or lt gt to connect lt gt to disconnect lt F10 gt Configuration menu lt Esc gt Exit to DOS Figure 1 RSNET On Line Screen The
45. during production ER CIM USER S MANUAL AUTOCNC 12 1 9204 9502 Required RSNET Alternate Names The following alternate names must be defined in the RSNET configuration when using AutoCNC stations stationl station2 stationn where n is the station number used in the CIMDEF definitions machines ml m2 mm where m is the machine number used in the CIMDEF definitions for that station Required RS232 Connections The following RS232 connections are required to download CNC programs at a CNC station 1 Cable from COM 2 of CNC station PC to port 2 of the 8 port RS232 card at the CNC station controller 2 Cable from COM 1 of CNC station PC to home port of station switcher 3 Cable from CNC machine to port 3 on the station switcher At stations with two CNC machines machine 1 is connected to port 3 and machine 2 is connected to port 4 For more information refer to the section on the switched RS232 network in the appendix CIM RS232 Connections 12 2 AUTOCNC ER CIM USER S MANUAL 9204 9502 Location of CNC Programs CNC files that are to be downloaded to the CNC machines must be located in specific directories reserved for this purpose These directories referred to as the downloading directories are generally located at the CNC station computer s When the CNC station is connected to the central CIM computer via an Ethernet LAN the CNC programs may be stored at the central CIM computer in the requi
46. ee eee oa e ai 5 11 Delete s pai 2s hk A ARA ee OE we eS ES A Seah 5 11 Report su ew nei EA AAA AE EE 5 11 File Manager s i ccros amp 45 A Ge ee ae E a a ee ES 5 13 Command Line Options 6 2 4042 4 e228 5 eb be bbe ee ees 5 14 ER CIM USER S MANUAL 9502 vii CHAPTER 6 ASRS Software User s Guide lt lt ee 6 1 IMFOduUchiOn s ss ELL a a a a a ds Oe ES 6 1 The ASKS Stati i e e fe A A A AA de eS 6 1 The ASRS Software 2 me ne OR a 6 1 Activating the ASRS Program eco rs isc e Ee Ree HOS 6 2 Getting Started s cei eae a Ad e Soe BB vem BRIS ES eS 6 2 Inspect Update Contents Laa Sinus S Ge a es Pareles GAS 6 5 Inspect Update Contents Screen Structure 2 00 6 6 Modifying Cell Contents iaa E rr ae ee eS 6 6 Template Definition le esas ac kee e e Seo Woe ah we BR OS 6 8 Store Retrieve a Part ceed Al ee Ve ea ee rer Ue a Oh OAS 6 10 Search Algorithm Used in Store Retreive 6 12 Barcode Splups e opta a e Ei A A da 6 13 Testing the Barcode 4 e ense osea de a owe eR ic A Bod 6 13 Activating the Barcode ye a a a e GS 6 14 GUNES Dl Bee AA ARAS A ee a A A SS A 6 15 ASRS POSIHMO S drets e a o ra a a 6 16 Robot Positions ko ea A GA o e WER Se a Ble eS 6 16 Pallet at Conveyor Station Positions 6 16 Buffer Positions Ga eS eee e ee ae EH eee e 6 16 Barcode Scanner Positions cea a AAA 6 17 Positions for Placing a Part on a Templa
47. ee o a a a aa e A ARN E terme the Softwar 2 4 a an a ee a E a ee A AA e a The CIM_CELL Graphic Display oa aa a a Th F nction Keysis iao aida e ri A a The Stations Screen ec fr ese E e a BPS da Setting a Station Location a soa e The Utilities Screen ra a SR The Production Report Screen Wicca ria e a The Second Function Key Menu aoaaa a eee Defining the Graphic Layout and Conveyor Type 2 2 CHAPTER 9 ACL CIM Application Programs and Positions Introd ction o nw ee i aoe Se a AOR de e ee oe aS Writing Application Programs 2 0 00000084 Control Variables for Station Application Programs Commands to Open and Close the Gripper Position Numbering Conventions 00 Required Programs s sa s sacro AAA Raw ee 8 Template Manipulation Programs 00 Positions for Default Template Manipulation Programs Robot Positions e ss c aoe sr Be be BR ee Dah Linear Slidebase Positions 228 Backing Up Positions to Disk 2 2 2 20040 Part Manipulation Programs 2 e Programs Required for Assembly and Other Advanced Tasks Optional Program for Automatic Downloading of CNC Programs Optional User Station Programs 0084 Standard Program Numbers for Execution from Station Teach Pendant 2 45 8 se css ee ee e a
48. gt Part gt Template gt Template gt Type or Type or feeder quantity feeder quantity Figure 5c Part Figure 5d Feeder Quantity Unknown The current contents of the cell are unknown 9 This designation is automatically assigned to a cell by the program when there is a conflict between the information entered by the user and the template type detected by the barcode reader The system will not store a template in a cell marked unknown nor will it remove a part or template from such a cell Figure 5e Contents Template Definition Templates are special trays designed to hold different parts Each part has a unique template type which can hold it A specific type of template can hold up to eight different predefined parts Each template has a specific type number from 1 to 99 that identifies it This number appears on a barcode sticker as shown in Figure 6 This sticker is affixed to the side of the template that faces the barcode scanner Figure 6 Template Barcode Sticker 6 8 ASRS ER CIM USER S MANUAL 9204 9502 There are six digits in the barcode The first left two digits represent the template type number while the next four digits are used as an ID number for the specific template When the barcode scanner is activated by the user all store and retrieve operations are automatically verified by comparing the template type read from the barcode with the information stored in t
49. lt Enter gt to confirm your selection ER CIM USER S MANUAL CIMDEF 3 9 9204 9502 If Raw material is selected the following fields are displayed Material Assembly definition Part ID Type of part WEONES processed material assembly Source station Name asrs Fi Select a part FS Report Fe Save current part Esc Previous menu F3 Delete curent part Figure 12 Part definition for raw material Screen Source station Define the station from which the part is to be taken Name Updated automatically according to the source station definition If Processed material is selected the following fields are displayed Material Assembly Definition Part ID Type of part Raw material f IAS Assembly Source material ID Manufacturing process Target station Remarks Fi Select a part FS Report Fe Save current part Esc Previous menu F3 Delete current part Figure 13 Part definition for processed material Screen 3 10 CIMDEF ER CIM USER S MANUAL 9204 9502 Source material ID Define the source material part number from which the processed part will be manufactured Name Updated automatically according to the source material part definition Manufacturing process Specify which process will manufacture this part Name Updated automatically according to the manufacturing process definition Target station The station to which this part is to be taken aft
50. machine number 2 ASRS Station Programs and Positions All programs necessary for ASRS control and operation are included in the CIM ACL system programs and in the ASRS software For a listing of the ACL ASRS programs refer to the ASRS section of the appendix System Program Listing After installation the ASRS controller should be initialized This is performed in a manner similar to all other station controllers The command to initialize the station controllers is found in the Station Controllers Setup menu which is accessed from the Setup Menu option in the CIM Main Menu The ASRS robot positions are stored in the vector CIM 500 and the carousel positions are stored in the vector SRSP 18 These position vectors are automatically defined when the ASRS software is loaded to the ASRS controller however the locations of the positions must be taught before the system can be operated A listing of the required robot and carousel positions follows Robot Positions All robot positions use the vector CIM 500 Pallet at Conveyor Station Positions CIM 9 on pallet CIM 19 above 9 ER CIM USER S MANUAL Station Application Programs 9 15 9211 9502 Buffer Positions The ASRS station currently uses only one buffer Positions for a grasping a template CIM 1 CIM 11 on buffer above 1 Barcode Scanner Positions CIM 10 CIM 8 above buffer 1 in front of the barcode scanner between 10 and 11 Positions
51. magnetic code The template type number ranging 1 99 as defined by the ASRS software The ID number of the finished part on the pallet as defined in the production order The ID number of the raw material used in the part on the pallet as defined in CIMDEF Sample programs installed in the CIM system normally use the following numbers for the materials 1 indicates the brass rod 11 indicates the perspex bar For example both pallet 4 and pallet 6 are carrying perspex bars ER CIM User s Manual 9209 9502 REPORTS 10 13 SUBPROC INFO NEXT STA LOCATION STATUS The identifying number of the next subprocesses to be performed on the material on the pallet Optional user defined variables used for quality control For example you can create the following definitions l indicates part which is flawed defective but accepted 2 indicates part which requires retooling 3 indicates part which has failed inspection part rejected These variables if used are defined in the station programs The station at which the next subprocess to be performed will take place The conveyor sector numbered 1 32 at which the pallet is currently located The pallet s current activity The possibilities are MOVING Pallet is moving between stations STOPPED Pallet is stopped at a station NOT IN USE The pallet is not on the conveyor 10 14 REPORTS ER CIM User s Manual 9209 9502 Stations
52. main RSDNL menu is RSNET If your system includes a switched RS232 network you can access the RSNET software and activate a communication path to your target device If the RSNET option is selected the program will activate the software and you will see the RSNET ON LINE screen For more information refer to the RSNET Software User s Guide Download The third option on the RSDNL main menu is Download When this option is selected the following window will appear r Main Menu Download File name Catalog This window lets you choose between entering a file name or viewing a list of files with the directory location and extension specified in the Options module File Name If you select File name the following window appears and prompts you for the name of the file to be downloaded The file name that was used in the last download appears on the screen r Nain Menu Download File name for download pawn ER CIM USER S MANUAL RSDNL 11 7 9204 9502 You can use this name or enter a new filename Once a name has been typed pressing lt Enter gt starts the downloading process When the process is complete you will see the following status report r Main Nenu r Download Status File downloading completed Catalog The second option Catalog displays a list of all files with the location and extension specified in the options module You may view the file names fr
53. not specified the program will supply the default name CENTRAL CIM STATION RSNET Configuration Data Files The configuration data used by RSNET is contained in the following files stations D1 This file is used when the Central CIM Network switcher is connected to COM1 port on Central CIM station computer stations D2 This file is used when the Central CIM Network switcher is connected to COM2 port on Central CIM station computer These files cannot be accessed directly by the user The program searches for these files in the following locations in this order e the current directory from which the RSNET software is run e the directory specified by the environment variable RSNET e the directory RSNET 4 14 RSNET ER CIM USER S MANUAL 9204 9502 When the desired file is not found in the first location the program looks in the second location and so forth until the file is found If it is not found in the third location a message is printed on the screen If the environment variable is set the software does not search for the RSNET directory even if the configuration file has not been found By default the station computers will contain a command similar to SET RSNET ARSNET1 in their AUTOEXEC BAT files This directory will contain the relevant configuration files for communication within each specific station Command Line Options The complete syntax for entering commands from the comma
54. option from the CIM Main Menu Alternatively at the DOS prompt H gt type REPORT and press lt Enter gt You will see the REPORTS Main Menu as shown in Figure 1 REPORTS Version 1 0 Copyright C 1992 Eshed Robotec MAIN MENU Tracking Pallets Orders Stations Buffers Conveyor Exit 4 T Select option Enter Activate option Figure 1 The REPORTS Main Menu ER CIM User s Manual REPORTS 10 1 9209 9502 The following options are available Tracking F1 A log of the CIM production status Pallets F2 A report showing the status of the pallets within the CIM cell Orders F3 A report showing the status of the production orders Stations F4 A report of the current activity at each of the CIM stations Buffers F5 A report of the current status of the buffers at the CIM stations Conveyor F6 A graphic display of the CIM conveyor indicating the status of the production elements on the conveyor Exit Quit the REPORTS software Each of these options will be convered in the following sections User Interface The option line at the bottom of each screen displays the specific keys which enable you to manipulate the display in that particular report screen A number of functions are common to many of the REPORTS screens e The function keys activate specific report screens Alternately you can scroll forward and backward through the screens by pressing F10 and F9 respectively Th
55. part For example an assembly may use two parts which are made from the same raw material but have undergone different manufacturing processes The variable RAWN allows the station program to differentiate between the materials SUBP Subprocess that part at buffer will undergo TASK Variable that refers to task to be performed on part at buffer Used in the programs TOMn FOMn FB and TOB When the station contains a machine this variable refers to the task in the CIMDEF subprocess definition screen When the tasks at a station are robot activities that do not use a machine the code for these activities is found in the program TOM1 The variable TASK is used to direct the program flow in TOM1 to the code relevent for the part being manufactured ER CIM USER S MANUAL Station Application Programs 9 3 921 1 9502 INFO Additional information about part This variable accompanies a part from station to station It can be used to transfer information obtained at one station to another station where the data will be used For example a part undergoes a quality check at a QC station The variable INFO is assigned a value according to the result When the part arrives at an unloading station station programs use INFO to decide whether to place the part in a finished parts container or discard it Commands to Open and Close the Gripper The robots in an ER CIM cell can use servo controlled grippers or pneumatically controlled gr
56. production data associated with that order to the central CIM controller Then production of those parts can start The production data is the information needed by the central CIM controller for the production of that order The production data includes information about the type and quantity of parts order information the initial and final locations of those parts material assembly information and where and how to process them process information After downloading the production data you can run or stop production You can also download another order while the previous one is being manufactured To create the production data PROD uses definitions stored in CIMDEF files Refer to the CIMDEF User s Guide chapter for more details ER CIM USER S MANUAL PROD 5 1 9204 9502 Activating the PROD Program Getting Started The PROD program will usually run at the central CIM management computer To activate select the Production Menu F2 from the CIM Main Menu Alternately type PROD followed by lt Enter gt at the DOS prompt The first screen displayed is the main menu PROD CIN PRODuction management user interface Version 1 30 Copyright CC 1990 Eshed Robotec Main menu Production Setup Order Entry File Manager Exit 1 T Pick option Enter Activate option Figure 1 PROD Main Menu A number of options are available Press the corresponding function key or use the arrow keys to activate any of the followin
57. system programs after a global abort for example This program is automatically executed when the controller is powered ON 3 URST Clears the status of buffers and machines This program runs automatically whenever the controller is turned on 4 CLEAR Optional user program 5 CIMP Attaches position vectors CIM CIMB 6 USERI Optional user program 7 USER2 Optional user program 8 USER3 Optional user program 9 for future use 10 INIT Available for use by the user At ASRS station with a circular ASRS sets carousel positions relative to 1 11 TOPLT Place template on pallet at conveyor station 12 FROMP Get template from pallet at conveyor station 13 TOBFR Place template on current buffer 14 FROMB Get template from current buffer 15 TOB Place part on template at current buffer 16 FB Get part from template at current buffer 17 TOM Place part in current machine and operate machine interface 18 FM Get part from current machine 19 WTM Wait for current machine to finish production performing any necessary interface actions 20 for future use 21 SELB1 Set current buffer as buffer number 1 9 14 Station Application Programs ER CIM USER S MANUAL 9211 9502 22 23 24 25 26 SELB2 Set current buffer as buffer number 2 SELB3 Set current buffer as buffer number 3 SELB4 Set current buffer as buffer number 4 SELM1 Set current machine as machine number 1 SELM2 Set current machine as
58. than NOVELL or LANTASTIC you will need to use a text editor to create and edit the LANSER BAT and LANCIM BAT files If you are not using a LAN you do not need to create or edit these files the ER CIM installation procedure will create them Installation and Upgrade Procedure If you are upgrading the software the installation procedure will detect your current configuration and maintain it To install upgrade the ER CIM software follow the steps below 1 Remove all unessential cards such as unused LAN cards from the computers in the ER CIM 2 To activate the installation procedure insert Diskette 1 into drive A in the central CIM computer make A the default drive then type MCIM followed by lt Enter gt Insert diskettes 2 through 4 as prompted xiv ER CIM version 1 84 UPDATE ER CIM USER S MANUAL 9407 9502 Note If an error message appears during the installation do not instruct the system to ignore the error Abort the installation procedure and contact your technical support representative After the software is installed the CIM Setup Definition screen is displayed Select the options according to your actual ER CIM installation Press lt Esc gt to save and exit this screen Reboot the central CIM computer Modify the programs for each station as described below in the section Station Files Initialize the central CIM controllers and the station controllers using the options in th
59. the Station switcher port connected to the Central CIM Network switcher This is the factory preset control character for the RS232switcher The control character for the Central CIM Network switcher is U while the control character for the station switchers is T This option not currently in use The gt lt TJ keys are used to move between fields All changes must be followed by lt Enter gt or they will not be saved once you move to the next field The following options are available to exit the screen lt Fl gt Saves the new station description prints DONE on the screen and returns to the Configuration screen The new station will be added to the graphic display 4 6 RSNET ER CIM USER S MANUAL 9204 9502 lt Esc gt Return to the Configuration screen without saving the changes When lt Esc gt is pressed this message appears on the screen Quit with no update are you sure Y N Pressing Y removes the New Station window from the Configuration screen pressing N erases the above message Inserting a Machine A machine element is inserted by pressing lt Ins gt from the Configuration screen This displays the following window in the upper left corner of the screen LEVEL level 1 level 2 To select the level use the TJ keys and press lt Enter gt If Level 1 is chosen a Machine definition window will be displayed on the screen as shown
60. to H CIMSYS ST In this directory locate a file named xxxx SMP where xxxx is the name of a sample file which you want to use Some of the samples files included in the ER CIM software are for example USERMILL SMP USERLATH SMP USERWELD SMP ASMBALLS SMP Copy and rename this file to directory H CIMSYS ST n where n 2 3 4 5 or 6 the number of the station Xviii ER CIM version 1 84 UPDATE ER CIM USER S MANUAL 9407 9502 Type COPY xxxx SMP n USERn DNL Then use the Station Setup Edit station program menu option to modify the file if necessary Be sure to make all changes to the USERn DNL file in the directory H CIMSYS ST POINTn CBU This file is created by the Station Setup Backup controller points menu option It contains all positions currently in the station controller at the time of the backup This file is used by menu options Station Setup Restore controller points and Station Setup Initialize controller It is no longer necessary to delete existing points in the controller before using the option Station Setup Restore controller points STATIONn CBU This file is created by the Station Setup Backup controllers option It contains all controller contents but not the configuration This file is used by menu option Station Setup Restore controllers This file is intended for use only after a controller breakdown PARxx CBU This file is created by the Station Setup Station setup definition op
61. to be downloaded is specified in the definitions entered in the RSDNL software The default extension is TAP but may be changed for each machine Refer to the chapter on RSDNL for more information Setting Up the Controller to Use AutoCNC If the version number of your CIM software is less than 1 80 the following steps must be performed at each CNC station where automatic switching of CNC programs is required before starting production 1 From the DOS prompt at the CNC station PC access the ACL controller by typing ATS followed by lt Enter gt Alternatively you can access the CNC station controller from the central CIM computer using RSNET 2 Next set the ACL variable TFLAG which controls whether the station will use automatic switching of CNC programs The controller will only execute CNC program switching when TFLAG is 1 The default value is 0 Type SET TFLAG 1 lt Enter gt 3 Now leave ATS by pressing lt Shift gt lt F9 gt followed by lt Enter gt Running the AutoCNC Software AutoCNC can only be activated at the station at which automatic downloading of programs will take place The task to file assignment and and file handling modules may be run from the central CIM station if the CNC station at which downloading is required is connected to the central CIM computer via the Ethernet LAN To activate AutoCNC from the C prompt of the CNC station type AC followed by lt Enter gt If the CNC stat
62. transmission parameters save the options information to an options file or load a previously saved options file Rsnet Access RSNET to activate or disconnect a communication path or to change the communication configuration When you exit RSNET you will return to the RSDNL main menu 11 2 RSDNL ER CIM USER S MANUAL 9204 9502 Download Enter name of file to be downloaded and activate downloading display a list of files with the extension and location specified in the Options module Exit Leave RSDNL software Each of these options will be covered in the following sections Options Choosing the first item Options gives the menu shown in Figure 2 Rsdnl Network Downloader User Interface Version 1 0 Copyright c 1991 Eshed Robotec r Hain Nenu Options Communit Set the default directory and extension Figure 2 The Options Menu The options are Program files Prompts you for the extension and location of the file to be downloaded Communication setup Sets the RS232 transmission parameters of the PC Save options Saves the information entered in the program file and communication setup modules to an options ER CIM USER S MANUAL RSDNL 11 3 9204 9502 file You are prompted for to enter a name for the options file Load options Loads a previously saved options file to the software before downloading You are prompted for the options file name Program Files If the Program files
63. uppermost central block shows the computer from which the RSNET screen was accessed If you are working at a CIM station you will see the name of the station here and if you are at the Central CIM computer you will see Central CIM Station The communication path connects the uppermost central block to the selected highlighted block the ASRS controller in Figure 1 It is indicated by a double line or a violet line on color monitors The name and alternate name of the selected block appear in the upper left corner of the screen The current communication channel COM1 or COM2 is shown in the upper right corner of the screen In this example COM 1 is used Further explanation may be found in the section on RSNET configuration data files at the end of this chapter 4 2 RSNET ER CIM USER S MANUAL 9204 9502 Activating a Communication Path To activate a communication path use the gt 4 keys to highlight the element to be connected The element s name and alternate name will appear in the upper left corner of the screen To activate the connection press lt Enter gt or lt gt If communication is established the activated path will be indicated by a double or violet line If communication is not established the line will remain unchanged To sever the connection with the selected element press the lt gt key Pressing lt Esc gt returns you to the CIM Main Menu or to DOS if the software was
64. which require delay time after a carriage return character is received You are prompted for the delay in milliseconds Recommended values for the EMCO C5 and Fl are 100 assuming that their Baud rate is 300 If no delays are required by the device enter 0 If the delays used are too large the downloading process will take too long If the delays used are not sufficient the transmission may be disrupted For more information on this software refer to the chapter RSDNL Software User s Guide RSNET Selecting the RSNET option accesses the RSNET software This allows you to define the switched RS232 communication configuration For more information refer to the chapter RSNET Software User s Guide Exit Choosing this option leaves the AutoCNC software ER CIM USER S MANUAL AUTOCNG 12 11 9204 9502 This page intentionally left blank 12 12 AUTOCNC ER CIM USER S MANUAL 9204 9502 CHAPTER 13 ACL Report and Reset Programs The ACL programs described in this chapter perform specific functions that can help you manage the ER CIM cell These programs allow you to display the status of the cell and to change the data to correct inconsistencies Some of these programs perform functions that are usually carried out within ER CIM software modules For example the program CSTAT allows you to modify the existence and location of a station on the graphic display This can also be done by accessing the Station Definit
65. 10 parts each parts 1 10 11 20 991 1000 Within a family all parts use the same two robot positions one above and one on a template For part number n 1 lt n lt 1000 the robot positions are CIM p1 above the template CIM p2 on the template where pl 201 int n 1 10 p2 pl 100 and int x is the integer part of x e g int 3 2 1 int 4 5 0 For example Parts 1 10 pl 201 above the template p2 301 on the template Parts 11 20 pl 202 above the template p2 302 on the template ER CIM USER S MANUAL ASRS 6 17 9204 9502 ASRS Robot Positions for Removing a Template from the Carousel Positions for access to CIM 31 41 51 61 ASRS Level 1 Positions for access to CIM 32 42 52 62 ASRS Level 2 Positions for access to CIM 33 43 53 63 ASRS Level 3 The positions should be recorded at the following locations for each level respectively Positions next to ASRS CIM 31 32 33 Positions in front of ASRS cell CIM 41 42 43 Positions inside ASRS cell CIM 51 52 53 above template Positions inside ASRS cell CIM 61 62 63 on template ASRS Robot Positions for Removing a Part from a Feeder Feeders at Level 1 CIM 71 81 91 Feeders at Level 2 CIM 72 82 92 Feeders at Level 3 CIM 73 83 93 The positions should be recorded at the following locations for each level respectively Positions in front of ASRS for CIM
66. 2 downloads all necessary CIM ACL programs to the station 2 controller Several controllers can be downloaded simultaneously using the number parameters for specific stations or the A parameter for all stations For example DNLST 3 4 5 loads the controllers of stations 3 4 and 5 DNLST A loads programs to all the controllers This procedure requires 5 20 minutes and should not be halted If the downloading is stopped before it has finished you will need to start the process over from the beginning D 2 System Management ER CIM USER S MANUAL 9204 9502 Controller Backup CIM ACL Station Program Backup The following utility programs can be used to perform routine backups and maintenance of the CIM ACL station programs These commands are issued at a computer which is connected to the central RS232 network switcher The switched RS232 network must be fully operational and the RSNET software must be properly configured All station switchers must be free for access by the central computer BACKST n RESTST n Creates a backup of the entire contents of station n controller For example BACKST 3 will backup the entire contents of the station 3 controller Several or all controllers can be backed up simultaneously using the number parameters for specific stations or the A parameter for all stations For example BACKST 4 6 backs up controllers at stations 4 and 6 BACKST A backs up all the controllers A s
67. 20P Baud rate 9600 300 150 2400 Word size 8 7 7 Stop bits 1 2 1 Parity None None Even 1 bit XON XOFF ON Off RS232 Connections ER CIM USER S MANUAL 9204 9502 APPENDIX C CIM I O Connections The I O wiring is divided into three categories e Conveyor PLC e Main Controller Station Controller Conveyor Programmable Logic Controller The conveyor consists of several pallet stations numbered according to the configuration of the CIM cell Each of these working stations contains two sensors and two pistons which are controlled by the Programmable Logic Controller PLC in the conveyor s control cabinet The conveyor s PLC is connected to all station controllers for command and status communication Main Controller The central CIM controller at the central control desk is connected with a single input and a single output to each of the local station controllers and to the conveyor PLC Station Controller Each station controller is connected to the following e PLC e Main controller e Magnetic multi sensor identification heads CNC or other machines The station controller may also be connected to other station equipment ER CIM USER S MANUAL 0 CONNECTIONS C 1 9401 9502 PLC 1 O Wiring PLC INPUT 0 CENTRAL CIM CONTROLLER OUTPUT 11 PLC INPUT 4 STAISTP STATION 1 CONTROLLER OUTPUT 5 PLC INPUT 5 STAIREL STATION 1 CONTROLLER OUTPUT 6 PLC INPUT
68. 20P X 22 4C TAILSTOCK PNP CONTROLLER OUTPUT 4 N O 120P X 22 5B DOOR OPEN CLOSE CONTROLLER INPUT 12 120P X 22 7B STATUS CYCLE START PNP CONTROLLER INPUT 13 do pane STATUS DOOR COSED PNP CONTROLLER INPUT 14 120P X 22 8A STATUS SPINDLE ON PNP CONTROLLER INPUT 15 120P X 22 1A STATUS ALARM PNP CONTROLLER OUTPUTS 1 4 COM a a de ang 24 V CONTROLLER GND 120P X 22 9C GND CONTROLLER INPUT 16 a STATUS DOOR OPEN PNP Station with Controller B In addition to the connections detailed in the table above e The output block must be set to EXTERNAL e All outputs connected to the EMCO 120P must be set to SOURCE e All inputs connected to EMCO 120P must be set to SOURCE EMCO 120P Machine Setup The preparations for this machine include both software parameters and hardware 0 CONNECTIONS ER CIM USER S MANUAL 9401 9502 Software Configuration Parameters Enter Edit mode and type MONITOR Now change the following parameters LOI 191 L03 1 L20 1 L40 54 011 24 040 144 041 13 T43 3 Hardware Preparations Connect X 22 PIN 9b to X 22 PIN 9c GND and X 26 PIN 22 to X 22 PIN Oa 24V 2 To install the pneumatic valve for the pneumatic door Connect one pole of the pneumatic switch to X 22 PIN 6c and the other pole to X 22 PIN 9b GND 3 Connecting the door closing magnetic sensor only if a new sensor is needed Connect X 26 PIN 22 24V to the brown wire and X 26 PIN 23 to the blu
69. 5 are the same as steps 1 and 2 for the EMCO F1 plus a third step Disconnect jumper J4 on the A6A116001 PC board the jumper is near the X 62 connector on this board ER CIM USER S MANUAL 9401 9502 0 CONNECTIONS C 7 Suggested Wiring for Station with EMCO VMC 100 Station with Controller A FROM TO SIGNAL NAME l O TYPE CONTROLLER INPUT 8 VMC 100 X 22 7B STATUS CYCLE START PNP CONTROLLER INPUT 9 VMC 100 X 26 12 STATUS DOOR CLOSE PNP TO BE CONNECTED CONTROLLER INPUT 10 TO THE DOOR STATUS DOOR OPEN PNP PISTON SENSOR CONTROLLER INPUT 11 VMC 100 X 22 1A STATUS ALARM PNP CONTROLLER OUTPUT 4 COM VMC 100 X 22 0A 24V CONTROLLER GND VMC 100 X 22 9B GND CONTROLLER OUTPUT 8 VMC 100 X 22 0B LOAD PROGRAM RS232 PNP CONTROLLER OUTPUT 9 VMC 100 X 22 2B REFERENCE HOME PNP CONTROLLER OUTPUT 10 VMC 100 X 22 3B FEEDHOLD PNP CONTROLLER OUTPUT 11 VMC 100 X 22 4B CYCLE START PNP CONTROLLER OUTPUT 1 N O VMC 100 X 22 IC VICE OPEN CONTROLLER OUTPUT 1 N C VMC 100 X 22 2C VICE CLOSE CONTROLLER OUTPUT 2 N O VMC 100 X 22 5B DOOR OPEN CLOSE Station with Controller B In addition to the connections detailed in the table above e The output block must be set to EXTERNAL e All outputs connected to the VMC 100 must be set to SOURCE e All inputs connected to VMC 100 must be set to SOURCE EMCO VMC 100 Machine Setup The preparations for this mac
70. 6 STA1 S1 STATION 1 CONVEYOR S PROXIMITY SENSOR 1 PLC INPUT 7 STA1 S2 STATION 1 CONVEYOR S PROXIMITY SENSOR 2 PLC INPUT 10 STA2STP STATION 2 CONTROLLER OUTPUT 5 PLC INPUT 11 STA2REL STATION 2 CONTROLLER OUTPUT 6 PLC INPUT 12 STA2 S1 STATION 2 CONVEYOR S PROXIMITY SENSOR 1 PLC INPUT 13 STA2 S2 STATION 2 CONVEYOR S PROXIMITY SENSOR 2 PLC INPUT 14 STA3STP STATION 3 CONTROLLER OUTPUT 5 PLC INPUT 15 STA3REL STATION 3 CONTROLLER OUTPUT 6 PLC INPUT 16 STA3 S1 STATION 3 CONVEYOR S PROXIMITY SENSOR 1 PLC INPUT 17 STA3 S2 STATION 3 CONVEYOR S PROXIMITY SENSOR 2 PLC INPUT 20 STA4STP STATION 4 CONTROLLER OUTPUT 5 PLC INPUT 21 STA4REL STATION 4 CONTROLLER OUTPUT 6 PLC INPUT 22 STA4 S1 STATION 4 CONVEYOR S PROXIMITY SENSOR 1 PLC INPUT 23 STA4 S2 STATION 4 CONVEYOR S PROXIMITY SENSOR 2 PLC INPUT 24 STASSTP STATION 5 CONTROLLER OUTPUT 5 PLC INPUT 25 STASREL STATION 5 CONTROLLER OUTPUT 6 PLC INPUT 26 STA5 S1 STATION 5 CONVEYOR S PROXIMITY SENSOR 1 PLC INPUT 27 STA5 S2 STATION 5 CONVEYOR S PROXIMITY SENSOR 2 PLC INPUT 30 STA6STP STATION 6 CONTROLLER OUTPUT 5 PLC INPUT 31 STA6REL STATION 6 CONTROLLER OUTPUT 6 PLC INPUT 32 STA6 S1 STATION 6 CONVEYOR S PROXIMITY SENSOR 1 PLC INPUT 33 STA6 S2 STATION 6 CONVEY
71. 6 PLC INPUT 5 RELEASE PNP SOURCE OUTPUT 7 CENTRAL CONTROLLER INPUT n CTRLR NPN SINK INPUT 1 CODE SENSOR NO 1 SENSOR 1 NPN SOURCE INPUT 2 CODE SENSOR NO 2 SENSOR 2 NPN SOURCE INPUT 3 CODE SENSOR NO 3 SENSOR 3 NPN SOURCE INPUT 4 CODE SENSOR NO 4 SENSOR 4 NPN SOURCE INPUT 6 PLC OUTPUT 203 O K SHIELD NPN SOURCE INPUT 7 ie ae TROLLER OUTPUT x CON NPN SINK CTRLR 12V COMMON OF CODE SENSORS 12V SHIELD GND CENTRAL CONTROLLER GND GND SHIELD ER CIM USER S MANUAL 0 CONNECTIONS C 5 9401 9502 Suggested Wiring for Station with EMCO F1 Station with Controller A FROM TO SIGNAL NAME I O TYPE CONTROLLER OUTPUT 12 F 1 X 22 1B LOAD RS232 PNP CONTROLLER OUTPUT 13 F 1 X 22 2B HAND AUTO PNP CONTROLLER OUTPUT 14 F 1 X 22 3B FEEDHOLD PNP CONTROLLER OUTPUT 15 F 1 X 22 4B RUN PROGRAM PNP CONTROLLER OUTPUT 2 COM r a ds vial q 24V CONTROLLER OUTPUT 2 N O F 1 X 22 IC VICE OPEN CLOSE CONTROLLER INPUT 12 F 1 X 22 7B CYCLE START STATUS PNP CONTROLLER INPUT 13 F 1 X 22 8B FEEDHOLD STATUS9 PNP CONTROLLER INPUT 14 X 62 15 ERROR STATUS PNP CONTROLLER INPUT 16 F 1 X 22 6B HAND AUTO STATUS PNP CONTROLLER GND F 1 X 22 9C GND PNP Station with Controller B In addition to the connections detailed in the table above The output block must be set to EXTERNAL e All outputs connected to the EMCO F1 must be set to SOURCE e All inputs connected to EMCO
72. ER CIM User s Manual Part 1 Chapters 1 13 amp Appendices A E Catalog 100037 ESED O Copyright 1995 2000 Eshed Robotec 1982 Ltd ER CIM User s Manual Catalog 100037 ISBN 965 291 051 1 February 1995 Second Edition 4 5 6 7 8 9 April 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 ER CIM USER S MANUAL ili 9502 ER CIM USER S MANUAL 9502 Table of Contents Software UPDATE ER CIM version 1 84 coc A o a ee e a xiii Installation Prerequisites A ie xiii Software PIUS arene e Matte e rs ro e aaa a da a ae i xiii DAVE om se t EAS xiii LAN Communication Network oaa a a a xiii LANSERBAT ad e A Gh we OP Se y xiii EANGIM BAT y it ri aa Se Sele KS X1V Installation and Upgrade Procedure 2 044 xiv CONFIG SYS and AUTOEXEC BAT Files a aaa e XV CIM Main Menu 2 sc ts E A Bele End OR e xvi CIM Setup Definitions ateo e got GS Rw e ia en xvi
73. ER CIM USER S MANUAL ASRS 6 15 9204 9502 Load ASRS data from disk Restore from disk to the ASRS station s controller data on contents of ASRS carousel and template to part correspondence Create MRP file Create an MRP Material Resource Planning file This file can be used later by the MRP program for various planning and purchasing functions The name of the file created is SRS MRP ASRS Positions The ASRS robot positions are stored in the vector CIM 500 and the carousel positions are stored in the vector SRSP 18 These position vectors are automatically defined when the ASRS software is loaded to the ASRS controller however the locations of the positions must be taught before the system can be operated A listing of the required robot and carousel positions follows Robot Positions All robot positions use the vector CIM 500 Pallet at Conveyor Station Positions CIM 9 on pallet CIM 19 above 9 Buffer Positions The ASRS station currently uses only one buffer Positions for a template CIM 1 on buffer CIM 11 above 1 6 16 ASRS ER CIM USER S MANUAL 9204 9502 Barcode Scanner Positions CIM 10 above buffer 1 in front of the barcode scanner CIM 8 Between 10 and 11 Positions for Placing a Part on a Template which is on a Buffer Differently shaped parts may require different robot positions in order to be placed or removed from a template For this reason parts are grouped into 100 families of
74. Figure 12 CIM Production Menu The options available in this menu are Run production Start the production of the previously downloaded order s Stop production Pause the production of the order currently being produced To restart the production use the Run Production option Reset CIM Cell Selecting this option will reset the CIM cell All status variables production requests and material flow commands will be cleared 5 8 PROD ER CIM USER S MANUAL 9204 9502 This command may be useful for restarting CIM production after an abnormal halt in CIM cell activities such as a machine collision or a power failure After performing a CIM Reset all templates and material must be removed from all conveyor pallets station buffers and machines Order Entry The Order Entry menu lets you enter view or modify orders This menu is essentially the same as in the Order Entry menu in the CIMDEF program Orders are numbered from 1 to 1000 thus up to 1000 different orders can be defined at a time You can define even more orders by using other order entry files refer to the File Manager section for more details Several options are available Select Each order has a unique identification number To define modify or view a specific order select it by typing the order s ID number and pressing lt Enter gt when you first enter the Order Entry screen If you have already selected an order and want to select a different one p
75. Fl must be set to SOURCE EMCO F1 Machine Setup On the back cover of the F1 control unit there is a PC board 1 Find the X104 connector and connect between the X104 PIN 1 and the X22 PIN Oa which is located on the same back cover panel 2 On this PC board there are four DIP switches set to 1100 Set position to 1010 C 6 0 CONNECTIONS ER CIM USER S MANUAL 9401 9502 Suggested Wiring for Station with EMCO Compact 5 Station with Controller A FROM TO SIGNAL NAME I O TYPE CONTROLLER OUTPUT 8 C 5 X 22 1B LOAD RS232 PNP CONTROLLER OUTPUT 9 C 5 X 22 2B HAND AUTO PNP CONTROLLER OUTPUT 10 C 5 X 22 3B FEEDHOLD NPN CONTROLLER OUTPUT 11 C 5 X 22 4B CYCLE START PNP CONTROLLER OUTPUT 1 COM a e TEN 24V CONTROLLER OUTPUT 1 N O C 5 X 22 IC CLAMPING DEVICE OPEN CLOSE CONTROLLER INPUT 8 C 5 X 22 7B CYCLE START STATUS PNP CONTROLLER INPUT 9 C 5 X 8B FEEDHOLD STATUS PNP CONTROLLER INPUT 10 C 5 X 62 15 ERROR STATUS PNP CONTROLLER INPUT 11 C 5 X 22 6B HAND AUTO STATUS PNP CONTROLLER GND C 5 X 22 9C GND Station with Controller B In addition to the connections detailed in the table above The output block must be set to EXTERNAL e All outputs connected to the EMCO Compact 5 must be set to SOURCE e All inputs connected to EMCO Compact 5 must be set to SOURCE EMCO Compact 5 Machine Setup The preparations of the Compact
76. GETTING PART FROM FEEDER PALLET The number of the pallet currently at the station NO PALLET will appear if there is no pallet at the station ER CIM User s Manual REPORTS 10 19 9209 9502 This page intentionally left blank 10 20 REPORTS ER CIM User s Manual 9209 9502 CHAPTER 1 1 RSDNL Software User s Guide Introduction RSDNL software facilitates downloading of files from a PC to a target device using RS232 communication The program modifies the PC s transmission parameters to suit the requirements of the target device The user defines the directory location and extension of the file to be downloaded This information along with transmission parameters may be saved to an options file for later use Previously saved options files can be loaded to the software The software provides easy access to RSNET software for RS232 communication configurations that include switchers Using RSNET you can activate a communication path between the PC and a target device such as a CNC machine ER CIM USER S MANUAL RSDNL 11 1 9204 9502 Activating RSDNL To activate the program type RSDNL and press lt Enter gt You will see the RSDNL main menu as shown in Figure 1 Rsdnl Network Downloader User Interface Version 1 0 Copyright c 1991 Eshed Robotec Main Menu Rsnet Figure 1 The RSDNL Main Menu The choices are Options Define the location and extension of the file to be downloaded and set the
77. L Activates a communication path from the Central CIM station to the controller of the QC station There will not be any graphic display This is the equivalent of entering the RSNET On Line screen highlighting the CONTROL element at the QC station and pressing lt Enter gt RSNET C2 Instructs the program to use computer port COM2 for its communication RSNET will use configuration data defined for COM2 which is stored in the file STATIONS D2 COM2 will be displayed in the upper right corner of the On Line and Configuration screens 4 16 RSNET ER CIM USER S MANUAL 9204 9502 CHAPTER D PROD Software User s Guide Introduction The PROD software is used to transfer production orders to the central CIM controller and to activate the CIM system Serving as a production supervisor PROD provides the following features e Creation and modification of orders e Downloading of production orders to the central CIM controller e Production control Orders and Downloading Orders instruct the CIM system which and how many parts to produce Download means transferring data from one computer to another by means of communication PROD downloads data from the central CIM management computer to the central CIM controller When you create an order using CIMDEF or PROD programs your order is saved on a file which is stored on your PC disk When you want to manufacture the parts listed in an order you must first download the
78. LLER INPUT 6 ER CIM USER S MANUAL 9401 9502 0 CONNECTIONS Central Controller I O Wiring Central CIM le Controller A To Signal Name Controller Controller 1 0 A B at Station at Station OUTPUT 5 STATION 1 CONTROLLER INPUT 7 CTRL 1 NPN PNP OUTPUT 6 STATION 2 CONTROLLER INPUT 7 CTRL 2 NPN PNP OUTPUT 7 STATION 3 CONTROLLER INPUT 7 CTRL 3 NPN PNP OUTPUT 8 STATION 4 CONTROLLER INPUT 7 CTRL 4 NPN PNP OUTPUT 9 STATION 5 CONTROLLER INPUT 7 CTRL 5 NPN PNP OUTPUT 10 STATION 6 CONTROLLER INPUT 7 CTRL 6 NPN PNP OUTPUT 11 PLC INPUT 0 RUN STOP PNP PNP OUTPUT 12 PLC INPUT 34 SUSPEND PNP PNP INPUT 1 STATION 1 CONTROLLER OUTPUT 7 CTRL 1 NPN NPN INPUT 2 STATION 2 CONTROLLER OUTPUT 7 CTRL 2 NPN NPN INPUT 3 STATION 3 CONTROLLER OUTPUT 7 CTRL 3 NPN NPN INPUT 4 STATION 4 CONTROLLER OUTPUT 7 CTRL 4 NPN NPN INPUT 5 STATION 5 CONTROLLER OUTPUT 7 CTRL 5 NPN NPN INPUT 6 STATION 6 CONTROLLER OUTPUT 7 CTRL 6 NPN NPN INPUT 7 PLC OUTPUT 200 e NPN NPN GND 24V OF THE POWER SUPPLY NPN NPN Not currently in use C 4 0 CONNECTIONS ER CIM USER S MANUAL 9401 9502 Station Controller I O Wiring Suggested Wiring for Station n I O Type I O Port To From Signal Name Controller Controller A B at Station at Station OUTPUT 5 PLC INPUT 4 STOP PNP SOURCE OUTPUT
79. M 80 MOVE CIM 81 MOVE CI 82 SPEEDA 50 MOVE CIM 83 OVED CIM 84 END PROGRAM GETP take finished part from assembly vice SPEEDA 40 MOVE CIM 74 MOVED CIM 73 SPEEDA 10 GOSUB OGRIP SET OUT 1 0 MOVE GE 72 OVE CIM 71 OVED CIM 70 GOSUB CGRIP MOVE CI 70 MOVE CIM 71 OVE CIM 72 SPEEDA 30 MOVE CI 73 MOVED CIM 74 END PROGRAM USER1 close electric vice holding assembly parts SET OUT 1 1 END ER CIM USER S MANUAL Station Application Programs 9 35 9211 9502 PROGRAM USER2 open electric vice holding assembly parts SET OUT 1 0 END PROGRAM USER3 RUN ASMBL END Assembly QC Vision Station Positions All positions are robot positions Group A The listing does not include the default template manipulation positions Refer to the section Positions for Default Template Manipulation Programs Part on Template Part from family 1 on buffer 1 CIM 31 Part from family 2 on buffer 1 CIM 32 Part from family 3 on buffer 1 CIM 33 Above 31 CIM 41 Above 32 CIM 42 Above 33 CIM 43 Part from family 1 on buffer 2 CIM 51 Part from family 2 on buffer 2 CIM 52 Part from family 3 on buffer 2 CIM 53 Above 51 CIM 61 Above 52 CIM 62 Above 53 CIM 63 Access point between 6x and 4x CIM 150 9 36 Station Application Programs ER CIM USER S MANUAL 9211 9502 Vision Positions Part from family 1 in CIM 89 inspection position Above 89 CIM 88 Above 88 CIM 87 Part from
80. M ID calculate part family ID intermediate positions IF RAW 0 SET ID 3 ELSE SET ID RAW 10 SET ID ID 1 ENDIF SET P1 BFR 20 SET P1 P1 10 SET Pl Pl ID SET P2 P1 10 END PROGRAM OGRIP OPEN END PROGRAM CGRIP CLOSE END PROGRAM FB takes part from template on buffer BFR GOSUB ID SPEEDA 60 MOVED CIM 150 SPEEDA 40 MOVE CIM P2 GOSUB OGRIP SPEEDA 10 OVELD CIM P1 GOSUB CGRIP MOVELD CIM P2 SPEEDA 60 OVED CIM 150 END PROGRAM TOB returns part to template on buffer BFR LE RAW gt 0 ANDIF TASK gt 900 if unloading part don t return it to template GOTO 9 ENDIF GOSUB ID SPEEDA 40 MOVE CIM P2 SPEEDA 10 ER CIM USER S MANUAL Station Application Programs 9 31 9211 9502 MOVELD CIM P1 GOSUB OGRIP MOVELD CIM P2 SPEEDA 60 MOVED CIM 150 LABEL 9 END PROGRAM TOG IF ID 1 SET PNT1 TE PNT1 gt SET PNT1 ENDIF SET P3 SET P4 SET P5 ELSE SET PNT2 LE PNT2 gt SET PNT2 ENDIF SET P3 SET P4 SET P5 ENDIF SPEEDA 50 MOVE CIM P5 SPEEDA 40 MOVE CIM P4 SPEEDA 5 MOVELD CIM P3 GOSUB OGRIP SPEEDA 10 OVEL CIM P4 SPEEDA 60 MOVED CIM P5 END PROGRAM FG IF Hanna NN ow o 4 E HH H n ET NDIF ID 1 P3 P4 P5 PNT1 PNT1 removes parts to palletizing rack for alum rod calculates where to place in rack PNT1 1 increments pos
81. M controller point to point RS232 Production start signals are given I O and point to point RS232 Station signals conveyor PLC to stop pallet with part 1 0 Pallet ID is read 1 0 Pallet ID is transmitted to central controller point to point RS232 Relevant production data is transmitted to the station controller point to point RS232 Template with part is taken from pallet and pallet is released I O Task to perform is checked in the production database point to point RS232 If CNC program needs to be changed the station controller sends a message to the station computer point to point RS232 Station computer downloads the new CNC program switched RS232 Machine is loaded and work is performed I O with machine Production data is transmitted to central controller point to point RS232 Central CIM controller updates internal production database and transmits the changes and the order status to central computer point to point RS232 ER CIM USER S MANUAL Communication Network A 3 9204 9502 This page intentionally left blank A 4 Communication Network ER CIM USER S MANUAL 9204 9502 APPENDIX B CIM RS232 Communication The CIM cell contains two types of RS232 networks e Point to point hardwired connections e Switched network Point to Point RS232 Connections Point to point connections link the central controller directly to each station controller Through these connections the cen
82. OR S PROXIMITY SENSOR 2 PLC INPUT 34 MAIN CONTROLLER OUTPUT 12 Not currently in use Each proximity sensor has 3 wires 24V BROWN GND BLUE N O SIGNAL WHITE C 2 0 CONNECTIONS ER CIM USER S MANUAL 9401 9502 PLC 1 O Wiring PLC OUTPUT 201 STA1 P1 STATION 1 CONVEYOR S PISTON 1 PLC OUTPUT 202 STA1 P2 STATION 1 CONVEYOR S PISTON 2 PLC OUTPUT 203 STA1 OK STATION 1 CONTROLLER INPUT 6 PLC OUTPUT 204 STA2 P1 STATION 2 CONVEYOR S PISTON 1 PLC OUTPUT 205 STA2 P2 STATION 2 CONVEYOR S PISTON 2 PLC OUTPUT 206 STA2 OK STATION 2 CONTROLLER INPUT 6 PLC OUTPUT 211 STA3 P1 STATION 3 CONVEYOR S PISTON 1 PLC OUTPUT 212 STA3 P2 STATION 3 CONVEYOR S PISTON 2 PLC OUTPUT 213 STA3 OK STATION 3 CONTROLLER INPUT 6 PLC OUTPUT 214 STA4 P1 STATION 4 CONVEYOR S PISTON 1 PLC OUTPUT 215 STA4 P2 STATION 4 CONVEYOR S PISTON 2 PLC OUTPUT 216 STA4 OK STATION 4 CONTROLLER INPUT 6 PLC OUTPUT 221 STA5 P1 STATION 5 CONVEYOR S PISTON 1 PLC OUTPUT 222 STA5 P2 STATION 5 CONVEYOR S PISTON 2 PLC OUTPUT 223 STA5 OK STATION 5 CONTROLLER INPUT 6 PLC OUTPUT 224 STA6 P1 STATION 6 CONVEYOR S PISTON 1 PLC OUTPUT 225 STA6 P2 STATION 6 CONVEYOR S PISTON 2 PLC OUTPUT 226 STA6 OK STATION 6 CONTRO
83. P 7 15 9204 9502 Once the raw material production requirements queries option is selected the next window asks you to choose the selection criterion All orders By order number By date By priority Order Number When a selection according to order number is chosen the next window asks for the range The default values of 1 to 1000 will always appear Change these numbers to suit your needs pressing lt Enter gt after each change In the example shown below a range of 1 to 20 was entered Enter order range From 1 To 20 If the range entered is not acceptable as in this example an error message is received Enter order range From 0 To 1000 Incorrect range Re enter Date When a selection according to date of production order is chosen the following window asks for the range The current date is the default for the start and end of the range Enter suitable dates pressing lt Enter gt after each entry Enter date range From 02 06 91 To 02 06 91 If the range you enter is not acceptable you will receive an error message as in the example shown below Enter date range From 00 To 02 06 91 Incorrect date Re enter Priority The third selection criteria available is the priority of the production orders In this case the following window asks you to specify the range of priorities Enter priority range From 11 To 10 Incorrect range Re enter MRP ER CIM U
84. PC s RS232 serial communication port used for transmission The options are COM1 and COM2 Baud rate Sets the transmission speed to the rate required by the target device The options are 300 1200 2400 4800 and 9600 bits per second Data bits The options are 7 bits and 8 bits Stop bits The options are 1 bit and 2 bits Parity Set the type of parity check The options are none odd and even Xon Xoff Set whether the Xon Xoff software protocol is used The options are yes and no delay after byte This option is intended for CNC machines such as EMCO C5 and F1 which require delay time You are prompted for the delay in milliseconds The recommended value for the EMCO CS5 and Fl is 37 assuming that the baud rate is 300 If no delays are required by the device enter 0 delay after lt CR gt This option is intended for CNC machines such as EMCO C5 and F1 which require delay time after a carriage return character is received You are prompted for the delay in milliseconds Recommended values for the EMCO C5 and Fl are 100 assuming that the baud rate is 300 If no delays are required by the device enter 0 ER CIM USER S MANUAL RSDNL 11 5 9204 9502 Note that when a switcher 1s used to connect between a PC and another device such as a CNC machine the switcher is the target device hence the transmission parameters of the switcher must be entered to the RSDNL software To leave the Communication Setup scre
85. SER S MANUAL 9204 9502 If the range entered is not acceptable as in the example shown below an error message 1s received Enter priority range From ile 10 Once the selection range has been entered the next window asks you to choose the report s destination Report Destination Screen Printer If you choose to send the report to file you will be prompted for a file name of up to eight letters with no extensions An example of a raw material production requirements report is shown in Figure 8 Re por t Raw Material Production Requirements Report Required Available PgDn Pgllp Move Page 4 1 Move Line Home End Start End Esc Quit Figure 8 Raw Material Production Requirements Report ER CIM USER S MANUAL MRP 7 17 9204 9502 File Manager The file manager lets you view or modify the names of the CIMDEF information files read by the MRP program e station definition file e process definition file e material assembly definition file e order entry file definition file Choosing the File Manager option from the main MRP menu displays the screen shown in Figure 9 File Manager CIN application name Station definition file Process definition file Material assembly definition file Order entry file Esc Previous menu Figure 9 File Manager Screen The default file names are CIM followed by the appropriate extension The extensions are added automatically by the pr
86. SYS file Be sure to reboot the computer after editing the CONFIG SYS file LAN Communication Network Any LAN can be used in the ER CIM Before installing the ER CIM software install the LAN software The ER CIM software installation requires the presence of two batch files LANSER BAT and LANCIM BAT in the central CIM computer LANSER BAT If the central CIM computer is also the network server this batch file must contain the command to activate the server LANSER BAT is called by the central CIM computer s AUTOEXEC BAT If the server is on another computer this batch file must be present but empty ER CIM USER S MANUAL ER CIM version 1 84 UPDATE xiii 9407 9502 LANCIM BAT This batch file contains all the commands required for the central CIM computer to login to the server and assigns drive H to the CIM directory If you are using either a NOVELL or LANTASTIC network it is recommended that you use the utility contained in ER CIM Diskette 1 for building the necessary batch files for these networks You may however use any text editor for this purpose After installing the LAN software and before installing the ER CIM software insert Diskette 1 into drive A and type A SETLAN NOVELL or SETLAN LANTASTI This will automatically create the proper batch files and place them in the root directory If necessary edit these files specifically for your computer If you are using a network other
87. Source or Destination Positions Position from which a robot takes or places a template or part Typical source or destination positions are the pallet at the conveyor station and the buffers For example position numbers from 1 to 8 are used for the buffers 9 is used for the pallet at the conveyor station Intermediate Positions Robot position on the way to or from a source or destination position usually directly above the source or destination position To obtain the intermediate position number add 10 to the source or destination number If there is another intermediate position above the first add 20 For example CIM 4 is a position on a buffer at a station CIM 14 is directly above CIM 4 and CIM 24 is directly above CIM 14 Required Programs Two kinds of programs are required for station applications template manipulation programs and part manipulation programs The system contains default template manipulation programs which are usually sufficient for most applications The part manipulation programs are specific to the station application and must be created or modified in accordance with the station layout machines robots and tasks to be performed If the default template manipulation programs are sufficient the USERn DNL files need only contain the part manipulation programs ER CIM USER S MANUAL Station Application Programs 9 5 9211 9502 Template Manipulation Programs The following activities are required
88. Station definition file The name of the current station definition file CIMDEF adds the extension STN to this name to form the actual station file name for example CIM STN ER CIM USER S MANUAL PROD 5 13 9204 9502 Processes definition file The name of the current processes and subprocesses definition file CIMDEF adds the extension PRC to this name to form the actual process definition index file name for example CIM PRC Material assembly definition file The name of the current parts definition file CIMDEF adds the extension PAR to this name to form the actual material assembly definition index file name for example CIM PAR Order entry file The name of the current order definition file CIMDEF adds the extension ORD to this name to form the actual order entry index file name for example CIM ORD Command Line Options Several options can be set by activating PROD with command line options PROD can be activated in batch mode to download an order run production stop production or reset the CIM cell Use the batch switches for this purpose If an error occurs while in this mode PROD will print an error message and return a non zero DOS exit code The command line syntax is PROD Batch_Switch Date_Switch Communication_Switch Batch_Switches d Application_Name Order_Number Application_Name is the CIMDEF application name If a name is not specified the default configuration name CIM is use
89. TION ROBOT LOADING MACHINE 1 WITH PART 35 STATION MACHINE 1 STARTED ASRS ROBOT PUTTING TEMPLATE ON BUFFER STATION MACHINE 1 FINISHED TOTAL PROCESS TIME 0 0 6 86 STATION ROBOT UNLOADING PART 35 FROM MACHINE 1 ASRS PART 12 NEW ON BUFFER 1 STATION ROBOT PUTTING PART 35 ON TEMPLATE ON BUFFER 1 STATION ROBOT GETTING TEMPLATE WITH PART 2 FROM BUFFER 2 STATION ROBOT TAKING TEMPLATE WITH PART 2 TO PALLET STATION PART 35 PIECE 4 SUBPROCESS 1 COMPLETED Alt F1 setup F9 F10 SCROLL F1 TRACK F2 PALL F3 ORDR F4 STAT FS BUFF F6 CONY Esc MAIN Figure 4 Display of Tracking Messages Note the colors used for displaying tracking messages Brown Displays the time used in the column on the left Black Normal CIM production operations Red Error messages Blue Removal and return of parts and templates to the ASRS carousel Magenta Machine activities start finish loading ER CIM User s Manual REPORTS 10 7 9209 9502 Orders The Orders Report screen shows the information relating to the order which was downloaded from PROD and is currently in production Up to 10 lines can be displayed at a time If the order has more than 10 lines use the lt PgDn gt and lt PgUp gt keys to scroll through the order lines LINE PART RAY SUBPR ASS Y PCS IN STATUS MATER PCS QTY PRODUC READY 1 READY 2 READY 2 READY 2 READY 2 READY 2 READY 2 READY 2 READY 2 READY 2 SWAN OU
90. The information displayed at the top of the Process definition screen is Process The number of the selected process Name The name of the process Number of Define the number of subprocesses Up to 100 subprocesses can be subprocesses defined Remarks User remarks for this process ER CIM USER S MANUAL CIMDEF 3 7 9204 9502 Processes definition Process Number of subprocesses Remarks process definition Subprocess Subprocess name Station Station name Using a machine i Machine name Task E Expected processing time Remarks Fil Previous subprocess Shift F1 10 subprocesses back Fe Next subprocess Shift F2 10 subprocesses forward Esc Processes definition To define view or modify the subprocesses of the selected process press F4 Use the Fl and F2 keys to move one subprocess backward or forward or the lt Shift gt F1 and lt Shift gt F2 keys to move ten subprocesses backward or forward Figure 10 Subprocess definition Screen The information displayed in the middle of this screen is Subprocess The number of the current subprocess Subprocess name The name of the subprocess Station The station at which this subprocess takes place Station name Updated automatically according to the station definition Using a machine Yes No Whether this subprocess uses a machine Use the left and right arrow keys to select and press lt Enter gt to confirm y
91. UO un U T T ED 25 SET OUT 2 1 open door CIMB 90 D CIM 90 D CIMB 90 IN 10 l wait for signal that door is open DA 10 CIM 97 D CIM 98 CIM 99 D CIM 100 JAW 32 no room to open gripper use JAW to open partially ED CIM 95 B CGRIP DA 10 D CIM 96 push part exactly in place D CIM 95 O ass Hf n FU dad Q O n Gt uN U T T a y 0 0 1 close vice oo ea H O H sw ll O lt al Q H o zg wo o outside of CNC machine E gt g K md Bi bi i 4 H 0 UT 4 0 T 0 close door oo 23 00UzZ0 ma gt H H H zZ o Il 1 door closed ENDIF PROGRAM USER1 open door if closed close door if open IF OUT 2 1 SET OUT 2 0 ELSE SET OUT 2 1 ENDIF END 9 28 Station Application Programs ER CIM USER S MANUAL 9211 9502 CNC Mill Station Positions This listing does not include the positions for the default template manipulation programs Refer to the section Positions for Default Template Manipulation Programs Robot Positions Group A Part from Family 2 Perspex on Buffer Part from family 2 on buffer 1 CIM 32 Part from family 2 on buffer 2 CIM 52 Above 32 CIM 42 Above 52 CIM 62 Access point between 6x and 4x CIM 150 CNC Machine Tending Positions Outside the machine CIM 90 Into the machine CIM 97 98
92. You can use the USERx SMP files 1f desired and modify them to suit your needs If you are using a SCORBOT ER VII SCORBOT ER IX or SCORA ER 14 at station n you must be sure to copy the robot s unique parameter file PAR CBU where is 7 9 or 14 from the ATS diskette for the robot into the directory H CIMSYS ST n Be sure that the serial number on the diskette matches that of the robot Any time you add a robot to a station or change the robot used at a station you must be sure to copy the robot s unique parameters to this directory To return to the CIM Main Menu type CIMM CNC Program Directories for Automatic Downloading During Production CNC files that will be downloaded to the CNC machines using AutoCNC must be located in specific downloading directories reserved for this purpose These directories are generally located on the CNC station s computer but may alternately be located on the central CIM computer if it is connected to the CNC station computer via an Ethernet LAN You are advised not to store the CNC programs at both the CNC station PC and the central CIM computer but if this is done both versions must be identical CNC Station PC When CNC program files are stored in the CNC station PC the downloading directory for each machine is defined as follows C CNC Ss Mm where s is the station number and m is the machine number 1 6 Installation ER CIM USER S MANUAL 9308 9502 For example if statio
93. able you will receive an error message as in the example shown below Enter date range From 00 To 02 06 91 Incorrect date Re enter Ld Priority The third selection criteria available is the priority of the production orders If this option is chosen the following window asks for the range of priorities Enter priority range From 1 To 10 If the range entered is not acceptable as in the example shown below an error message is received Enter priority range From 11 To 10 Incorrect range Re enter AAA eee ER CIM USER S MANUAL MRP 7 11 9204 9502 Once the selection criteria and an acceptable range are chosen the next window requests the destination of the report Report Destination Screen Printer If the file option is chosen you must specify a file name with up to eight characters Do not add any extensions the program automatically adds REP to the name entered Once the program has finished writing the production orders it prints a message on the screen telling you how many were generated Queries and Reports The Queries option uses the CIM database information to generate three different types of reports e Raw material production requirements e Inventory report e Production order validity report Selecting this option from the main MRP menu screen displays the following screen Queries Menu Production order validity Inventory report Raw material production requir
94. achine before production This method can only be used if each CNC machine will run only one program during a production order 2 Remote downloading of programs by the user before the production order is started A single program is downloaded from a CNC station PC or the central CIM computer to a CNC machine over the switched RS232 network This method is much faster than entering the program lines manually however it requires the user to access RSNET software to activate the communication link and RSDNL software to perform the actual downloading The programs may be generated using CADCAM software As with the previous method each CNC machine can use only one program during each production order For more information on this method refer to the chapter RSDNL Software Users Guide 3 Automatic downloading of CNC programs from the CNC station PC during production The fastest method it allows multiple CNC programs to be used by each machine during production of an order As in the second method the programs may be generated using CADCAM software Since the AutoCNC program uses RSDNL to perform the actual downloading using specific definitions for each machine the user must make sure the current definitions transmission parameters file extension and location for each machine are suitable before activating AutoCNC This chapter describes the third method using AutoCNC software to automatically download programs to CNC machines
95. allel male connector ASRS female connector STATION STATION 2 1 optional STATION STATION 3 6 SWITCHER STATION STATION 4 5 Figure 2 Switched RS232 Network Option 1 B 2 RS232 Connections ER CIM USER S MANUAL 9204 9502 STALI ON STATION 1 SWITCHER 3 CENTRAL DESK main computer STATION STATION a 5 Legend Xx crossed parallel M male connector F female connector Figure 3 Switched RS232 Network Option 2 N station nufiber ATN CONTROLLER YY SWITCHER SWITCHER 1X 15 mS m 2 COMPUTER CONTROLLER Figure 4 Typical Station with Robot Only ER CIM USER S MANUAL RS232 Connections B 3 9204 9502 Im DATA PORT N Legend x Seating Figure 5 Typical Station with One CNC Machine parallel M male connector F f l i yy tm N MAIN tm DATA PORT N emale connector SWITCHER CONTROLLER N station number X m la m CNC tml tol bial vo SWITCHER 9 mia m2 a t ORT Lim DATA M ACL PORT 1 COMPUTER com 2 tf ee oro OATALPORT 2 10 CONTROLLER ren Figure 6 Typical Station with Two CNC Machines B 4 RS232 Connections ER CIM USER S MANUAL 9204 9502 ER CIM USER S MANUAL 9204 9502 RS232 Connections B 5 The switcher ports connected to the various devices must be set to the following transmission parameters On e a EMCO F1 C5 EMCO VMC100 1
96. am has been added to the ER CIM software to facilitate communcation with the SQC software This is a resident TSR program which places all data received from the RS232 port into the keyboard buffer this data is then treated the same as manual keyboard entries The program is located in the central CIM computer in the directory H UTIL To activate type one or both of the following RSKBD for RS232 on COM1 default RSKBD C2 for RS232 on COM2 To remove from memory type the following RSKBD U RSKBD C2 U Device Installation The following sections give instructions for the connection of devices to the RS232 controller ports ER CIM USER S MANUAL ER CIM version 1 84 UPDATE xxiii 9407 9502 Using SQC Software 1 Connect the SQC computer to a controller port n 2 In the USERn DNL file make the following changes e Add the following lines at the beginning of the file INCLUDE CIMSYS ST PORTn DMC INCLUDE CIMSYS ST SQC DMC n station controller port number INCLUDE is an ACLoff line command e To send data to the SQC program include the following lines at the appropriate locations in your ACL station programs SET NSIZE n number of digits SET NSEND num number to send GOSUB SENDL send the number e To send the data ID to the SQC program include a prolog two lines at the appropriate locations in your ACL station programs SET NSEND id id of samp
97. an acceptable part number and pressed lt Enter gt you will receive the Raw Material Information Screen as shown in Figure 3 Raw Material Information Raw material ID 1 Name Plastic 10 10 2 Minimum stock quantity 30 Unit price 12 5 Minimum order quantity 10 Delivery time 2 Days Supplier ACME Plastic Co 99 Somewhere St Anytown NA Remarks color white Fi Select F5 Report F2 Save current Esc Previous menu F3 Delete curent Figure 3 Raw Material Information Screen The screen contains the following fields Part Name Number assigned to the part in the CIMDEF database The part identified by this number must be a raw material This field is not accessible from this screen Name assigned to the part in the CIMDEF database This field is not accessible from this screen Minimum stock quantity Minimum inventory required Unit price Price per item in dollars Minimum order quantity Supplier s requirement for minimum order size Delivery time Number of days required by supplier to deliver an order Supplier Supplier s name and address Remarks Additional comments on the material 7 6 MRP ER CIM USER S MANUAL 9204 9502 The bottom of the screen lists a number of options Fl Return to the raw material selection screen F2 Save the current raw material information You will receive the message Writing to file F3 Delete the current raw material in
98. at every station no matter what manufacturing process is carried out e The robot removes a template from a conveyor pallet e The robot places a template on a buffer e The requested manufacturing process is performed e The robot removes a template from a buffer e The robot returns a template to a conveyor pallet except at an unloading station Since the template activities are common to all stations default programs for these tasks are stored in the files TMPLTA DNL and TEMPLTB DNL when the robot is mounted on a slidebase If the user wants to change the programs for a specific station for example to change the robot s speed he must copy the file using the same name and adding the station number as the last character in the name For example to change the template manipulation programs for station 2 copy the file TMPLTA DNL to TMPLTA2 DNL and modify the new file as desired If necessary you can also change the template manipulation programs for the ASRS by modifying the programs in the file ASR DNL Generally you should not need to change these programs When the station controller is initialized the following programs are downloaded automatically along with the system programs FROMP Takes template from the conveyor pallet TOPLT Returns template to the conveyor pallet FROMB Takes template from the buffer BFR TOBFR Returns template to the buffer BFR You will not usually need to write these programs since ad
99. at station to Automatic mode after n 1 4 downloading a program WTEn This is a system program that waits for the downloading process to n 1 4 be finished This program must be used with CNC machines which cannot accept I O commands while a program is being downloaded The user must call this program from the program TOMn using the ACL command GOSUB WTLn This line must be placed before the first command that sends an I O signal to the CNC machine The following two programs should only be used if robot intervention in this case turning a part over is required during the manufacturing process SFLPn This is a system program which is called by WI Mn when the CNC n 1 4 machine is ready for the part to be turned over by the robot FLIPn User programs to turn over a part removed from a CNC machine n 1 4 called by SFLPn Optional Program for Automatic Downloading of CNC Programs TASKn Performs automatic downloading of CNC programs when AutoCNC cannot be used Uses the variable TASKn During production this program is run immediately after FB 9 12 Station Application Programs ER CIM USER S MANUAL 9211 9502 Optional User Station Programs The following optional programs have been created They have controller assigned program numbers which allow them to be accessed from the teach pendant as discussed in the next section Default versions of programs STA and STB are included in the ACL system programs the rest a
100. at the end of a working session The backup files are located in the H CIMSYS ST directory The contents of a controller are saved in a file called STATIONn CBU where n is the station number When only positions are backed up they are saved in a file called POINTSn CBU ER CIM USER S MANUAL CIM Main Menu 2 9 9210 9502 F4 F5 F6 F7 F8 The backup restore procedure can take up to 15 minutes per station During the procedure you will see the asterisk moving across the bottom of the screen If a station controller is re initialized after a backup of positions has been performed the positions stored in the backup will be restored to the controller Station controllers setup Station setup definitions F1 Initialize controllers F2 Activate ATS F3 Backup controllers Fy Restore controllers F5 Select station jackup controller points Station 1 Fi Restore controller points Fr Station 2 F2 Editing station program F8 Station 3 F3 Station 4 F4 All stations Performs backup of entire contents of selected or all station controllers Restores entire contents of selected or all station controllers Performs backup of positions only at selected or all controllers Restores positions only at selected or all controllers You can select one specific station or all stations Edit the file USERn DNL for the selected station This file contains all of the user ACL programs for station n These programs are describe
101. ation 2 Station 3 Station 4 tte select Enter activate Esc previous menu Figure 3 Tracking Setup Screen Track pallet in station If you select Yes a message line will be displayed whenever any pallet arrives at and leaves a selected station Since so many pallets arrive at and leave the stations the default is set to No in order to limit the number of lines in the report Print station message If you select All a message line will be displayed whenever any activity occurs at all the stations Select Selected to specify the stations for which you want to see tracking information If you have chosen Yes to the Track Pallet in Station option pallets arriving at and and leaving the specified stations will be tracked Select station Specify the stations whose activities you want to monitor The number of stations which appear in the menu are determined by the number of stations defined in the SETUP when the system is installed 10 4 REPORTS ER CIM User s Manual 9209 9502 Setup File In addition to viewing the tracking data on screen you may also choose to record the data in a file on either the hard disk or a diskette If you select File Setup you then have the following options Screen Printer FILE SETUP Tracking sent to file NO File name H REPORT TRK Track pallet in station YES Print station message ALL 4 SELECTED Select station Station 1 Station 2 Station 3 Stat
102. cation For example if you want to use the application programs in the file USERMILL SMP and the CNC mill is located at station 2 in your ER CIM configuration do the following e Copy the file USERMILL SMP to the file USER2 DNL in the H CIMSYS ST directory of the central CIM computer e Next modify the programs as needed using the ACL Off Line utility e Then initialize station 2 9 2 Station Application Programs ER CIM USER S MANUAL 9211 9502 Control Variables for Station Application Programs The following ACL global variables global with respect to all the programs at one controller are used in the station application programs as given in the following sections These variables with the exception of BFR and INFO refer to information from the CIMDEF data files The variables are read only with the exception of INFO and should not be changed BFR Buffer currently in use buffers are numbered from 1 8 Used in the programs FB and TOB MACH Machine number TASKn Number of task to be performed at machine n Used by the program TASKn which may be used to perform automatic downloading of CNC programs when AutoCNC cannot be used This variable can be used for example to reference a specific CNC program The following variables are used in the programs TOB FB TOMn and FOMn PART ID of part to be manufactured RAW ID of raw material at buffer RAWN Number of row in assembly component table which refers to the
103. central computer and reaching all stations and machines including CNC and robot controllers During the development of various station programs the switched RS232 network allows the central computer to work with selected machines It is then used for preloading the machines with production data and for downloading production commands and programs For complete details of RS232 connections refer to the appendix CIM RS232 Connections Ethernet LAN An Ethernet Local Area Network LAN connects all cell computers This facilitates the sharing of a database common to all stations The common database includes all the data needed to perform the various production tasks materials processes orders actual manufacturing programs CNC and robot programs The Ethernet LAN enables the sharing of various devices such as a central server hard disk and central printer and allows remote access to any computer on the LAN Any computer on the LAN can then be used to develop the CIM database and configuration and the various CNC and robot programs A 2 Communication Network ER CIM USER S MANUAL 9204 9502 CIM Production Communication Sequence A typical CIM communication sequence prior to and during production would include the following stages Station controller is accessed by the central computer switched RS232 Data and programs are read from database on the central computer Ethernet Production data is downloaded to central CI
104. connections are given after the program listings for each station application CNC Lathe Station Programs USERLATH SMP GLOBAL ID GLOBAL Pl GLOBAL P2 OP EN E E TU H Ei n H HH an mm wn un aaa 4 H ea Z U PROGRAM EN Hna E O n al P1 P1 P1 P2 UB ID T DA 60 bi D CI T DA 40 T DB 4 ath amp CIM PROGRAM ID TDS ID RAM FB P D CIMB BFR B OGRIE EDA 10 ELD CIM P1 UB CGRIF ELD CIM P2 EDA 60 D Pp ED CIM 150 OGRIP ROGRAM CGRIP calculate part family ID and intermediate RAW 10 positions for buffer BFR ID 1 BER 20 P1 10 P1 ID P1 BFR 20 ID 10 P1 10 take part from template on buffer BFR 150 access point 2 9 20 ER CIM USER S MANUAL 9211 9502 Station Application Programs PROGRAM TOB GOSUB ID SPEEDA 60 MOVED CIM 150 SPEEDA 40 SPEEDB 40 MOVE CIM P2 MOVED CIMB BFR SPEEDA 10 MOVELD CIM P1 GOSUB OGRIP MOVELD CIM P2 SPEEDA 60 MOVED CIM 150 END PROGRAM WTM1 DEFINE R SET OUT 3 DELAY 100 SET OUT 3 WAIT IN 10 WAIT IN 10 ET SBUSY PEND R FROM R SET OUT 9 MOVE CIMB 90 MOVE CIM 93 WAIT IN 12 OVE CIM 94 MOVED CIMB 90 SET OUT 9 GOSUB OGRIP SPEEDA 10 SPEEDB 2 OVE
105. d for all files Selecting this option will download the requested order The relevant definitions will be taken from the CIMDEF application definition specified If a previous order has not been fully manufactured the new order will be added to the existing one 5 14 PROD ER CIM USER S MANUAL 9204 9502 Ir Selecting this option will start the production of a previously downloaded order s Selecting this option will suspend the currently produced order t Selecting this option will reset the CIM cell Date_Switches These switches will affect the date fields in the production entry screens ad American date format mm dd yy ed European date format dd mm yy Communication_Switches This switch selects the part which should be used for communication with the central CIM controller cl Communication port used is COM1 c2 Communication port used is COM2 Examples PROD D 11 C2 Will download order 11 using CIM configuration files with the name CIM Downloading will be performed on COM2 PROD When entered at the DOS prompt will give a list of the command line options ER CIM USER S MANUAL PROD 5 15 9204 9502 This page intentionally left blank PROD ER CIM USER S MANUAL 9204 9502 CHAPTER 6 ASRS Software User s Guide Introduction The ASRS Station The ASRS Automatic Storage and Retrieval System station stores and retrieves parts in different stages of processing
106. d in the chapter ACL CIM Application Programs and Positions You will not be able to access the ASRS station programs using this option If you are using DOSS you will access the file through the regular DOS editor Otherwise you will enter the editor defined in the batch file EDIT BAT in the root directory of H Once you have finished editing the USERn DNL file you must reinitialize controller n CIM Main Menu ER CIM USER S MANUAL 9210 9502 Using the CIM Menu at a Secondary Central CIM Computer or a Station Computer When the command CIM is entered at the secondary central CIM computer or at a station computer connected to the Ethernet LAN the system loads the net drivers and prompts you for your user name and password Once the computer has been booted you will receive the DOS prompt C gt Type CIM followed by lt Enter gt You will be prompted to enter a name name Type USER followed by lt Enter gt You will be prompted for a password password Do not type anything simply press lt Enter gt Next the main CIM menu will appear on the screen Figure 7 gives an example of how the main CIM menu may appear ER CIN Computer Integrated Manufacturing Version 1 72 Copyright CC 1992 Eshed Robotec Main menu CIN definition Production ASAS MRP Reports Graphics menu Communication menu Setup menu Exit 47t Pick option Enter Activate option ER CIM USER S MANUAL CIM Ma
107. d out If this setup is not first performed you will not be able to access any other options in this submenu Make sure you modify this setup whenever the robots or equipment used in the cell are changed You must then reinitialize the central CIM controller and all station controllers affected by the change The top two rows ask you to define the number of stations the ASRS location the number of pallets the ASRS type carousel compact or square and the conveyor cycle the amount of time required for the conveyor to make a complete circuit of the cell in hundredths of a second Next you must define the specific characteristics of each station The definition is performed for each station on the bottom half of the screen while the top half continually displays the station definitions Use the arrow keys to move within the screen 2 8 CIM Main Menu ER CIM USER S MANUAL 9210 9502 The information you must supply includes the location of the station on the graphic tracking representation of the conveyor The conveyor is divided into 32 sectors The first station is generally located at sector 1 Other fields include the number of peripherals and the number of machines Up to five controller axes depending on the number of driver cards installed in the controller may be connected to peripheral devices such as a linear slidebase or an ASRS carousel The field Number of peripherals gives the number of available axes A mac
108. de e ASRS Station Programs and Positions 4 Robot Positions s lt s e so sa s EGS e ES we ee ee eas Pallet at Conveyor Station Positions a aoa a a a a e Butter Positions y sis taos a RAE RI Barcode Scanner Positions 2 2 e ER CIM USER S MANUAL 9502 Positions for Placing a Part on a Template which is on a Buffer 9 16 ASRS Robot Positions for Removing a Template from the Carousel 9 17 ASRS Robot Positions for Removing a Part from a Feeder 9 17 ASRS Carousel Positions uc toh 4 ol a eek A eS 9 18 ER CIM Sample Applications 2 2 20084 9 18 Part Numbering Systems 4 do a o Ge Sea Ew ok a we a es 9 18 SALONS ign BSE na a He AP o A LA A sas ae a ol wae 9 19 Sample Application Programs Positions and I O Connections 9 19 CNC Lathe Station Programs USERLATH SMP 9 20 CNC Lathe Station Application Positions 0 9 24 Robot Positions Group A 2 ee 9 24 Part from Family 1 on Template 9 24 CNC Machine Tending Positions 9 24 Linear Slidebase Positions Group B 4 4 9 25 CNC Machine Tending Positions 9 25 CNC Lathe Station VO ves ge op e Gomi Se ow te Ne ele Ee 9 25 CUTS e iaa adie phys white ea Tg WY ght ALA es 9 25 DPS 2 AA hss ee ee we Ra os Be 9 25 CNC Mill Station Programs USERMILL SMP 02
109. display software and return to the DOS shell After typing your DOS command you may return to WIZCON by typing exit at the DOS prompt F9 Return to the CIM_CELL graphic screen ER CIM USER S MANUAL Graphic Tracking 8 7 9207 9502 The Production Report Screen Pressing F4 from the CIM_CELL screen displays the Production Report screen shown in Figure 4 PRODUCTION REPORT PART 8 ORDERED IN PROCESS COMPLETED REMARKS 3 1 a RELEASED missing raw mat 5 2 READY 5 WORK ING Figure 4 CIM Graphic Tracking Production Report This screen lists the quantity of each part by finished part number in the order being manufactured The quantity completed quantity in progress and specific remarks generated by the system are listed for each part number The following remarks may appear READY System ready for release of the next raw part from ASRS WORKING Production in progress Cannot release a raw part at this time RELEASED All raw parts in the order have been released from ASRS RELEASED missing raw mat All available raw parts have been released Number available was insufficient 8 8 Graphic Tracking ER CIM USER S MANUAL 9207 9502 DONE Every item in the order has been processed DONE missing raw mat All available raw parts processed Number available was insufficient This report is generated after production data has been transmitted to the Central CIM Management computer For an on line report use the
110. e CIM Main Menu CONFIG SYS and AUTOEXEC BAT Files The installation of ER CIM version 1 84 appends lines to the CONFIG SYS and the AUTOEXEC BAT but does not alter existing lines in these files During the installation the old AUTOEXEC and CONFIG files are saved with extension OLD If your existing AUTOEXEC and CONFIG files contain the appended lines from the previous ER CIM version the upgrade installation procedure will result in duplication of some of these lines You should delete the redundant lines otherwise drivers may load twice into memory and error messages may appear ER CIM USER S MANUAL ER CIM version 1 84 UPDATE XV 9407 9502 CIM Main Menu When you complete the ATS to ASRS station operation and when you exit the ASRS software module the RS232 switcher between the computer and the station controller is disconnected This allows another computer to connect to the same controller without requiring the switcher to be repowered CIM Setup Definition Additional options now appear in the CIM Setup Definition screen e Definition of the direction of the conveyor s movement e Definition of the robots used in conjunction with Controller B SCORBOT ER IX SCORA ER 14 PERFORMER MK2 ASRS ASRS ACL Files The directory H CIMSYS ST has three files which contain the programs for the specific type of ASRS used in the ER CIM e ASRCRC DMC carousel e ASRSQR DMC square e ASRCMP DMC compact In add
111. e Delete function is available displayed at the bottom of screen This will delete from disk the file describing the selected object Note that deleting unnecessary files frees disk space Station Definition The Station Definition menu lets you define view or modify definitions of stations and machines working at each station The stations are numbered from 1 to 8 that is up to eight stations can be defined To define or view station information use the F1 and F2 keys to reach the desired station number After you have selected a station you can view or modify its definition Station definition Station 2 Station name Machining station Number of machines at station Fil Previous station FY Machine definition F2 Next station F5 Report F3 Save to disk Esc Previous menu ER CIM USER S MANUAL CIMDEF 3 5 9204 9502 Figure 7 Station definition Screen The information displayed at the top of the Station definition screen is Station The number of the current station Station name The name of the station Number of machines at station Define how many machines are functioning at that station Up to 10 machines can be defined Station definition Station Station name Number of machines at station _ Machine definition Machine Machine name Type Asrs Feeder Packer UN Lathe Qc Other Remarks Fil Previous machine Fe Next machine Esc Station definition To d
112. e T and J keys are used to highlight a report line or option line e Pressing lt Enter gt activates the option selected e Pressing lt Esc gt takes you from a screen or subscreen to the REPORTS Main Menu Tracking The Tracking screen logs the activities of the CIM cell The Tracking Report contains lines of text which give the time and a description of the current activity of the CIM cell The tracking information can be displayed on the screen and or sent to a file and or sent to a connected printer 10 2 REPORTS ER CIM User s Manual 9209 9502 18 44 12 ASRS COMMUNICATION K 18 44 12 STATION 3 COMMUNICATION STATUS COMMUNICATION O K 18 44 12 STATION 2 COMMUNICATION STATUS COMMUNICATION O K Alt F1 setup F9 F10 SCROLL F1 TRACK F2 PALL F3 ORDR F4 STAT FS BUFF F6 CONY Esc MAIN Figure 2 The TRACKING Report Screen Tracking Setup To define the Tracking Report output activate the Tracking Setup menus Press lt Alt gt FI The Tracking Setup screen contains several submenus which are activated according to the options you select Setup Screen This is the default option All tracking data is displayed on the screen and no file is created ER CIM User s Manual REPORTS 10 3 9209 9502 If you select Screen Setup you then have the following options Screen File Printer SCREEN SETUP Track pallet in station YES Print station message JAMES SELECTED Select station Station 1 St
113. e initiated by the user If the template type read from the barcode does not agree with the controller s data the following will occur e if the template is being stored the system will place it in a cell and mark the contents as unknown e if the template is being retrieved the system will return the template to a cell in the carousel mark the contents as unknown and will then attempt to remove another suitable template 6 14 ASRS ER CIM USER S MANUAL 9204 9502 Utilities The ASRS Utilities module lets you backup or restore the ASRS data and the contents of the controller s memory initialize the controller and create an MRP file for further processing by the MRP software Utilities Utilities menu ATS Advanced Terminal Software Reset ASAS control Save ASAS data to disk Load ASAS data from disk Create MAP file 47t Pick option Enter Activate option Esc Abort Figure 12 Utilities Menu The options in this menu are ATS Advanced Terminal Software Load ATS from disk to access the controller s ACL environment Reset ASRS Reset various ACL variables to regain controller function after a sudden loss of control such as may occur when an abort command is entered from the teach pendant during a user initiated store or retrieve operation Save ASRS data to disk Save to disk data describing the current status and contents of ASRS carousel and the template to part correspondence list
114. e it has finished you will need to start the process over from the beginning ER CIM USER S MANUAL System Management D 1 9204 9502 Station Controller Setup All station controllers must be properly connected to the RS232 switched network The following commands are issued from a computer connected to the central RS232 network switcher STATION INITST DNEST n Enters the directory containing the programs for initializing the station controllers This is usually located at H CIMSYS ST Before performing the download the system must be informed of various configuration options This is performed by running the INITST program This program prompts the user for all the necessary station configuration data INITST defines the robots and machines used in the system This enables the proper downloading of CIM ACL system programs to each station controller using DNLST The user is prompted for Number of stations Station number of ASRS usually station number 1 Type of robot SCORBOT ER Vplus or SCORBOT ER VID Number of machines at station Whether robot is mounted on slidebase at each station This information is saved in the file SETUP CIM This program should only be used at the time of installation or when changes are made in the configuration Erases the current controller contents and performs initial loading of CIM ACL programs and user station programs to the station controller For example DNLST
115. e should perform Materials Materials or parts are the entities which move between stations and machines according to a predefined path or process The CIM system recognizes three types of materials Raw Material A material which will be processed Processed Material A material which results from the processing of a material Assembly A part which is assembled from processed materials ER CIM USER S MANUAL CIMDEF 3 1 9204 9502 Orders Orders instruct the CIM system which and how many parts to produce During the production stage orders are selected and downloaded to the central CIM controller Refer to the PROD software User s Guide chapter for more details Activating the CIMDEF Program Getting Started To run CIMDEF select the CIM Definition Menu F1 from the CIM Main Menu Alternately type CIMDEF followed by lt Enter gt at the DOS prompt on all computers logged in on the CIM ETHERNET LAN The first screen displayed is the main menu CIMDEF CIN cell definition Version 1 50 Copyright C 1990 Eshed Robotec Main menu Station definition Process definition Material assembly definition Order entry File manager Exit 47t Pick option Enter Activate option Figure 1 CIMDEF Main Menu A number of options are available To activate any of the following screens press the corresponding function key or use the up and down arrow keys followed by lt Enter gt Station definition Define stati
116. e type Baud rate 9600 8 data bits 2 stop bits No parity No handshake Interleaved 2 of 5 first length 6 ER CIM USER S MANUAL 9204 9502 Barcode Scanner Setup E 1 This page intentionally left blank E 2 Barcode Scanner Setup ER CIM USER S MANUAL 9204 9502
117. e very useful for monitoring station consistency They are also vital tools for restarting the production process after an unexpected program halt such as a user abort or a robot collision RBFR Displays the contents of buffers machines pallet at station if exists and robot gripper CBFR Allows the alteration of the contents of buffers and machines The usual sequence for restoring station operation after an unexpected halt is as follows 1 Use RBFR to verify that the reported status is indeed the actual one 2 If necessary use CBFR to modify the content of buffers and machines according to their actual status 3 Run the AUTO program which will run all necessary CIM ACL programs The Reset Program The RESET program clears all CIM cell and or CIM station activities If the manufacturing sequence is disturbed this program is useful for clearing the system and restarting activities If activated at the main CIM controller all CIM tracking and status variables are cleared at the main controller and at all connected station controllers If activated at a station the status of all buffers and tasks is cleared 13 2 ACL Management Programs RT CIM USER S MANUAL 9209 9205 APPENDIX A CIM Communication Network The ER CIM environment is fully integrated on all levels of communications e Inputs Outputs e Point to point RS232 connections e Switched RS232 network Ethernet LAN Input Output Connections The
118. e wire of this sensor To gain feedback to the controller s input connect X 26 23 through X 22 to the proper input ER CIM USER S MANUAL 0 CONNECTIONS C 11 9401 9502 This page intentionally left blank C 12 0 CONNECTIONS ER CIM USER S MANUAL 9401 9502 APPENDIX D CIM Controller Management Programs Controller Setup Following is a description of the software tools used to setup the ACL controllers for CIM operation These commands download the necessary CIM ACL system programs and specific station programs During normal operation selecting the proper options in the CIM Main Menu will activate the functions described in this appendix You can however activate these operations from the DOS prompt The switched RS232 network must be fully operational and the RSNET software must be properly configured All station RS232 network switchers must be free for access by the central computer Central Controller Setup Perform the following steps at the central CIM computer CENTER Enters the directory containing the programs for initializing the main controller This is usually located at H CIMSYS CENTER DNL Erases the current controller contents and downloads all CIM ACL system programs to the central controller The central CIM controller must be connected to COM on the central CIM computer This procedure requires approximately 40 minutes and should not be halted If the downloading is stopped befor
119. efine view or modify the machines at the selected station press F4 Use the F1 and F2 keys to reach the desired machine number Figure 8 Machine definition Screen The information in the middle of the screen is Machine name The name of the machine Type Define the machine type Use the right and left arrow keys to choose the type and press lt Enter gt to confirm selection The different types are Asrs Feeder Packer Mill Lathe Qc and Other If you select Other you will be prompted to enter a name for the Other type 3 6 CIMDEF ER CIM USER S MANUAL 9204 9502 Remarks User remarks for this machine Process Definition The Process Definition menu lets you define view or modify definitions of processes and their subprocesses Processes are numbered from 1 to 1000 thus up to 1000 different processes can be defined at a time You can define even more processes by Processes definition Process 1 Name Base making Number of subprocesses Remarks This process is used to make a base for_a lamp Fi Select a process FY Subprocess definition Fe Save current process F5 Report F3 Delete current process Esc Previous menu using other process definition files refer to the File Manager section for more details To define or view a process you must select it enter its ID number After you have selected a process you can modify or view its definition Figure 9 Process definition Screen
120. ements Each of these options will be discussed in the following sections Production Order Validity Report This request produces a report on the validity of all orders or a specified range of orders This option allows you to find errors before starting the actual production cycle To correct errors you will need to use the CIMDEF software Orders are listed consecutively Valid orders are followed by the message O K If errors are found the line number in which the error appears is listed followed by a one line error message 7 12 MRP ER CIM USER S MANUAL 9204 9502 The following are examples of typical error messages Part number is out of range The part number given in the order is not within the accepted range 1 1000 Empty order The order does not contain any part numbers A summary of the results of the report appears on the last page It includes number of orders checked the number valid and the number not valid Once the production order validity option is chosen the next window requests the destination of the report Report Destination Screen Printer If the file option is chosen you must specify a file name with up to eight characters and no extension Enter file name without extension raw ER CIM USER S MANUAL MRP 7 13 9204 9502 An example of a production order validity report is given in Figure 6 Report Production Orders Validity Report Order Order Order Order Order
121. en Printer File Save The report is sent to the monitor This allows the user to scroll through the report The report is sent to a printer Make sure a printer is connected and ready The report is sent to a file You are prompted for a report file name The extension REP will automatically be added to the name For example if you enter XX the actual report file name will be XX REP Screen Printer Enter file name without extension process Figure 5 Report file name Window Report destination To keep the changes you have made after defining or modifying a station process material or order and before exiting the screen use the Save option This will save your changes to disk Press F3 when in the Station definition screen and F2 when in all others Note that you are always prompted to save your changes Part not Figure 6 Save before exit verification Window 3 4 CIMDEF ER CIM USER S MANUAL 9204 9502 Select Each process material and order has a unique identification number To define modify or view a specific object select it by typing the object s ID number and pressing lt Enter gt when you first enter the Process Material Assembly or Order screens If you have already selected an object and want to select a different one pressing F1 will usually let you enter another object s ID number Delete To cancel a process material or order previously selected press F3 when th
122. en press lt Esc gt You will return to the Options menu Save Options The Save Options option allows you to save the communications setup program file location and program file extension information If you select this option you will be prompted for the name of a file in which to save these options as shown below r Hain Nenu r Options __ Options file name OPT1 Load options The previously saved options file name will be displayed In this example the name OPT1 appears The cursor prompts you to add a new name If you make any changes you must press lt Enter gt to save them You will receive a message that the file is being saved and then you will return to the Options menu To exit this window without saving any changes press lt Esc gt You will return to the Options menu Load Options This option lets you load an existing options file to the software If you choose this option you will see the following screen r Nain Nenu r Options __ Options file name OPT1 The previous entry for the options file name is displayed In this example the name OPTI was used 11 6 RSDNL ER CIM USER S MANUAL 9204 9502 The cursor prompts you to add a new name If you make any changes you must press lt Enter gt to save them If the name you enter is not in the current directory you will receive an error message RSNET The second option on the
123. en processed into a chess piece Part numbers 3 10 are available for other processed materials derived from part 1 The robot can handle all parts in this family using the same positions Similarly part family 2 contains the raw perspex block part 11 and parts derived from it such as parts 12 and 13 One exception to this convention is the assembly defined in this application as part 21 or 15 in some cases This part is arbitrarily assigned to part family 3 Stations The programs and positions that follow are for an ER CIM cell configured with the following stations e CNC mill station e CNC lathe station e Assembly quality control and unloading station Sample Application Programs Positions and I O Connections The following files can be found in the H CIMSYSI ST directory of the central CIM computer If you want to use these files copy the USERx SMP file where x is LATH MILL or ASSM to the USERn DNL file for the corresponding station You must copy the entire file for each station application you choose For example if you want to use the sample CNC lathe station programs and the CNC lathe is located at station 2 in your ER CIM configuration do the following First copy the file USERLATH SMP to USER2 DNL make any modifications you need using the ACL Off Line utility then initialize the controller at station 2 ER CIM USER S MANUAL Station Application Programs 9 19 9211 9502 The required positions and I O
124. entered from the DOS shell Changing Configuration The RSNET software can be used to add delete or modify the stations and machines in the communication configuration To activate this option press lt F10 gt from the On Line screen The following window appears Enter CONFIGURATION screen Y N Pressing Y displays the Configuration screen shown in Figure 2 CONTROL ER Uplus ROBOT ER Vplus Central CIM Station CONFIGURATION use lt lT gt to Select lt Enter gt to Modify lt Ins gt Add lt Del gt Del lt Esc gt ON LINE menu ER CIM USER S MANUAL RSNET 4 3 9204 9502 Figure 2 RSNET Configuration Screen This screen is similar to the On Line screen with the following differences On the left side of each station the elements enclosed in double squares there are two numbers The upper number is the number of the station switcher port connected to the central CIM switcher The lower number is the station number which is also the central CIM switcher port to which this station is connected For example in the Configuration screen shown above port 1 on the project station switcher is connected to port 4 on the Central CIM switcher On the left of each machine the element enclosed in a single square is a number This is the switcher port to which the machine is connected In the configuration shown in Figure 2 for example the controller in the project station is connected to p
125. eparate file is created for the backup of each controller The name automatically assigned to the file reflects the number of the controller which was backed up For example STATION1 CBU for the contents of station 1 Restores the backup file created by BACKST n For example RESTST 3 will backup the entire contents of the station 3 controller Several or all controllers can be backed up simultaneously using the number parameters for specific stations or the A parameter for all stations For example RESTST 4 6 restores controllers at stations 4 and 6 RESTSTA restores all the station controllers ER CIM USER S MANUAL 9204 9502 System Management D 3 Position Backup After CIM installation is completed positions are sometimes updated The following two commands will help you manage position changes BACKSTP n Executes a backup of station n positions only Several or all controllers can be backed up simultaneously using the number parameters for specific stations or the A parameter for all stations If this command is executed and the controller is later reloaded by means of the command DNLST the positions which were backed up will be reloaded to the specified station RESTSTP n Restores positions at the specified station which were backed up by means of the BACKSTP command Note ACL prevents the overwriting of predefined positions If you want to restore these positions to a preloaded controller you must f
126. equate default programs are provided as shown below The listing is in a format ready for the ACL Off Line Downloader If these programs suit your application and they often will you only need to record the default positions as described in the following section Note bolded lines will be included only if a linear slidebase is used The system contains two versions of each of these programs one for a station with a linear slidebase 9 6 Station Application Programs ER CIM USER S MANUAL 9211 9502 and one for a station without The software automatically selects the proper version to download according to the station configuration in the Station Setup definition of the Station Setup Menu get template from pallet PROGRAM FROMP SPEED 40 MOVED CIMB 9 MOVED CIM 19 GOSUB OGRIP SPEEDA 5 MOVELD CIM 9 DELAY 50 G S OSUB CGRIP PEEDA 10 OVELD CIM 19 END get template from buffer uses variable BFR PROGRAM FROMB DEFINE B1 SET B1 BFR 10 calculate intermediate position SPEED 40 MOVED CIMB BFR OVED CIM B1 GOSUB OGRIP SPEEDA 5 ELD CIM BFR VELD CIM B1 put template on pallet PROGRAM TOPLT SPEED 40 MOVED CIMB 9 MOVELD CIM 19 SPEEDA 5 MOVELD CIM 9 DELAY 50 GOSUB OGRIP SPEEDA 10 OVELD CIM 19 END ER CIM USER S MANUAL Station Application Programs 9 7
127. er 2 CIM 2 Template on buffer 8 CIMIS Template on pallet CIM 9 Above 1 CIM 11 Above 2 CIM 12 Above 9 CIM 19 Linear Slidebase Positions Buffer 1 template and part CIMB 1 Buffer 2 template and part CIMB 2 Pallet template CIMB 9 Positions CIM 1 through CIM 8 refer to buffers 1 through 8 Position CIM 9 is the position of the template on a pallet at the conveyor station If a slidebase is used Group B positions must also be recorded CIMB 1 through CIMB 8 are the location of the slidebase for grasping a template that is on the corresponding buffer while position CIMB 9 refers to the pallet station position Define only those positions which refer to your specific station layout Stations with one or no CNC machines have only two buffer positions Stations with two CNC machines have four buffer positions buffers 1 and 2 are near machine 1 and buffers 3 and 4 are near machine 2 Record these positions while the robot is holding a template at the proper location that is position CIM 1 is the location of the robot holding a template at buffer 1 while CIMB 1 is the linear slidebase position when the robot holds a template at buffer 1 The remaining positions used in the default template manipulation programs are set as relative in XYZ coordinates to the defined positions For example position CIM 11 has ER CIM USER S MANUAL Station Application Programs 9 9 921 1 9502 been previously defined as 100 mm abo
128. er information stored in the RSDNL options file RSNET Enter the RSNET software to change the configuration of the switched RS232 network Exit Exit the program Activate Program Selecting Activate Program from the main menu displays the screen shown in Figure 3 AUTOCNC Automatic Downloading of CNC Programs Version 1 0 Copyright C 1992 Eshed Robotec station 2 WAITING Esc return to main menu Figure 3 The AutoCNC Status Screen The top row on the screen displays the station at which the program is running This information is taken from definitions in the AUTOEXEC BAT bat files of each station computer The window in the center of the screen shows the program status In this example the current status displayed above the window is WAITING Within the window the first line starting shows that the program has been activated and the next line waiting shows that it is waiting for a command from the CNC station controller to download a program to the CNC machine ER CIM USER S MANUAL AUTOCNC 12 7 9204 9502 When the program is downloading the status box displays the number of the machine being downloaded to the number of the task and the alternate names of the cell elements currently connected by RSNET Pressing lt Esc gt deactivates the automatic downloading and returns you to the main menu File to Task Assignment AutoCNC software allows the user to define the correspondence between tas
129. er it has been processed Name Updated automatically according to the target station definition If Assembly is selected the following fields are displayed Naterial Assembly definition Part ID Name Tupe of part raw material processed material Bassemblu Number of parts to assemble 0 to 8 material quantity manufacturing process Assembly station Target station Ho Remarks F1 Select a part F5 Report F2 Save current part Esc Previous menu F3 Delete curent part Figure 14 Part definition for Assembly Screen ER CIM USER S MANUAL CIMDEF 3 11 9204 9502 Number of parts to assemble 0 to 8 Table of parts Material Quantity The number of processed part types used to assemble this part If you choose a number from 1 to 8 a table of parts will be displayed This table defines the various parts from which the assembly is to be assembled The number of a raw material to be processed by the manufacturing process for use in the assembly The amount of parts of Material needed for the assembly Manufacturing process Assembly station Name Target station Name Remarks Order Entry The process which the material undergoes before assembly The station at which the assembly of the parts will take place Updated automatically according to the assembly station definition The station to which the part is to be taken after it has been assembled In
130. er quantity Status On line mode Keys Legend Pallp PaDn Select level Arrow keys Select cell Unknown Empty Home End First Last cell Template Enter Update cell Esc Previous menu Part on H Feeder a template Figure 4 Inspect Update Contents Screen In On Line mode the graphic display is continuously updated to show the contents of the ASRS controller s memory Similarly changes entered from this screen are continuously transmitted to the controller s memory In Off Line mode the contents of the carousel are automatically cleared directly after entering the program To display ASRS contents data that was previously saved to a file a Utilities option must be used to load the contents of a file to the program Changes made from this screen can also be stored to a file using a Utilities option ER CIM USER S MANUAL ASRS 6 5 9204 9502 Inspect Update Contents Screen Structure 1 The Inspect Update Contents screen is divided into 6 sections Current level cell contents Status line Keys Legend Current level Communication This is the upper part of the screen It contains two rows of cells the upper row shows the contents of cells 1 to 9 and the bottom row shows the contents of cells 10 to 18 This line is located directly beneath the cell displays In on line mode status messages show the current ASRS activity such as Retrieving part In off line mode the message Off line is d
131. example CIM STN Processes definition file The name of the current processes and subprocesses definition file CIMDEF adds the extension PRC to this name to form the actual process index definition file name for example CIM PRC Material assembly definition file The name of the current parts definition file CIMDEF adds the extension PAR to this name to form the actual material assembly index definition file name for example CIM PAR Order entry file The name of the current order definition file CIMDEF adds the extension ORD to this name to form the actual order entry index file name for example CIM ORD Command Line Options Several options can be set by activating CIMDEF with command line options The command line syntax is CIMDEF Application_Name Date_Switch Application_Name The CIMDEF Application name Date Switches ad American date format mm dd yy ed European date format dd mm yy ER CIM USER S MANUAL CIMDEF 3 15 9204 9502 Examples CIMDEF C MB ad CIMDEF This will load the CIMDEF software with the configuration files CIM_B and use American format dates When entered at the DOS prompt this will give a list of the command line options CIMDEF ER CIM USER S MANUAL 9204 9502 CHAPTER 4 RSNET Switched RS232 Network Software User s Guide Introduction The Switched RS232 Network is used to communicate between e the Central CIM station
132. family 2 in CIM 99 inspection position Above 99 CIM 98 Above 98 CIM 97 Palletizing Rack Positions Part from family 1 in cell of CIM 101 108 palletizing rack 1 Above 101 108 CIM 121 128 Above palletizing rack 1 CIM 149 Part from family 2 in cell CIM 151 158 of palletizing rack 2 Above 151 158 CIM 171 178 Above palletizing rack 2 CIM 200 Assembly Positions Ready to drop part from family 2 CIM 92 into assembly vice Push part from family 2 into CIM 90 91 exact position in assembly vice Above 92 CIM 93 94 Part 1 placed inside hole CIM 80 in part 2 ER CIM USER S MANUAL Station Application Programs 9 37 9211 9502 Assembly QC Vision Station I O Above 80 outside the hole in part 2 Above 81 Assembled part 21 in the assembly vice Near 70 Above 70 71 Outputs Close vice Open vice Start vision Inputs Vision has finished CIM 8 1 CIM 82 83 84 CIM 70 CIM 71 CIM 72 73 74 OUT 1 1 OUT 1 0 OUT 9 1 IN 9 1 9 38 Station Application Programs ER CIM USER S MANUAL 9211 9502 CHAPTER 10 REPORTS Software User s Guide Introduction The REPORTS software provides a complete on line display of the production status of all the CIM elements Using feedback from the controllers the software generates various reports which track the CIM production Activating REPORTS To activate the program select the Reports F5
133. for Placing a Part on a Template which is on a Buffer Differently shaped parts may require different robot positions in order to be placed or removed from a template For this reason parts are grouped into 100 families of 10 parts each parts 1 10 11 20 991 1000 Within a family all parts use the same two robot positions one above and one on a template For part number n 1 lt n lt 1000 the robot positions are CIM p1 CIM p2 where For example above the template on the template pl 201 int n 1 10 p2 pl 100 and int x is the integer part of x e g int 3 2 1 int 4 5 0 Parts 1 10 pl 201 above the template p2 301 on the template Parts 11 20 pl 202 above the template p2 302 on the template 9 16 Station Application Programs ER CIM USER S MANUAL 9211 9502 ASRS Robot Positions for Removing a Template from the Carousel Positions for access to CIM 31 41 51 61 ASRS Level 1 Positions for access to CIM 32 42 52 62 ASRS Level 2 Positions for access to CIM 33 43 53 63 ASRS Level 3 The positions should be recorded at the following locations for each level respectively Positions next to ASRS CIM 31 32 33 Positions in front of ASRS cell CIM 41 42 43 Positions inside ASRS cell CIM 51 52 53 above template Positions inside ASRS cell CIM 61 62 63 on template ASRS Robot Positions for Removing a Part from a Feeder
134. formation on this part You will be asked to verify this command FS Generate a report of the information for all raw material parts or for a selected range lt Esc gt Exit this screen and return to the previous screen If you have made changes but have not saved them by pressing lt F2 gt you will prompted to do so when you exit this screen Raw Material Purchase Order A raw material purchase order contains the information necessary to order the required raw materials from the supplier Purchase orders may be issued according to the following specifications e satisfy minimum stock quantity e fulfill all production orders e fulfill a range of production orders The software numbers the purchase orders consecutively by referring to the file NORD MRP which stores the number of the last purchase order issued When the purchase orders are sent to the printer each order is printed on a separate page ER CIM USER S MANUAL MRP 7 7 9204 9502 Choosing the Raw Material Purchase Order option from the MRP main menu displays the screen shown in Figure 4 Raw material purchase order Issue Purchase Orders Menu o satisfy minimum stock quantities To fullfill all production orders To fullfill selected production orders 47t Pick option Enter Activate option Esc Abort Figure 4 Raw Material Purchase Order Menu Each of these options will be discussed separately in the next sections Satisfy Minimum Stock Quantity
135. from a PC to a device such as a switcher or a CNC machine using RS232 communication F8 F9 These options are used to activate user defined programs such as a CAD CAM program The option activates the user batch files USER1 BAT or USER2 BAT You must customize these batch files located in the C CIM or H directory to meet your specific needs If communication is not properly established an appropriate message will be displayed Communication menu RSNET Fi Activate ATS to central controller Fe Activate ATS to ASRS controller F3 sponc sk if switcher is ON How to continue Station 2 Station 3 F3 Abort Station Y FY Ignore ER CIM USER S MANUAL CIM Main Menu 2 5 9210 9502 Controller Setup Select F8 in the Main Menu to activate the Setup Menu This menu is used for initializing the CIM ACL controller and for performing the backup and restore operations on one or all the controllers in the CIM system When this menu is activated you are presented with two options F1 for central CIM controller operations F2 for station controller operations ER CIN Computer Integrated Manufacturing Version 1 72 Copyright C 1992 Eshed Robotec Setup menu Stati 47t Pick option Enter Activate option Esc Abort Figure 4 Setup Menu Central CIM Controller Initialization Select F1 in the Setup Menu to setup the central CIM controller You will be presented with three options Ce
136. g a printer plug the printer cable into the connector on the protection key Printer operation is not affected by the key The central CIM computer needs a second protection key for operating the graphic tracking software The two keys are daisy chained e Make sure all station files user programs USER2 DNL USER4 DNL and position files POINTS1 CBU POINTS4 CBU are properly backed up on diskette e Make sure the hard disks in all computers have a directory DOS which contains the necessary DOS files e Make sure an Ethernet network card is installed in every computer from which you want to access the central CIM computer e Make sure a COM3 card is installed in the central CIM computer Central CIM Computer Program Installation 1 Insert diskette CIM 1 into drive A ER CIM USER S MANUAL Installation 1 1 9308 9502 Make sure the DOS prompt is A Check whether your cell has a LAN network If so type MCIM and press lt Enter gt If not type MCIM NOLAN and press lt Enter gt All files will be copied to the hard disk When prompted by the system insert diskettes CIM 2 CIM 3 and CIM 4 and press lt Enter gt When the station setup screen appears enter the information for your cell refer to the chapter The CIM Menu in this manual Press lt Esc gt to exit this screen If your cell does not have a LAN i e the command MCIM NOLAN was used in section 2 skip the rest of this section and p
137. g on the conveyor are represented by brown squares The finished part number of the material carried by the pallet is displayed in yellow For example when a raw material part is placed on the conveyor 8 2 Graphic Tracking ER CIM USER S MANUAL 9207 9502 the screen displays the number of the processed material that will be manufactured from this part according to the current production order Empty pallets are not shown When a pallet reaches a station for processing the part number and pallet are no longer shown on the screen Once the processing has finished and part has been returned to the conveyor the part number and pallet reappear on the screen The Function Keys The function key menu is displayed at the bottom of the CIM_CELL screen Fl F2 F3 F4 F5 F6 F7 F9 F10 Access the WIZCON help facility This is not required for regular CIM operation Enter Stations screen This screen allows you to define and change the location of the stations on the conveyor Enter Utilities screen This screen allows you to run other CIM software Enter Production Report screen which shows the status of the production order currently being manufactured Start production This command can only be given after production order and information have been downloaded using the PROD software Stop production suspends manufacturing Stops release of new raw material into the manufacturing process Display second par
138. g screens Production setup Select and download orders control production Order entry Enter complete orders Similar to the Order entry module in the CIMDEF program File manager Define the CIMDEF file names that PROD will use Exit Exit the program 5 2 PROD ER CIM USER S MANUAL 9204 9502 Production Setup This menu lets you select an order download the selected order and start or stop the manufacturing process Production Setup Production Setup menu Select producti order Download production data CIN production Reset CIN cell 47t Pick option Enter Activate option Esc Abort Figure 2 Production Setup Menu The options in this menu are Select Production Order Select the order for downloading Download production data Perform the actual download to the central CIM controller CIM production Control the manufacturing of the downloaded order Reset CIM Cell Resets the CIM System Use the up and down arrow keys to select the desired option and press lt Enter gt ER CIM USER S MANUAL PROD 5 3 9204 9502 Select Production Order This option prompts you to define the type of order you want to select Production Setup menu Figure 3 Type of order Window There are two types of orders Previous This is an order previously defined in the Order Entry option of the CIMDEF or PROD programs Immediate An immediate order which the user creates after selecting this o
139. gure 17 Report destination Window Three options are possible Screen The report is sent to the monitor This allows the user to scroll through the report Printer The report is sent to a printer Make sure a printer is connected and ready File The report is sent to a file You are prompted for a report file name The extension REP will automatically be added to this name For example if you enter xx then the actual report file name will be Report destination Screen Printer File Enter file name without extension order XX REP Figure 18 Report file name Window 5 12 PROD ER CIM USER S MANUAL 9204 9502 File Manager The File Manager menu lets you view or modify the names of the CIMDEF files used by PROD These are the definitions which detail the way to interpret the requested orders and their production processes This option is essentially the same as the File Manager in the CIMDEF program File manager CIN application name Station definition file cim Process definition file proci Naterial assembly definition file newpart Order entry file cim Esc Previous menu Figure 19 File Manager Screen Various CIM configurations and definitions can be saved under different file names Five names are possible CIM application name The name of the current CIM application This name is copied to the next four file names if lt Enter gt is pressed while the cursor is in this field
140. hat e the station s RS232 switcher is turned on and is currently connecting the PC with the ASRS controller You can use the RSNET software if necessary e the station controller is turned on the power LED indicator lights e the PC and the controller RS232 cables are correctly connected You then have three options as to how to continue Retry Try to reestablish communication Use this option after you have tried to correct the problem Abort Exit the program Ignore Enter the program without establishing communication Off line mode Enter off line mode This allows you to change the ASRS storage and template data within the program without affecting the contents of the controller s memory This data can be stored to a file on disk and restored to the controller at a later time If you want to access the off line mode directly do one of the following At the central CIM computer s H gt prompt type ASRS O and press lt Enter gt e At the ASRS station s DOS prompt type ASRS O and press lt Enter gt If communication is established or if either Ignore or Off Line mode was selected the ASRS main menu will be displayed ER CIM USER S MANUAL ASRS 6 3 9204 9502 Compact ASAS Automatic ge amp Retrieval System user interface Version 1 30 Copyright C 1991 92 Eshed Robotec Main menu Inspect Update contents Template definition Store Retrieve a part Barcode Setup Utilities Exit 47t Pic
141. he ASRS controller For more information on the barcode scanner and its required settings refer to the appendix Preparing the LS 6x20 Barcode Scanner for Operation The Template Definition module lets you define which template types can hold which parts After this option is selected ASRS reads the correspondence information from the controller Status Reading data from controller Percentage compl Figure 7 Reading data completion Status Window You will then see a screen similar to the following figure Definition Template type Can hold part ono co o o o o o o Pb He Pm Ww Ww ll _ lt 3 MER A 13 AN 2 8 Pp o Enter Input field Home End Start End of line 47t Move line Tab Shift Tab Move field PaUprPgDn Move page Esc Previous menu Figure 8 Template to part correspondence Screen The table contains 30 lines but you can view only ten lines at a time Use the up and down arrow keys to scroll one line up or down and the lt PgUp gt and lt PgDn gt keys to ER CIM USER S MANUAL ASRS 6 9 9204 9502 scroll ten lines up or down The information in this screen is Line The line number in the correspondence table Template type The type number of the template This number should be in the range of 1 through 99 Can hold part List of up to 8 different parts which can fit on the corresponding template type In Figure 8 for exa
142. he F4 and F7 key functions will not be covered here Setting a Station Location To set a station location press lt F5 gt The following message will appear on the bottom of the screen Gate select Hit gate s key or move to desired gate then J Here the word gate means station To select a station type the station number using the numerical keypad then press lt Enter gt You may also select a station by using the 4 keys to move the blue circle cursor through the station location table to the desired station number and then pressing lt Enter gt A new function key menu will appear on the bottom of the screen along with the following message Gate STATION1 STATION PLACE Enter value then d 3 The selected station appears on the left side of the message and the current station location appears on the far right side In this example station 1 is currently located at sector 3 To change the location type the desired sector number and press lt Enter gt The station location table will be updated and the yellow letters st will appear next to the desired sector on the conveyor diagram Another way of setting a station location once the station number has been selected is to use the function keys listed at the bottom of the screen to move the yellow letters st along the conveyor to the desired sector ER CIM USER S MANUAL Graphic Tracking 8 5 9207 9502 The key functions are FS
143. he user may download a program from the central CIM computer or the CNC station computer to a CNC prior to beginning production The first step is to connect the computer on which the CNC programs are stored to the CNC machine using RSNET This can be performed using the graphic display as described in the chapter on RSNET or the command line option may be used ER CIM USER S MANUAL RSDNL 11 9 9204 9502 For example to connect the central CIM computer to a CNC machine at a station using the command line format type the following from the H drive at the central CIM computer RSNET station_name machine_name where station_name and machine_name are the alternate names entered into the RSNET software for the CNC station and the specific CNC machine you wish to download to If there is only one CNC machine of this type in the ER CIM cell or if you are using the RSNET configuration for the local CNC station the station name may be omitted The next step is to set the options and program file definitions used by RSDNL Once these are set the RSDNL downloading command can be selected and entered or the command line option can be used to download the file 11 10 RSDNL ER CIM USER S MANUAL 9204 9502 CHAPTER 12 AUTOCNC Software User s Guide Introduction The ER CIM system supports three methods of loading CNC programs G code to the CNC machines 1 Manual programming or loading of a CNC program from tape to a CNC m
144. hine include both software parameters and hardware Software Configuration Parameters Enter Edit mode and type MONITOR C 8 0 CONNECTIONS ER CIM USER S MANUAL 9401 9502 Now set the following parameters LOI 191 L03 1 L20 1 L40 22 011 24 040 144 041 13 T43 3 Hardware Preparations To install the pneumatic valve for the pneumatic door connect one pole of the pneumatic switch to X 22 PIN 6c and the other pole to X 22 PIN 9b GND To connect the door closing magnetic sensor only if a new sensor is needed Connect the X 26 PIN 13 24v to the brown wire and X 26 PIN 12 to the blue wire of this sensor To gain feedback to the controller s input connect X 6 12 through X 22 to the proper input To install the pneumatic valve for the pneumatic vice connect one pole of the pneumatic switch to X 22 PIN 3a and the other pole to X 22 PIN 9c GND ER CIM USER S MANUAL 0 CONNECTIONS C 9 9401 9502 Suggested Wiring for Station with EMCO 120P Station with Controller A FROM TO SIGNAL NAME VO TYPE CONTROLLER OUTPUT 3 N C 120P X 22 1C CHUCK OPEN CONTROLLER OUTPUT 3 N O 120P X 22 2C CHUCK CLOSE CONTROLLER OUTPUT 12 120P X 22 3C TAILSTOCK OPEN PNP CONTROLLER OUTPUT 13 120P X 22 2B REFERENCE HOMES PNP CONTROLLER OUTPUT 14 120P X 22 3B FEEDHOLD PNP CONTROLLER OUTPUT 15 120P X 22 4B CYCLE START PNP CONTROLLER OUTPUT 16 1
145. hine is a station device that actively performs a production activity and is not connected to the ACL controller Examples of machines include CNC machines and machine vision units The ASRS carousel is not a machine in this sense since it 1s connected to an axis of the ACL controller Each machine generally requires two buffers The table on the right side of the screen lists the number of buffers per machine at each station Once you have entered definitions they are saved in a file SETUP CIM in the CIMSYS ST directory Once the SETUP CIM file has been created all available options in the Station Controller Setup menu will be active F2 initializes specified or all station controllers with CIM ACL system programming Performs the proper configuration for all or selected controllers and downloads the proper CIM ACL programs Programs scroll on the screen as they are downloaded In addition to ACL system programs the specific user programs for the selected stations are also downloaded during station controller initialization These programs are taken from the filer USERn DNL where n is the station number Refer to the chapter CIM ACL Station Programs F3 activates ATS at a selected station Backup Restore of Station Controllers F4 through F7 perform backup and restore operations to station controllers and are used to save to disk ette the contents of all station controllers Use this option to backup all CIM cell applications
146. ich refers to the physical C CIM directory in the central CIM computer CIM Main Menu ER CIM USER S MANUAL 9210 9502 CHAPTER 3 CIMDEF Software User s Guide Introduction The CIMDEF software is used to set up the CIM structure materials processes and orders The program allows the user to define the actual process which will take place during production CIMDEF s simple user interface makes it easy for the user to quickly learn to operate the software Stations and Machines A station is a location around the CIM conveyor where specific activities take place The ASRS Automatic Storage and Retrieval System station stores and retrieves parts used in the manufacturing process A machining station may contain CNC Computer Numerically Controlled machines for processing parts A quality control station QC may utilize a vision system Machines are grouped at stations together with the robots to perform the tasks required at each station CIMDEF lets you define the stations in your CIM environment and the machines which operate at these stations Processes and Subprocesses A process is the sequence of actions a material follows in the CIM environment Each process consists of one or more subprocesses Each subprocess defines exactly where the material should be at a specific stage that is at which station and at which machine if any in that station and what is to be done at that location for example the task the machin
147. in Figure 4 Name Alt name Connected at port 0 description Figure 4 Machine Definition Window Level 1 connection This is a description of a machine which is directly connected to the central CIM network switcher ER CIM USER S MANUAL RSNET 4 7 9204 9502 The following fields must be entered Name Name of machine up to 8 letters may be used Alt name Alternate machine name up to 8 letters may be used If AutoCNC software will be used be sure to use the required names as specified in the chapter AutoCNC Software User s Guide Connected at port Number of port on the central CIM network switcher to which machine is connected description Two line description of the machine This text is displayed in upper left corner of the screen when this element is selected highlighted The gt lt TJ keys are used to move between fields All changes must be followed by lt Enter gt or they will not be saved once you move to the next field The following options are available to exit the window lt FI gt Save the new station description print DONE on the screen and return to the Configuration screen The new machine will be added to the graphic display lt Esc gt Return to the Configuration screen without saving the changes When lt Esc gt is pressed the following message is displayed on the screen Quit with no update are you sure Y N Pressing N removes the above me
148. in Menu 2 11 9210 9502 Figure 7 The CIM Menu Activated from a Station other than the ASRS As can be seen the Production and ASRS options are enclosed by parentheses and cannot be activated from this station The options available at the secondary CIM computer are same as those available from the central CIM computer with the exception of those options that use the central CIM controller Options that are not available are enclosed in parentheses The ASRS option is available at both the ASRS station and the secondary CIM computer The Production option however is only available at the central CIM computer Options that are activated from a station access the station controller and not the central CIM controller For example choosing the Activate ATS to Station from the Communication menu will activate ATS at the station controller You will not be given a choice of stations at which to activate the program ER CIN Computer Integrated Manufacturing Version 1 72 Copyright CC 1992 Eshed Robotec Communication menu SNET Fi Activate ATS to central controller F2 Activate ATS to ASRS controller F3 Activate ATS to station controller F4 Activate ATS F5 AUTOCNC F6 RSDNL FT External user defined program Fe External user defined program F9 1 T Pick option Enter Activate option Esc Abort Figure 8 gives an example of the communication menu when activated from a station Figure 8 The Communication Menu Activated fro
149. ion 4 Tracking sent to file If you select Yes a window will appear prompting you for a file name FILE SETUP LEUH NREPORT TRK REPORT TRK is the system s default file name You may use any valid DOS file name and extension and any path Simply type the file name and press lt Enter gt The file is created as soon as you exit the Tracking File Setup menu The tracking information which you request in the Setup will be sent to this file The file is automatically updated and saved as long as the REPORTS software is activated or until the Tracking to File option is reset to No Track pallet in station If you select Yes for the Track Pallet in Station option a message line will be created whenever any pallet arrives at and leaves the selected station s ER CIM User s Manual REPORTS 10 5 9209 9502 Print station message If you select All a message line will be added to the file whenever any activity occurs at all the stations Select Selected to specify the station s for which you want to record tracking information If you select Yes for the Track Pallet in Station option a message line will be printed whenever any pallet arrives at and leaves the selected station s Select station Specify the stations whose activities will be recorded Setup Printer In addition to monitoring the tracking data on screen and recording the data in a file you can also send the message lines to a connected printer f
150. ion PC is currently connected to the Ethernet LAN you can select the AutoCNC option from the communications menu of the main CIM menu Note that the CNC programs will be taken from the downloading directories of the central CIM computer in this case ER CIM USER S MANUAL AUTOCNC 12 5 9204 9502 You will see the AutoCNC main menu as shown in Figure 2 AUTOCNC Automatic Downloading of CNC Programs Version 1 0 Copyright C 1992 Eshed Robotec Main menu Activate program File to task assignment File handling RSDNL RSNET Exit 1 T Pick option Enter Activate option Figure 2 The AutoCNC Main Menu The main menu presents the following options Activate program Run AutoCNC at the specified station The program will download a file only when requested to do so by the station controller When AutoCNC is running at a CNC station PC the PC cannot run any other programs File to task assignment Define view or modify the correspondence between task number from the CIMDEF subprocess definition and CNC program file name for each CNC machine at each station File handling Access the file handling utility to copy specified CNC program files to or from the downloading directory delete a specified file or view a list of specified files in the downloading directory or another directory 12 6 AUTOCNC ER CIM USER S MANUAL 9204 9502 RSDNL Activate the RSDNL software to change the file extension of the CNC files or oth
151. ion screen of the CIM Graphic Tracking Software The RESET program allows you to clear all status variables before restarting the system ACL Report Programs The CIM ACL system report programs let the user view the current status of the CIM cell or station These programs also allow the user to modify CIM status and configuration variables For the proper display of the report tables ATS version 1 41 or higher must be used Main Controller Reports These programs exist in the central CIM controller To activate these reports you must connect the central controller using ATS Then activate the programs using the format RUN progname The station location is given in the range of 1 through 32 with 1 being the upper right corner of the conveyor RSTAT Displays all defined stations their location and communication status CSTAT Allows modification of station existence and location on the graphic display RPLT Displays the current location of pallets and their contents RT CIM USER S MANUAL ACL Management Programs 13 1 9209 9205 EPET Allows the display and alteration of pallet contents Displays the conveyor location of each pallet and the part which is currently placed on each pallet RORD Displays the current order The order can be changed by using the PROD software RPROC Displays the manufacturing tasks required for each part in the order currently being produced Station Controller Reports The following programs ar
152. ippers Servo grippers are connected to driver cards on the ACL station controller and are controlled using the ACL commands OPEN and CLOSE Pneumatic grippers are controlled via output signals from the station controller To make the user programs suitable for either type of robot gripper the programs OGRIP which opens the gripper and CGRIP which closes the gripper are placed in the USERn DNL file These programs are written to suit the type of gripper used at the station When a station program performs an action that requires the gripper to be opened or closed OGRIP and CGRIP are called using the command GOSUB Consider the following examples 1 A pneumatic gripper which opens when controller output 3 is on PROGRAM OGRIP Y SET OUT 3 1 DELAY 200 END PROGRAM CGRIP Y SET OUT 3 0 END 2 A servo gripper PROGRAM OGRIP Y OPEN END PROGRAM CGRIP Y CLOSE 9 4 Station Application Programs ER CIM USER S MANUAL 9211 9502 If the type of gripper used at a station is changed the user only needs to modify the programs OGRIP and CGRIP in the USERn DNL file The extension Y must be added to the program name as shown above so that the current version will replace the existing version during downloading to the controller Position Numbering Conventions Robot positions used in the sample CIM application use the position vector CIM The following numbering conventions are used at each station
153. irst use the ACL command UNDEF to erase the location definition of the positions you want to overwrite with RESTSTP If you are using the default position vectors use the commands UNDEF CIM and UNDEF CIMB Use RSNET and ATS to access the requested controller Several or all controllers can be restored simultaneously using the number parameters for specific stations or the A parameter D 4 System Management ER CIM USER S MANUAL 9204 9502 APPENDIX E Preparing the LS 6x20 Bar Code Scanner for Operation To set up the LS 6x20 bar code scanner for operation in the ER CIM cell it must be programmed using the bar codes listed in the following table These bar codes can be found in the section Programmer s Guide of the Product Reference Guide for the LS 6x20 scanner The bar codes must be scanned in the order in which they appear in the table Note To prevent interference from adjacent bar codes on the same page it may be useful to cut a hole in a blank sheet of paper and place it over the bar code before scanning If you make a mistake when scanning you must repeat the entire sequence from step 1 Step Name of Bar Code to Scan oa 1 SET DEFAULT 19 2 INTERLEAVED 2 OF 5 22 LENGTH 1 Range 01 31 3 0 23 4 6 23 5 ENTER 23 6 PARITY 28 7 SPACE 28 8 ENTER 28 This procedure sets the bar code scanner for the following setup RS232 parameters Bar cod
154. is found The user can change the order of the search by modifying the values of the ACL array SRSI used by the program SRSII refer to the appendix CIM ACL System Program Listing SRSI 1 is the number of the first cell that will be checked SRSI 2 is the number of the second cell that will be checked and so forth Cell numbers 1 18 refer to level A 19 36 refer to level B and 32 54 refer to level C 6 12 ASRS ER CIM USER S MANUAL 9204 9502 Barcode Setup The barcode scanner reads the template type number from a sticker affixed to the side of the template The barcode contains six digits The first left two digits represent the template type number while the next four digits are used as an ID number for the specific template The Barcode Setup option lets you activate the barcode reader and test its operation When this option is chosen from the main ASRS menu the following screen appears Barcode Setup 47t Pick option Enter Activate option Esc Abort Figure 11 Barcode Setup Screen Testing the Barcode The first option Test barcode activates a barcode test sequence To run this sequence you must first place a template that has a barcode sticker on buffer 1 If you select this option the following message will appear on the screen Place template on buffer 1 Ready y n In this sequence the robot removes the template from buffer 1 and carries it to a point across from the sca
155. isplayed Displays the keys available at present time A legend for the cell contents There are five types of cell contents empty cell empty template part on a template feeder and unknown Each has its own graphic representation When a cell is empty no symbol appears Shows the level whose cell contents are currently displayed in the upper sector The carousel levels are marked from A the lowest level to C the highest level Use the lt PgUp gt and lt PgDn gt keys to change the current level Shows the communication status between the PC computer marked PC and the ASRS controller marked ASRS The name of the side which is working at that moment either PC or ASRS will blink and be highlighted When data is transferred an arrow showing the direction will appear between the two sides Modifying Cell Contents The user should make sure that the ASRS contents are properly updated whenever parts and templates are manipulated manually To modify the contents of a cell do the following 1 Select current level The current level is the highlighted letter in the current level sector Use lt PgUp gt and lt PgDn gt to select the desired level 6 6 ASRS ER CIM USER S MANUAL 9204 9502 2 Select current cell The current cell is the cell whose frame is highlighted The number of each cell appears above it Use the arrow keys to select the desired cell If you want the current cell to be in fro
156. ition this directory has three files which contain the commands needed for calling the DMC files e ASRCRC DNL e ASRSQR DNL e ASRCMP DNL When you complete and exit the CIM Setup Definition screen the appropriate ASRxxx DNL file is copied to the file named ASR DNL When the ASRS controller is initialized downloading of the ASR DNL calls the ASRxxx DMC file Note that the ASR DNL file no longer contains ACL programs XVi ER CIM version 1 84 UPDATE ER CIM USER S MANUAL 9407 9502 Retrieve Store Part The Retrieve Store a Part option has been changed You are no longer prompted to specify a Destination or Source when a part is moved from or to the ASRS By default the part is taken from Buffer 1 or placed on Buffer 1 except at an ASRS which uses pallets and not buffers REPORTS The following features have been added to the REPORTS software e An option for saving all messages originating in the controller which can be used for reconstructing the process An ER CIM interface for MAPICS and FOURTH SHIFT which is activated from the REPORTS software module AUTOCNC You can now define and use up to four machines in one station Graphic Tracking VIEW BAT A new batch file has been added in this version It allows you to view the different graphic representations of the ER CIM system before using the CHANGE option To activate use the same format as for CHANGE Type for example H WIZCON gt VIEW
157. ition by 1 each time 8 1 100 PNT1 120 PNT1 149 access position if part is base PNT2 1 8 1 150 PNT2 170 PNT2 200 access point take part from rack remove parts in oppos order from that in which they wer 100 PNT1 120 PNT1 149 lt PNT1 PNT1 1 T ll placed 9 32 Station Application Programs ER CIM USER S MANUAL 9211 9502 ELSE SET P3 150 PNT2 SET P4 170 PNT2 SET P5 200 SET PNT2 PNT2 1 LP PNT2 lt 1 SET PNT2 8 ENDIF ENDIF SPEEDA 50 OVE CI P5 SPEEDA 40 MOVE CIM P4 SPEEDA 5 MOVELD CIM P3 GOSUB CGRIP SPEEDA 10 OVEL CIM P4 SPEEDA 60 MOVED CI P5 END PROGRAM CLEAR j clear grill position variables SET PNT1 0 SET PNT2 0 END PROGRAM TOM1 take part to machine vision application and insert it GOSUB ID IF TASK gt 900 GOSUB TOG ELSE TE ID 1 P3 87 set pos for vision inspection of alum rod P4 88 P5 89 Ho bi H H H H P3 97 set pos for vision inspection of perspex part P4 98 P5 99 H 90000 M 4 H Hea o e 4 lt uv na U T UO D Hs o ER CIM USER S MANUAL Station Application Programs 9 33 9211 9502 MOVE CIM P4 SPEEDA 40 MOVED CIM P3 ENDIF
158. ivate the Graphics Menu ER CIM Computer Integrated Manufacturing Version 1 72 Copyright C 1992 Eshed Robotec 1 T Pick option Enter Activate option Esc Abort Figure 2 Graphic Tracking Simulation Menu The only option currently available is Tracking F1 Selecting F1 will activate the CIM On Line Graphic Tracking Software This provides a graphic representation of the working CIM cell and also gives you on line report options For more details refer to the CIM Graphic Tracking Software chapter in this manual ER CIM USER S MANUAL CIM Main Menu 2 3 9210 9502 Communication Menu Select F7 in the Main Menu to activate the RS232 Communications Menu This menu is used for access to the various elements which are located on the RS232 network The RSNET software can be activated for user initiated RS232 connections to the required stations or alternately the software performs the connection automatically and then loads ATS for user communication ER CIN Computer Integrated Manufacturing Version 1 8 Copyright C 1992 Eshed Robotec Communication menu ISNET Activate ATS to central controller Activate ATS to ASAS controller Activate ATS to station controller Activate ATS AUTOCNC RSDNL External user defined program 1 External user defined program 2 47t Select option Enter Activate option Esc Abort Figure 3 RS232 Communications Menu The Communication Menu offers you a number of options
159. k numbers and CNC program files for each machine at each station When the central CIM computer or another computer on which AutoCNC definitions are entered and the CNC station computer s are linked by an Ethernet LAN the file to task correspondence need only be entered at the central CIM computer Selecting the second option File to task assignment from the main AutoCNC menu displays a screen similar to Figure 4 Assignment machine E 2 holel holee threads logo Figure 4 The File to Task Assignment Table The top row of this screen lets you select the current station and machine number The example in Figure 4 gives the file to task correspondence for machine at station 2 Each row in the table lists the line number task number corresponding file name and any remarks 12 8 AUTOCNC ER CIM USER S MANUAL 9204 9502 Use the T 4 arrows to access the various fields If you make any changes you must press lt Enter gt to save them File Handling Selecting the third option File Handling from the AutoCNC main menu displays the screen shown in Figure 5 File handling Source directory b cncs station 2 machine Pr 2 File name Extension tap Get from source F1 Save to source Delete file F3 Catalog FY TAP 19 03 09 91 04 TAP 19 03 09 91 04 TAP 19 03 09 91 04 Catalog of source F5 TAP 19 03 09 91 04 TAP 19 03 09 91 04 5 File s 908288 bytes free Main menu ESC Figure 5 The
160. k option Enter Activate option Figure 3 ASRS Main Menu You can choose between several options Inspect Update contents View and modify the contents of each cell at each level of the carousel Template Definition Define which parts can be held by each template type Store Retrieve a part Transfer parts on templates or empty templates between the buffers and the carousel using the ASRS robot Barcode Setup Activate or test the optional barcode reader to read the template type number from a barcode sticker on the side of the template Utilities Access ATS reset the ASRS controller after the control has been disrupted backup and restore ASRS and template data to disk from the controller s memory create a file for MRP analysis 6 4 ASRS ER CIM USER S MANUAL 9204 9502 Exit Exit the program If you are running the program in off line mode and have changed the ASRS cell contents or template data you will be prompted to save the changes before leaving the program Inspect Update Contents In this module of the ASRS software you can view or modify the contents of each cell After you have selected this option you will see a screen similar to the one shown in Figure 4 however the cell contents will be different Inspect Update contents Part gt Template gt Type or feeder quantity 10 11 12 13 14 15 16 17 18 Part gt Template gt Type or feed
161. le GOSUB SNDLS send the id 4 digits and send a one line epilog GOSUB SNDLE 3 Before starting a production order you must do the following e Run the program RSKBD on the SQC computer e Activate SQC and define the proper values e Call up the Real Time menu which will then remain on display during production XXIV ER CIM version 1 84 UPDATE ER CIM USER S MANUAL 9407 9502 Height Gauge 1 Connect the Height Gauge to port 4 of the switcher Connect controller port n to port 3 of the switcher Configure switcher port 4 as follows baud rate 2400 data bits 8 stop bits 2 no parity no XON XOFF 2 In the USERn DNL file make the following changes e Add the following lines at the beginning of the file INCLUDE CIMSYS ST PORTn DMC INCLUDE CIMSYS ST HG DMC n station controller port number INCLUDE is an ACLoff line command e You must add the program START PROGRAM START which must contain the line GOSUB HGSTR In program WTMn include the following lines MOVE CIMB 3 first point GOSUB CKHG1 MOVE CIMB 4 second point GOSUB CKHG2 IF HGRES 0 SET RESn 1 reject ENDIF n machine number ER CIM USER S MANUAL ER CIM version 1 84 UPDATE XXV 9407 9502 3 OPTIONAL To also use SQC statistical software program Add the following lines at the beginning of the USERn file preceding the FINCLUDE lines from Step 2
162. m a Station other than the ASRS 2 12 CIM Main Menu ER CIM USER S MANUAL 9210 9502 DOS Commands for Activating System Programs The CIM Main Menu is usually sufficient for accessing and activating all CIM programs However if you wish to directly activate various options from the DOS prompt following is a list of the available commands These DOS commands can be entered only after you have exited to the DOS prompt H by pressing F9 from the CIM Main Menu CIMM RSNET ATS ATSST WIZ CIMDEF PROD Activates the CIM Main Menu Activates the RS232 Network Management software Can be activated from any computer in the CIM system At central CIM management computer the screen will display the entire CIM communication network At station computer the screen will only display the communication configuration for the station From central CIM management computer activates the Advance Terminal Software ATS at the central CIM controller From central CIM secondary computer activates ATS at the station controller currently connected by RSNET From station computer activates ATS at that station s controller From central CIM secondary computer activates ATS at the station controller currently connected by RSNET Activates the Graphic Tracking software WIZCON Can only be activated at the central CIM management computer Activates the software for defining the CIM system elements machines equipment
163. me of the layout file without any extension Typical examples of layout file names include 103 standard 3 station ER CIM configuration 104 standard 4 station ER CIM configuration For example to change the graphic layout to an oval conveyor with a standard 3 station ER CIM configuration type CHANGE OV 103 To see a listing of the available layout files for a particular conveyor shape type the following CHANGE shape where shape is either SQ or OV 8 10 Graphic Tracking ER CIM USER S MANUAL 9207 9502 CHAPTER 9 ACL CIM Application Programs and Positions Introduction In an ER CIM system the user defines which manufacturing processes or applications are performed at each station Each station controller requires its own ACL programs to control the robot and the machines used in the specific manufacturing application These programs are termed station application programs Default programs for template manipulation are provided with the ER CIM software In general these programs are suitable for all stations and will not need to be modified These programs are given in the section Template Manipulation Programs The programs which control the actual manufacturing process must be written to suit the specific robot machines and application at each station Designated names as given in the section Part Manipulation Programs must be used The ASRS station programs which do not normally need modificatio
164. move to next sector F6 move to previous sector F7 move between sectors by increments of 10 FS move between sectors by increments of 10 The sector number will be displayed on the right side of the message at the bottom of the screen and will also appear in the station location table To keep this station location press lt Enter gt When you return to the CIM_CELL screen the updated station locations will appear on the conveyor The Utilities Screen Pressing F3 from the CIM_CELL screen displays the screen shown in Figure 3 ATS COM center CIMDEF PRODUCTION ORDER RSNET ATS COM2 stations ASKS DOS shell RETURN TO CIM_CELL screen Figure 3 CIM Graphic Tracking Utilities Menu 8 6 Graphic Tracking ER CIM USER S MANUAL 9207 9502 The options are Fl Activate the Advanced Terminal Software ATS for direct access to the Central CIM controller F2 Access the CIMDEF software F4 Access the PROD software to download or modify an order F5 Access the RSNET software This option is only available if the central computer running WIZCON is connected to the Central CIM Network Switcher F6 Access a station controller via the Central CIM Network switcher This option is only available if the central computer running WIZCON is connected to the Central CIM Network switcher F7 Access the ASRS software RSNET should have been used previously to connect to the ASRS station controller F8 Leave the CIM graphic
165. mple template type 11 can hold parts 1 2 3 and 12 and part 44 can only fit on template type 10 Remember to define a unique template type for each part type in the system When finished press the lt Esc gt key to exit Verify Save changes to controller yn If you have made any changes you will be prompted with the following message Figure 9 Save changes verification Window Press Y yes to confirm if you want your changes to be saved The information will then be written to the controller s memory Store Retrieve a Part This option lets you use the robot to store and retrieve specific parts or empty templates Store and retrieve operations are performed automatically during production following a request from the central CIM controller This option lets you request the storage or retrieval of a part or an empty template You will be prompted by four windows to determine what and where to retrieve or store 6 10 ASRS ER CIM USER S MANUAL 9204 9502 Retrieve Store Tupe of action Retrieve from ASRS Destination Store in ASAS Buffer 1 Type of object Part on a template Empty template Verify e the object Cyn Figure 10 Retrieve and Store Screen The four windows are Type of action What action should be performed There are 2 options Retrieve from ASRS Retrieve a part or an empty template from the carousel Store in ASRS Store a part or an empty template in the ASRS carousel
166. n are not given in this chapter They can be found in the appendix System Program Listings A number of ACL variables have been defined for use in the station application programs These are discussed in the section Control Variables for Station Application Programs Whether you use the original or modified default programs or write your own you will need to record the robot and linear slidebase if present positions used in the programs for each station The positions required by each program and the position numbering conventions are described in this chapter The positions required for the ASRS station are also given In addition sample station programs are given in the section Sample ER CIM Applications You can use these programs modify them or create your own programs based on these examples ER CIM USER S MANUAL Station Application Programs 9 1 9211 9502 Writing Application Programs ER CIM station application programs should be written at a PC using the ACL Off Line utility This allows you to use any full screen editor to write and easily revise your programs The entire set of CIM application programs for each station must be saved to a file USERn DNL n station number in the directory H CIMSYS ST at the central CIM computer When a station is initialized the USERn DNL file and various system programs are downloaded from the central CIM computer to the station controller Comment lines that begi
167. n 3 contains two CNC machines the CNC programs will be found in the following locations for machine 1 CACNCISIAM1 for machine 2 C CNC S3 M2 Central CIM Computer When CNC program files are stored in the central CIM computer the files for each CNC machine must be located in the following directory H CNC Ss Mm where s is the station number and m is the machine number Note To import a CNC program from another location such as a CAD program directory or diskette to a downloading directory use the AutoCNC file handling utility Central and Station Controller Program Installation Using the Setup Menu and its submenus accessed by pressing F8 in the CIM Main Menu execute the following procedures at the central CIM computer Refer to the Controller Setup section in Chapter 2 The CIM Menu for more information 1 Access the setup screen and verify that all information is correct If not update the screen 2 Initialize the central CIM controller 3 Make sure all RS232 cables are connected and that all automatic RS232 switchers are on and free for access from the central computer no local computer controller connections are active 4 Check that the RSNET map represents the configuration of your cell If not update the configuration 5 Initialize the controller at each station ER CIM USER S MANUAL Installation 1 7 9308 9502 If a file POINTn CBU exists this file contains the most recent backup of
168. n with the characters or are not transmitted to the controller If you want modify a station application program or add another program you should make these changes to the USERn DNL file and then reinitialize the station controller The command to initialize the station controllers is found in the Station Controllers Setup menu which is accessed from the Setup Menu option in the CIM Main Menu If you would like to test a new station program or modifications to an existing program you can write or edit the program directly to the station controller s memory using ATS Be aware however that the next station initialization will download the current USERn DNL file and erase any changes you have made If you want to keep the changes you must enter them into the appropriate USERn DNL file and reinitialize the corresponding station controller Note If one program calls another using a GOSUB command the program that is Called must precede the program that calls it in the USERn DNL file Sample sets of CIM application programs are given in the section Sample ER CIM Application Programs These files are present in the H CIMSYS ST directory If you want to use these files copy the USERx SMP file where x is LATH MILL or ASSM to the USERn DNL file for the corresponding station You must copy the entire file of programs for each station application you choose Then you may modify the programs for your particular appli
169. nd line of the DOS shell is RSNET station_name machine_name Ccom Any or all of the options within brackets may be used If you do not enter any options you will enter the RSNET graphic display as described in this chapter Activating a Communication Path A communication path can be activated from the command line without invoking the graphic display To use this option the station and machine names must be specified and the path must already exist in the configuration The syntax is RSNET station_name machine_name The options in brackets are station_name Name of the station to be connected to The alternate station name may also be used machine_name Name of machine to be connected to Note If the station name is omitted the connection is made with the first machine of that type that occurs in the configuration i e starting with station 1 ER CIM USER S MANUAL RSNET 4 15 9204 9502 If communication cannot be established you will receive the following message Communication error Defining the Communication Port The RS232 computer port to which the Central CIM Network switcher is connected is defined from the command line The syntax is RSNET Ccom The options for Ccom are C1 The COM1 port is used RSNET will use the configuration data file stations D1 C2 The COM2 port is used RSNET will use the configuration data file stations D2 Examples RSNET QC CONTRO
170. nges e Add the following line at the beginning of the file INCLUDE CIMSYS ST RVPRO DMC INCLUDE is an ACLoff line command e In program WTMn you may include any command which calls a vision function For example GOSUB SCAN GOSUB SNAP GOSUB THRES The results of vision functions are written to global variables such as SCNST SCNCN Refer to the ROBOTVISIONpro User s Manual for a complete list and explanation of the vision variables and the vision functions which can be accessed by ACL programs ER CIM USER S MANUAL ER CIM version 1 84 UPDATE XXIX 9407 9502 This page intentionally left blank XXX ER CIM version 1 84 UPDATE ER CIM USER S MANUAL 9407 9502 CHAPTER 1 Installation Upgrade and Setup Procedures Installation Upgrade of ER CIM Program Files A set of four diskettes labeled CIM 1 through CIM 4 is used for installation or upgrading of existing software Instructions that are written in italics should only be followed when upgrading the software Before installing or upgrading the software e Turn on the central CIM computer e Turn on all other computers to be used Turn on any printers which are connected e Make sure all software protection keys are plugged in All computers in the CIM system are supplied with a software protection key The key must always be plugged into a printer parallel port on the computer while you are Operating the CIM system If you are usin
171. nner so the barcode may be read Next the robot returns the template to buffer 1 ER CIM USER S MANUAL ASRS 6 13 9204 9502 If the barcode can be read the following message will appear Barcode is The barcode number will appear on the screen If the scan was not successful the following message will appear Error reading barcode If this message appears you must identify and correct the problem Possible causes include e robot is not aligned properly in front of the barcode scanner robot position was not properly set or robot was not homed e barcode scanner RS232 cable not properly connected to the ASRS controller point to point network e barcode scanner not properly connected to the power source on the ASRS controller e barcode scanner not properly setup the setup procedure is described in the appendix Preparing the LS 6x20 Barcode Scanner for Operation e barcode label is missing damaged misaligned or obscured by dirt Activating the Barcode Selecting the second option Barcode Active toggles between yes barcode reader activated and no barcode reader inactivated When the Barcode Active option is chosen the robot takes all templates both empty and those carrying a part as they are stored or retrieved to the barcode scanner to verify their template type numbers This includes store and retrieve operations performed automatically during production as well as thos
172. ns The software also supports a database for raw material information Activating the MRP Program To activate the MRP software select the MRP Menu F4 from the CIM Main Menu Alternately type MRP lt Enter gt at the DOS prompt You will see the Main MRP Menu shown in Figure 1 MRAP Material Resource Planning Version 1 00 Copyright CC 1991 Eshed Robotec Main Menu Raw material information Raw material purchase orders F2 Queries File manager Exit yt Pick option Enter Activate option Figure 1 Main MRP Menu ER CIM USER S MANUAL MRP 7 1 9204 9502 These options are available Raw material information Supplements information on raw materials in the CIMDEF database Includes inventory and supplier information Used to generate MRP queries reports and raw material purchase orders Raw material purchase orders Generates purchase order according to user s specifications Queries Reports Reports on quantities of raw material required to produce a selected range of orders or to meet minimum inventory requirements Produces reports of ASRS inventory or production order validity File Manager Reviews or modifies the names of the CIMDEF data files used by the MRP software Exit Exits the MRP software Each of these options will be described in more detail in the following sections Common Features A number of common features are found in many MRP screens The and J keys are
173. nt of the robot s location so that you can see it press the lt Alt gt M keys and the carousel will rotate Make sure the robot s gripper is outside the carousel so the carousel can turn freely 3 Press Enter Pressing Enter will open a five option window with the five different cell contents available Empty template Feeder Unknown Pick an option and press lt Enter gt The new cell contents will be updated both on your PC screen and in the ASRS controller s memory The different options are Empty cell The current cell is an empty one 1 Part gt Empty template The current cell holds an empty template Template gt You will be prompted for the template type Type or number feeder quantity Figure 5a Template Type Part on a template The current cell contains a template holding a part You will be prompted only for the part Part gt number The template type number is Template gt obtained from the Template Definition Type or feeder quantity Table Figure 5b Part ER CIM USER S MANUAL ASRS 6 7 9204 9502 Feeder The current cell holds a feeder for a specific type of part You will be prompted for both the number of the part in the feeder and the quantity When the ASRS system is instructed to supply a part which can be found only in the feeder the robot will place the matching template on a buffer and will then fetch the part from the feeder and put it on the template 1 Part
174. nter gt When installation is completed remove the diskette from drive A Turn off the computer and then turn it on again Station Computer Program Installation 1 Insert diskette CIM 1 into drive A Make sure the DOS prompt is A Type MCIMS n and press lt Enter gt where n is the number of the station For example to install the ER CIM software at station 2 type MCIMS 2 ASRS Station ASRS Version First initialize the station computer as the ASRS station computer For example to initialize station 1 type MCIMS 1 ASRS and press lt Enter gt When intallation is completed remove the diskette from drive A If you have received a special ASRS diskette and the ASRS station computer is not connected to a network perform the following steps e insert the diskette into the A drive e copy the file ASRSSQR EXE from diskette to the C ASRS directory using the same name e copy the file ASRSSQR EXE from the diskette to the directory C ASRS using the name ASRS P When intallation is completed remove the CIM 1 diskette from drive A 1 4 Installation ER CIM USER S MANUAL 9308 9502 CNC Station with Automatic Downloading To initialize a station computer that will store CNC programs for automatic downloading to a CNC machine insert diskette CIM 1 into drive A and make sure the DOS prompt is A gt Then type MCIMS n CNC and press lt Enter gt where n is the number of the station For example MCIMS
175. ntil at least one has finished the first process ALL RELEASED No more materials are required by the order MISSING Some materials are missing DONE MISSING System has completed production on all available parts and pieces the remainder are missing DONE All parts and pieces in the order have been completed 10 10 REPORTS ER CIM User s Manual 9209 9502 Conveyor The Conveyor Report screens provides an on line graphic display of the elements on the conveyor ILI ze 2 1 show PARTS 2 show RAW MATERIALS 3 show TEMPLATE TYPES 4 show PALLET ID OOOO 1 4 select display F9 F10 SCROLL F1 TRACK F2 PALL F3 ORDR F4 STAT FS BUFF F6 CONY Esc MAIN Figure 6 The CONVEYOR Report Screen The Conveyor screen shows a graphic representation of the 32 sectors which comprise the conveyor The CIM station numbers appear along the inner perimeter of the conveyor and the sectors at which they are located are highlighted Sector number is the third box from the right at the top of the screen In the example shown in Figure 6 stations are located at Sector 2 Station 3 Sector 8 Station 1 and at Sector 19 Station 2 Numbers representing the elements move in a counter clockwise direction around the conveyor reflecting their actual status on the conveyor In this example all the pallets currently on the conveyor are being tracked ER CIM User s Manual REPORTS 10 11 9209 9502
176. ntral controller setup Activate ATS Fi Initialize controller Fe Update setup F3 2 6 CIM Main Menu ER CIM USER S MANUAL 9210 9502 Fl activates ATS to the central CIM controller F2 initializes the central CIM controller This option performs the proper configuration for the central CIM controller and then downloads all CIM ACL system programs to the controller This procedure can take up to 30 minutes You will see the programs scroll on the screen as they are downloaded F3 updates the central controller s setup information This option makes sure the information in the central CIM controller matches the current station setup information Use this option after making changes to the station setup definitions but before initializing the controllers Station Setup Definitions Select F2 in the Setup Menu to display the menu for initialization backup restore operations and program editing for the station controllers ER CIN Computer Integrated Manufacturing Version 1 72 Copyright CC 1992 Eshed Robotec Station controllers setup Station setup definitions Initialize controllers Activate ATS Backup controllers Restore controllers Backup controller points Restore controller points Editing station program 1 T Pick option Enter Activate option Esc Abort Figure 5 Station Controllers Setup Menu When this menu is accessed from the central CIM computer you will be prompted for the station at which t
177. o activate the option with the exception of the first option Station setup definitions When this menu is accessed from a station computer all options will operate on the station controller ER CIM USER S MANUAL CIM Main Menu 2 7 9210 9502 Fl activates the program INITST for station definition The following screen will be displayed and will allow you to define the robots and peripheral equipment at each station CIM Setup Definition Number of stations 1 8 Y ASRS station number _1 Number of pallets _8 ASRS type RE compact square Conveyor cycle in 17100 sec 6400 Station Station location Robot type Number of peripherals Number of machines Robot on slidebase Using SCORBASE Speed controlled conv al al ECN 1 OOF Nii al OOO NN siele O Olein niom zz ll ODIO wif Station Setup Station 2 Location 1 32 8 Robot tupe 5 7 5 AM machine 1 Number of peripherals 0 1 WAA 37475 Number of machines 0 Mr 27374 Is the robot located on slidebase MM Yes Using SCORBASE Ml Yes lt F1 gt Previous station lt F2 gt Next station lt ESC gt Update and exit Figure 6 CIM Station Setup Screen This definition is used later for selecting the proper configuration and CIM ACL system files that will be downloaded when the station controller initialization is performed This stage must be performed before initialization of the station controllers is carrie
178. o the configuration of the CIM cell Also included are a Utilities option which allows the user to access other CIM software and a production report facility CIM Graphic Tracking Software utilizes WIZCON to provide these features WIZCON a graphic tracking and reporting software package has been adapted for this application Many WIZCON features are not described in this chapter For more information refer to the WIZCON documentation provided with the CIM software Entering the Software To activate the graphic tracking software from the central management computer select the graphics menu F6 from the CIM Main Menu You will be presented with two options Select the tracking option F1 Alternately type WIZ followed by lt Enter gt at the DOS prompt You will see the CIM_CELL screen shown in Figure 1 ER CIM USER S MANUAL Graphic Tracking 8 1 9207 9502 MANAGEMENT STATION UNLOAD ING Qc Figure 1 CIM Graphic Tracking CIM_CELL Screen The CIM_CELL Graphic Display This CIM_CELL screen shown in Figure 1 gives a real time graphic color display of the flow of material in the CIM cell On the periphery are detailed representations of the elements located at each station robots CNC machines computers controllers and other devices The CIM cell conveyor is located in the center of the screen Stations are represented by hatched squares on the conveyor When production is in progress loaded pallets movin
179. of the downloading completed so far Production setup menu Select production order Download production data Status Downloading production data to controller Percentage completed Figure 10 Downloading completion Status Window If a previous order is being manufactured you will be prompted with a How to Production setup menu Select production order Download production data Status Previous order has not been fully manufactured How to continue Add new order to existina order Replace existing order with new order Abort download continue message ER CIM USER S MANUAL PROD 5 7 9204 9502 Figure 11 How to continue Window There are three options Add new order to existing order This will cause the new order information to be appended to the existing one The two combined orders will be treated as one larger order The production of the previous order and the newly requested products will continue Replace existing order with new order This will cause the new order to replace the existing one The products already in process will complete their production cycle New material relating to the previous order will not be released Abort download This option will cancel the download sequence CIM Production Production Setup menu Select production order Download production data CIM production This option lets you start or stop the production of the previously downloaded order s
180. ogram The name appearing in the CIM application name field is copied to the next four file names if lt Enter gt is pressed while the cursor is in this field Any time you modify an entry you must press lt Enter gt before continuing to another field or the changes you made will be lost 7 18 MRP ER CIM USER S MANUAL 9204 9502 Exit This option exits the MRP software When this option is chosen a message is printed on the screen asking you to verify the command as shown in Figure 10 MRP Material Resource Planning Version 1 00 Copyright C 1991 Eshed Robotec Main Menu Are you Esc Abort Figure 10 Exit verification Window Typing Y exits the program typing n or pressing lt Esc gt removes the Verify window from the screen ER CIM USER S MANUAL MRP 7 19 9204 9502 This page intentionally left blank 7 20 MRP ER CIM USER S MANUAL 9204 9502 CHAPTER 8 CIM Graphic Tracking Software User s Guide Introduction CIM Graphic Tracking Software provides the user with a graphic display of a working CIM cell showing the progress of a part as it travels on the conveyor from station to station The screen display includes detailed representations of the station elements such as computers controllers CNC machines and robots The software which can only be run from the central CIM management computer allows the user to change the locations of the stations on the conveyor according t
181. oho ape Ge e ds A ee oe we 10 7 OPLEES A E EA wr aed 10 8 CONVEYORS ecards o Vat Gone a e Roe ESA 10 11 AGUS ruega at Sar Gel a De no De nn ls daa Y hte et et A 10 13 SATIONS 4 2245 tes ate Gxt a E A A AE A dl te Se t 10 15 A NN A cue a git gh Et Bo WP ag 10 17 CHAPTER 11 RSDNL Software User s Guide 2 002 11 1 MOGUCOM e td ese a Gees Reyes win Be Be te Bees he BA Beis 11 1 Activatine RSDNE a Aveo SoS oe RO Ge e aa AE OSs 11 2 OPHONS ot ewes RS AS e A GS ee i 11 3 Protan Files e E A ria aa 11 4 Communication Setup e a or e a e ES WO Re 11 4 Save OPHONS peta e SAE TE A A e 11 6 Load Options LEE AE e A A a A as 11 6 RSNET Lita bres e to ded a ede a A A 11 7 Dowload sciens edo yale ae 4 8 dim e Soe e ay BBS GOS 11 7 Pile Names Eo a Ay a Sua E A Gale ae Da LS BBS 11 7 Calo 2 Se bi eh Bete a ae EM AS oe a hy A Se x 11 8 PTE gee irie hn ca tae TE E eee lng Se vie pe ae ee GR e e eta ad 11 8 Command Line Options 0 00000 2 ee 11 9 Pre production Downloading of CNC Programs Using RSDNL 11 9 CHAPTER 12 AUTOCNC Software User s Guide lt lt 12 1 Introduction 2 ais he e A a a A ek E O oh 12 1 Required RSNET Alternate Names 2 e o 12 2 stations s aa OX So hag A ee A A A E A ae ee ee oR 12 2 machines 2 DAA A bok Rie eh A AR 12 2 Required RS232 Connections see ae a Gee eS A 12 2 Location of CNC Programs 2 23 be 2 eee ee a ee 12 3 CNC S
182. om this screen but you cannot initiate downloading ain Menu ownload le name log To leave this screen press lt Esc gt You will return to the Download window Exit Choosing the last option Exit leaves the RSDNL software If you have made any changes to the data files while running the program you will receive a message that the files are being saved when you exit the program 11 8 RSDNL ER CIM USER S MANUAL 9204 9502 Command Line Options The RSDNL software may also be run in batch mode The syntax is RSDNL Options_File Download_File where Options_File is the name without extension of an options file generated by RSDNL and Download_File is the name without extension of the file to be downloaded Note that the extension and location of the file to be downloaded are specified in the options file Before using this option the following steps must be performed 1 An RS232 communication link must be activated between the PC from which the file will be downloaded and the target device When the PC and the target device are connected to a switched RS232 communication network RSNET can be used to activate the communication link 2 The required options must be entered to the RSDNL software and stored in an options file To receive a brief description of the batch mode options type RSDNL Pre production Downloading of CNC Programs Using RSDNL Using RSNET and RSDNL software t
183. onfiguration Screen the ASRS Controller for example displays the window shown in Figure 7 Name CONTROL Alt name ER Vplus Connected at station number Connected at port _2 description ROBOT ER Vplus Figure 7 Modify Machine Window Again the gt lt TJ keys are used to move between fields All changes must be followed by lt Enter gt or they will not be saved once you move to the next field Note that you cannot access the third and fourth fields since they refer to the network configuration The following options are available to exit the window lt Fl gt Save the updated machine configuration description and print DONE on the screen lt Esc gt Return to the Configuration screen without saving the changes When lt Esc gt is pressed the following window appears on the screen Quit with no update are you sure Y N Pressing Y removes the Modify Machine widow from the Configuration screen pressing N erases the above message ER CIM USER S MANUAL RSNET 4 11 9204 9502 Deleting Elements To remove a machine use the TJ keys to highlight the machine on the Configuration Screen that you want to delete then press lt Del gt The following message will be displayed on the screen Remove machine are you sure Y N Entering N removes the message entering Y removes the element and displays the following message on the screen for a few seconds Done
184. ons and machines Process definition Define processes and subprocesses 3 2 CIMDEF ER CIM USER S MANUAL 9204 9502 Material Assembly definition Define materials Order entry Enter orders File manager Define the CIMDEF file names Exit Exit the program Common Features Some functions are used by several options The Report and Save functions are used in Station Process and Material Assembly definition and in Order entry The Select and Delete functions are used in Process and Material Assembly definition and in Order entry Report The Report function lets you receive information on a range of objects For example you can get a report of all the processes defined Activate this option by pressing F5 where available at bottom of screen The following window will then appear Figure 2 Type of report Window Two types of reports are possible Partial A report of a range of objects You are prompted to define the requested range For example a report of processes 4 to 15 Type of report Partial Full Enter process range From 4 To 15 Figure 3 Range of report Window Full A report of all the objects defined For example a station report gives a report of all the stations defined ER CIM USER S MANUAL CIMDEF 3 3 9204 9502 After selecting the type of report select where to direct the report Report destination Figure 4 Report destination Window Three options are possible Scre
185. ontroller for I O Expansion 2 xxviii ROBOTVISIONpro ER CIM Interface 0 2 2024 XXIX ER CIM USER S MANUAL 9502 CHAPTER 1 Installation Upgrade and Setup Procedures 1 1 Installation Upgrade of ER CIM Program Files 1 1 Central CIM Computer Program Installation 02 1 1 Central Station Second or Third Computer Program Installation 1 3 Station Computer Program Installation 1 4 ASRS Station ASRS Version o o ee 1 4 CNC Station with Automatic Downloading 2 2 1 5 Additional Installation Procedures Loading USERn DNL Files 1 5 CNC Program Directories for Automatic Downloading During Production 1 6 CNC Station PO 5 a Ae A e e Ge OR whe Ot OO 1 6 Central CIM Computer ak je ok 2 A Oh eS 1 7 Central and Station Controller Program Installation 2 1 7 Barcode Scanner Programming Setup 1 8 CHAPTER 2 The CIM Menu oa oe and a a Se ae a A ce a ee 2 1 Activating CIM System Programs 2084 2 2 Graphic Tracking Menu 2 s 4 2 6 bbe A 2 3 Communication Menu gga AA ae ee A AA 2 4 Controller Set p i x s 4 4 4 o s Bek A AE a ee 8 2 6 Central CIM Controller Initialization 2 en 2 6 Station Setup Definitions 0 2 2 2 2 00 0084 2 7 Backup Restore of Station Controllers 00 2 9 Using the CIM Menu at a Secondary Central CIM
186. option is selected the following box will appear on the screen You are prompted to enter the extension and directory location of the program file to be r Nain Nenu r Options _ Program files Extension tap Directory H AUTOCNC downloaded The information used in the previous downloading will appear on the screen In the example shown above the extension is tap and the file is found in the directory H1AUTOCNC To modify the information in a field first select the field using the T J arrows then press lt Enter gt to access the editing mode Type the information then press lt Enter gt to save and exit the editing mode To leave this screen press lt Esc gt You will return to the Options menu Communication Setup When Communication Setup is chosen the following window appears on the screen r Nain Nenu r Options _ Communication Setup Com port con2 Baud r 11 4 RSDNL ER CIM USER S MANUAL 9204 9502 This window lets you specify the transmission parameters required by the target device The current settings are displayed To change a parameter s setting use the TJ arrows to highlight the parameter and press lt Enter gt A new window will display the available settings Then use the T J arrows to select a setting and press lt Enter gt The new value will appear on the screen The transmission parameter settings are Com port The
187. or on line printing of the tracking information Screen File PRINTER SETUP Tracking sent to printer Track pallet in station Print station message GPA SELECTED The options are the same as those described for the File Setup If you select the Tracking Sent to Printer option you will be prompted to confirm that a printer is connected to the system Note The setup data is recorded and saved in a file named CONFIG REP The system refers to this file whenever the REPORTS software is activated Thus if the Tracking to Printer option was active when you previously exited the REPORTS software the next time you activate the software you will immediately be prompted to confirm that a printer is connected 10 6 REPORTS ER CIM User s Manual 9209 9502 Tracking Display In the example shown in Figure 4 three stations are being tracked However production activity has occured only at Station 1 ASRS and Station 2 Machining Pallets are not being tracked TRACK ING ASRS RELEASED RAW MATERIAL 11 FOR PART 35 STATION PART 2 SUBPROCESS 1 COMPLETED STATION ROBOT GETTING TEMPLATE FROM PALLET STATION ROBOT TAKING TEMPLATE WITH PART 35 TO BUFFER 1 ASRS INSTRUCTED TO RELEASE RAW MATERIAL 1 FOR PART 2 STATION ROBOT GETTING PART 35 FROM TEMPLATE ON BUFFER 1 ASRS CANNOT RELEASE RAW MATERIAL 1 FOR PART 2 ASRS INSTRUCTED TO RELEASE RAW MATERIAL 11 FOR PART 12 ASRS ROBOT GETTING TEMPLATE FROM ASRS STA
188. or order delivery This field will be used later for the MRP Material Resource Planning analysis A table is displayed in the middle of the screen There are 40 lines in one order but you can view only ten at a time Use the lt PgDn gt and lt PgUp gt keys to scroll the lines up and down The information in this table is Line The line number in the order Part ID The number of the part you want to order ER CIM USER S MANUAL CIMDEF 3 13 9204 9502 Part name Updated automatically according to the Part ID field Quantity The amount of parts of Part ID you want to order File Manager The File Manager menu lets you view or modify the names of the files used by CIMDEF This facility lets you define different CIM configurations and save each of them under a different name File manager CIN application name Station definition file cim Process definition file proci Naterial assembly definition file newpart Order entry file cim Esc Previous menu Figure 16 File manager Screen Five names are possible CIM application name The name of the current CIM application This name is copied to the next four file names if lt Enter gt is pressed while the cursor is in this field 3 14 CIMDEF ER CIM USER S MANUAL 9204 9502 Station definition file The name of the current station definition file CIMDEF adds the extension STN to this name to form the actual station file name for
189. ort 2 of the station switcher and the PLC is directly connected to port 7 on the central CIM switcher The following keys may be used to make configuration changes Make sure the NumLock key is not pressed lt Ins gt Add machine or station to configuration lt Del gt Delete machine or station from configuration lt Enter gt Modify information on an existing element Inserting Elements Note When inserting an element there is no need to illuminate the location in the diagram at which you want to place the element The software will position the element according to its station and port numbers Pressing lt Ins gt from the Configuration screen displays the following window in the upper left corner of the screen LEVEL level 1 level 2 An element inserted at Level 1 is connected directly to the element in the upper most central block while an element at Level 2 is connected through a station 4 4 RSNET ER CIM USER S MANUAL 9204 9502 To select the desired level use the TJ keys followed by lt Enter gt If Level 1 is chosen the following window appears in the left corner of the screen Station Machine Station represents a CIM station connected to the central CIM switcher A machine represents an element which is directly connected to the central CIM switcher To select an option use the T 4 keys followed by lt Enter gt Inserting a Station
190. ot available prompts you for the report s destination Once an option is chosen a message will flash on the screen informing you that the report is currently being prepared Report Destination Screen Printer Choosing the screen option will display the report on the screen The bottom of the screen shows the numerical keypad keys used to view the report PgDn PgUp Move one page down up PIN Move one line down up Home End Move to start end of file To exit the report and return to the previous screen press lt Esc gt ER CIM USER S MANUAL MRP 7 3 9204 9502 If you choose the printer option you will receive the following message re printer is connected z to continue To continue printing press lt Enter gt To abort the print command press lt Esc gt This will return you to the Report Destination window If you choose to send the report to a file you will be prompted for the file name Enter file name without extension raw Enter a name with up to eight characters Do not add any extensions the program automatically adds REP to the name you entered If this file already exists you will receive the following message File raw rep already exists Overwrite y4n You can either write over the previous contents of the file or enter a new file name Raw Material Information The raw material database supplements the information on raw materials contained in the CIMDEF database
191. our selection Machine If using a machine enter the machine number at that station Name Updated automatically according to the machine definition Task The task to be performed in this subprocess Expected processing time CIMDEF ER CIM USER S MANUAL 9204 9502 The amount of time you expect the subprocess to take Remarks User remarks for this subprocess Material Assembly Definition The Material Assembly Definition menu lets you define view or modify definitions of materials parts Material Assembly definition Part ID Type of part RE E MIST processed material assembly Parts are numbered from 1 to 1000 thus up to 1000 different parts can be defined at a time You can define even more parts by using other parts definition files refer to the File Manager section for more details To define or view a part you must select it enter its ID number After you have selected a part you can modify or view its definition Figure 11 Material Assembly definition Screen top The information at the top of this screen is Part ID The number of the selected part Name The part name Type of part raw material processed material assembly Select the type of the part Raw A material which will be processed Processed A material which results from the processing of a material Assembly A part which is assembled from processed materials Use the left and right arrow keys to select and press
192. pear in uppermost block in the graphic display Machines may be added deleted or modified as described previously All connections will be Level 1 connections between the station switcher and the machine Figure 8 shows the On Line screen when RSNET is run from the computer at a typical CNC station MILL Z mill M2 CNCstat lt lt ON LINE gt gt gt use 1T4 gt to Select lt Enter gt or lt to connect lt gt to disconnect lt Fi0 gt Configuration menu lt Ese gt Exit to DOS Figure 8 RSNET On Line Screen for CNC Station Notice that the uppermost central block contains the CNC station and the station elements lathe mill and controller are displayed horizontally across the screen The station computer does not appear in the diagram since it is implicitly represented by the uppermost central block To modify the uppermost central block highlight this block from the Configuration screen and press lt Enter gt The Modify Station window will be displayed on the screen as shown in Figure 9 ER CIM USER S MANUAL RSNET 4 13 9204 9502 MODIFY STATION Name CNCstat_ Alt name Number of ports 5 El Station number 0 Description Station port connected to center 1 Control character lt Ctrl gt T Delay before disconnect Figure 9 Modify Station Window for Upper Block This station may be modified in same way as any other station with the following exception If the station name is
193. ption To select a previous order type its number Production Setup menu Dow Tupe of order ta crn Res Immediate Enter order 1 Figure 4 Previous order number entry Window You can now view but not modify your selected order Use the lt PgUp gt and lt PgDn gt keys to scroll 10 order lines up or down and the lt Esc gt key to exit 5 4 PROD ER CIM USER S MANUAL 9204 9502 Order 4 Order date 15 01 91 Delivery date 15 01 91 Priority Lamp Lamp cover Flt p o PallpPabn Scroll up down Esc Previous menu Figure 5 Select Previous order Screen Immediate order Base for _a lamp OO EN PR o Fi Clear order PqUp PgDn Scroll up down Esc Previous menu Figure 6 Immediate order entry Screen ER CIM USER S MANUAL PROD 9204 9502 5 5 Use Fl to clear the immediate order contents A table is displayed in this screen There are 40 lines in one order but you can view only ten lines at a time Use the lt PgDn gt and lt PgUp gt keys to scroll the lines up and down The information in this table is Line The line number in the order Part ID The number of the part you want to order Part name Updated automatically according to the Part ID field Quantity The amount of parts of Part ID you want to order Download Production Data This function performs the actual downloading of the selected order Choose this option onl
194. re currently empty All programs may be modified as required by the application STA STB CLEAR START URST INIT USERn n 1 3 Program to home the robot and bring it to a starting position the default version calls the program STB Executes the homing procedure for other axes HHOME program for axis 7 and brings the slidebase to a starting position A user definable program for clearing user variables Used for example to clear a variable describing the status of a loading tray Runs whenever the controller is turned on or reset Runs whenver the controller is turned on Available for the user at the ASRS station this program sets the coordinates of the carousel positions or the robot positions for the square ASRS relative to one position These three programs are available for the user Standard Program Numbers for Execution from Station Teach Pendant Following is a list of the default teach pendant program numbers This list will help the user to manually execute the programs described To find out more about the program numbers refer to the DIR command in the ACL Reference Guide 1 STA Runs the robot homing program STA which calls the homing program STB Make sure the robot is in a safe and suitable position before running this program Normally this will also cause the program CIM to be run ER CIM USER S MANUAL 9211 9502 Station Application Programs 9 13 2 CIM Runs all CIM ACL
195. red downloading directories The AutoCNC program running from the CNC station PC will access these files for downloading You are advised not to store the CNC programs at both the CNC station PC and the central CIM computer but if this is done both versions must be identical Note If you want to use a CNC program from another location such as a CAD program directory or diskette it must first be copied using the Get from Source option in the AutoCNC file handling utility which will automatically place it in the proper downloading directory CNC Station PC The downloading directory for each machine is defined as follows C CNC Ss Mm where s is the station number and m is the machine number For example if station 3 contains two CNC machines the CNC programs will be found in the following locations for machine 1 C CNC S3 M1 for machine 2 C CNC S3 M2 Note When performing the initialization procedures for a station computer that will store CNC programs for automatic downloading to a CNC machine type MCIMS n CNC and press lt Enter gt where n is the number of the station Refer to the chapter Initialization and Setup Procedures ER CIM USER S MANUAL AUTOCNG 12 3 9204 9502 Central CIM Computer When CNC program files are stored in the central CIM computer the files for each CNC machine must be located in the following directory H CNC Ss Mm where s is the station number and m is the machine number
196. ressing F1 will usually let you enter another order s ID number Note that this selection has nothing to do with the selection of an order for downloading In this section the term select refers to order entry selection Order Entry Screen To define or view an order you have to select it by entering its ID number After you have selected an order you can modify or view it An order can contain up to 40 lines Thus you can specify up to 40 different parts in an order You can view only ten lines of an order at a time Use the lt PgDn gt and lt PgUp gt keys to scroll the lines up and down ER CIM USER S MANUAL PROD 5 9 9204 9502 Order y Order entry Priority 1 Order date 15 701 91 Delivery date 15 01 91 t e 3 gt 3 ak 2 3 o i Lamp Lamp cover Pb Pp LE Fi Select an order F5 Report F2 Save current order PgUp PgDn Scroll up down F3 Delete current order Esc Previous menu Figure 13 Order entry Screen The information in this screen is Order Priority Order date Delivery date The number of the selected order The priority of the selected order The priority is a number between 1 to 10 1 is the highest priority 10 is the lowest This field will be used later for the MRP Material Resource Planning analysis Date order was entered Planned date for order delivery This field will be used later for the MRP Material
197. roceed to section 6 Note the following instructions apply only to the standard LAN software used with the ER CIM cell If your cell has a LAN the Ethernet LAN Main Functions menu will appear If you are entering this menu for the first time only the option Control Directory Maintenance will appear If this is not the first time this menu has been entered the full Main Functions menu screen will appear If you do not want to change the setup press lt Esc gt to exit the program and proceed to section 6 If this is the first time you are entering this menu or if you want to change the LAN setup select the option Control Directory Maintenance and press lt Enter gt The Control Directory Maintenance menu will be displayed Choose Create Control Directory and press lt Enter gt To create the default control directory C LANTASTI NET press lt Enter gt You will return to the Control Directory Maintenance menu Press lt Esc gt to return to the Main Functions menu 1 2 Installation ER CIM USER S MANUAL 9308 9502 Choose Individual Account Management and press lt Enter gt You will see a list of the current users Press lt Ins gt and a window will open up prompting you for a user name Type USER and press lt Enter gt When prompted for the user s password press lt Enter gt When prompted for the user s description press lt Enter gt When prompted for the number of concurren
198. s A number of sample application files have been added to the directory H CIMSYS ST These files have the extension SMP Refer to the section above USERn DNL for details on using the sample files XX ER CIM version 1 84 UPDATE ER CIM USER S MANUAL 9407 9502 ACL Central CIM Controller New Variables RELTM QCFLG MAPIX Following a not found message from ASRS the wait time before the next attempt to get material from ASRS in hundreths of a second 3000 default 0 do not try again 1 uses results of a quality control inspection default 0 assumes part has passed quality control inspection 0 production orders are executed only after a start production command is entered default 1 all production orders are executed as soon as received ACL Station Controller New Variables For program WTMn n machine number TASKn INFOn RESn read only same as in previous versions Read Write User defined information about the part which remains associated with the part throughout processing Write only Result of a quality control inspection 0 part passed inspection default 0 user defined value part failed inspection system then activates commands for removing part from production process to rejection box and releasing another part instead For program FB and RJCT RESUL If part rejected RESUL receives value of RES ER CIM USER
199. s issued as shown below An example of a purchase order is given in Figure 5 Report Date 30 05 91 Purchasing order 25 To ACME Plastic Co 99 Somewhere St Anytown NA Item 1 Item name Plastic 10 10 2 Quantity 60 Price per unit 12 50 Total price 750 00 Delivery time 2 days Date 30 05 91 Purchasing order 26 To ACME PArt 6 Company PgDn PgUp Move Page 4 1 Move Line Home End Start End Esc Quit Figure 5 Purchase Order Report ER CIM USER S MANUAL MRP 7 9 9204 9502 Fulfill All Production Orders The second option is to fulfill all production orders The MRP software accesses the CIMDEF database to determine the total production order requirements and the ASRS database to check the quantities in stock The program uses this information to generate raw material purchase orders to satisfy all production requirements When this option is chosen the next window to appear on the screen asks the user whether to write the purchase orders to the screen to a file or to the printer Report Destination Screen Printer If the file option is chosen you must specify the file name Enter file name without extension raw Enter a name with up to eight characters Do not add any extensions the program automatically adds REP to the name entered Remember that all reports generated by the MRP software have this extension Fulfill Selected Production Orders The third op
200. ser should not write them When the activity to be performed does not involve a machine the system software activates programs TOM1 WTM1 and FM1 in turn TOM contains robot commands to perform the desired manufacturing process FB Takes part from template located at buffer number BFR TOB Returns part to template located at buffer number BFR 9 10 Station Application Programs ER CIM USER S MANUAL 9211 9502 TOM1 TOMn n 2 4 WTM WTMn n 2 4 FM1 FMn n 2 4 Usually this program takes a part to machine number 1 and inserts it When CNC machines are used this program commands activities such as door and vice opening If the task does not involve a machine this program will contain sections of code with robot commands and the value of the variable TASK will be used to direct the program flow to the code for the required task If you are using AutoCNC for automatic downloading of programs to the CNC machine you may need to use the program WTLn as described in the following section Programs Required for Assembly and Other Advanced Tasks This program uses the variable TASK1 Similar to TOM1 but takes part to machine number n if present at the station and inserts it Uses the variable TASKn Since this program operates the robot only one TOMn program may run on the controller at any one time Activates machine number 1 and waits for it to complete its task This program uses the variable TASK1
201. spex block Processed by a CNC mill to make a decorative base for the chess piece A hole is made in the base to hold the chess piece The two processed parts can also be assembled to create a finished product the chess piece set in the decorative base Part Numbering Systems In the ER CIM system each raw material is given a part number When a raw material is processed it becomes a processed material and uses a different part number An assembly comprised of two or more processed materials requires its own part number 9 18 Station Application Programs ER CIM USER S MANUAL 9211 9502 In this application part numbers are grouped into families of 10 parts Within each family all parts have similar geometry and can be handled using the same set of robot positions Each part family is assigned a number stored in the variable ID For example part family 1 contains parts 1 9 and part family 2 contains parts 10 19 Hence part 7 has a part ID of 1 and part 11 has a part ID of 2 In families 1 and 2 in this application the lowest part number in the family is assigned to the raw material and the remaining numbers are used by processed materials derived from this raw material This assumes that changes in part geometry due to processing will not require new robot positions in order to handle the part For example consider part family 1 Part 1 is the raw aluminum rod before processing and part 2 is the rod after it has be
202. ssage Pressing Y erases the New Machine window from the Configuration screen If Level 2 is chosen after pressing lt Ins gt from the Configuration screen the Machine definition window will be displayed on the screen as shown in Figure 5 4 8 RSNET ER CIM USER S MANUAL 9204 9502 NEW Name Alt name Connected at stat Connected at port description MACHINE ion number 2 Figure 5 Machine Definition Window Level 2 connection This is a description of a machine located at one of the stations The following fields must be entered Name Alt name Connected at station number Connected at port description Name of machine up to 8 letters may be used Alternate machine name up to 8 letters may be used If AutoCNC software will be used be sure to use the required names as specified in the chapter AutoCNC Software User s Guide Number of station at which the machine is located Number of port on station switcher to which machine is connected Be careful not to use the number of the port connected to the central CIM switcher Two line description of the machine This text is displayed in upper left corner of the screen when this element is selected highlighted The gt lt TJ keys are used to move between fields All changes must be followed by lt Enter gt or they will not be saved once you move to the next field ER CIM USER S MANUAL 9204 9502 RSNET 4 9
203. t F2 gt Delete file lt F3 gt Catalog lt F4 gt Catalog of source lt F3 gt Main menu lt Esc gt RSDNL Copy the selected files to the downloading directory for the specified machine Copy the selected files from the downloading directory to the source directory Delete the selected file s Warning Do not use wild cards to specify files to be deleted List selected file s in the downloading directory List the selected file s in the source directory Return to the main AutoCNC menu Selecting RSDNL from the main AutoCNC menu accesses the RSDNL software This allows you to change the information stored in the RSDNL options file such as the CNC file extensions When using RSDNL in combination with AutoCNC the RSDNL target device is a switcher The options file contains the transmission parameters required for the switcher and should generally not be changed It is possible however that you may need to change the following parameters delay after byte This option is intended to compensate for differences in the Baud rate used by the switcher and the CNC machines You must enter a delay time in milliseconds The recommended value for the EMCO CS5 and Fl is 37 assuming that their baud rate is 300 If no delays are required by the device enter 0 12 10 AUTOCNC ER CIM USER S MANUAL 9204 9502 delay after lt CR gt This option is intended for CNC machines such as EMCO C5 and F1
204. t logins for this user type 10 and press lt Enter gt You will return to the list of current users You can add additional users if desired Now press lt Esc gt to return to the Main Functions screen Choose the option Shared Resources Management and press lt Enter gt The Shared Resources Management screen will display the path C LANTASTI NET Press lt Ins gt You will be prompted for a resource name Type CIM and press lt Enter gt Next you will be prompted for the server s true path a true path does not contain virtual directory names Type C CIM and press lt Enter gt This information will be added to the Shared Resources management table Press lt Esc gt to return to the Main Functions menu then press lt Esc gt again to exit the program 6 Remove the diskette from drive A 7 If you have received a special ASRS diskette insert this diskette into the A drive of the central CIM computer From the A prompt type UPDATE and press lt Enter gt 8 Remove the diskette from drive A 9 Turn off the computer and then turn it on again Central Station Second or Third Computer Program Installation 1 Insert diskette CIM 1 into drive A ER CIM USER S MANUAL Installation 1 3 9308 9502 Make sure the DOS prompt is A Type MCIM 2 and press lt Enter gt All files will be copied to the hard disk To initialize a third central station computer type MCIM 3 and press lt E
205. t of function key menu Exit the program This will bring you to the WIZCON options menu Choose the exit option to get back to the DOS shell Run the login sequence Not used in the current version The function keys that call up new screens are described in the following sections ER CIM USER S MANUAL Graphic Tracking 8 3 9207 9502 The Stations Screen Pressing F2 from the CIM_CELL screen calls up the Station Definition screen shown in Figure 2 station no 1 station no Z station no 3 station no 4 station no 5 station no 6 station no station no 8 Figure 2 CIM Graphic Tracking Station Definition Screen The conveyor is divided into 32 numbered sectors starting with sector 1 in the upper right side and progressing counterclockwise around the conveyor The yellow letters st on the periphery of the conveyor indicate that a station is located at that sector The left side of the screen contains a table of the stations and their locations Up to eight stations are allowed on the conveyor If less than eight are used those not in use are listed as being located at sector 0 In the example shown in Figure 2 stationsl 4 are in use and their locations are listed The remaining station locations are listed as 0 8 4 Graphic Tracking ER CIM USER S MANUAL 9207 9502 The function key menu is displayed at the bottom of the screen FS Define a station location on the conveyor F9 Return to the CIM_CELL screen T
206. tation PC Eo e306 Xo eee eae Eee ee ee eS 12 3 Central CIM Computer a4 4 a we we a 12 4 CNC Program Names Extensions and Suitability 2 12 4 Setting Up the Controller to Use AutoCNC 2 2 a 12 5 ER CIM USER S MANUAL 9502 xi Running the AutoCNC Software 12 5 Activate Progra sica AS GA aS ecg oe Gee Ben wh a te 2 cd 12 7 File to Task Assignment e A ot ate fe AA A 12 8 File Handling as ao ge lo tees E OCS Gp a Gera be oe AS 12 9 ESDND 56 dar doi te ah ale ae ot Ge ein as butte WE ylides we Sn Gh A OS 12 10 RSNET sm cage Oi E HB ee He BS ho A e Se He i A ES 12 11 EXI e rr ah Ga So gt oa al Be Ht ada A gt ae ah a ay 12 11 CHAPTER 13 ACL Report and Reset Programs o o 13 1 ACL Report Programs ae fb ead Oa See eee we Be wee eS 13 1 Main Controller Reports 22 de ae ee Se ee da 13 1 Station Controller Reports 2 2 e 13 2 The Restr Propra ri a ra ein a eS e ed 13 2 APPENDIX A CIM Communication Network lt lt eee eee A 1 Input Output Connections 2 a a a A 1 Point to Point RS232 Connections o A 1 Switched RS232 Network 053 4 24 ak ac DOS A 2 Ethernet LAN soe 2 6 ok eR oe A AS E A AE a A 2 CIM Production Communication Sequence A 3 APPENDIX B CIM RS232 Communication o B 1 Point to Point RS232 Connections o B 1 Swi
207. tched RS232 Network 2 2 2 B 1 APPENDIX C CIM I O Connections gt 2 4 S04 ar a ee ge See Ek C 1 Conveyor Programmable Logic Controller C 1 Maim Controller sta sie BP e el Bal abe AA C 1 Station Controller 2004 sk bole A Ge Ble Gene Se we Ve Be ee eG C 1 PIC TVO Wy ani ad lwo wwe e Ge AG he a pial at BA C 2 PLC VO WINS ova 0 E wh xe Bo a A A A ee SD C 3 Central Controller I O Wiring 2 2 2 ee C 4 Station Controller I O Wiring 2 1 o C 5 Suggested Wiring for Station n 2 2 0 0084 C 5 Suggested Wiring for Station with EMCO F1 02 2 C 6 Station with Controller A 2 e C 6 Station with Controller B Yoo pl el a a C 6 EMCO F1 Machine Setup e o as A we a Gl C 6 xii ER CIM USER S MANUAL 9502 Suggested Wiring for Station with EMCO Compact5 C 7 Station with Controller A ee C 7 Station with Controller B a a 1 ee o C 7 EMCO Compact 5 Machine Setup 0040 C 7 Suggested Wiring for Station with EMCO VMC 100 2 2 C 8 Station with Controller A 2 2 aa ee e C 8 Station with Controller B a a 2 ee C 8 EMCO VMC 100 Machine Setup 2 4 C 8 Software Configuration Parameters 204 C 8 Hardware Preparations aia oi gece gy ee eR wt a eS oe C 9 Suggested Wiring for Station with EMCO 120P 2 22 C 10 Station with Controller A 2 2 ee ee C 10
208. te which is on a Buffer 6 17 ASRS Robot Positions for Removing a Template from the Carousel 6 18 ASRS Robot Positions for Removing a Part from a Feeder 6 18 ASRS Carousel Positions cate aoe ri ee Ke ee eS 6 19 CHAPTER 7 MRP Material Resource Planning Software User s Guide 7 1 Introduchon e a a eee 7 1 Activating the MRP Program 7 1 Common Features lt x s sosa soes o ae a PE 7 2 Reports and Production Orders 2 2 7 3 Raw Material Information e 7 4 Raw Material Purchase Order o a 5442 2588 taa ea 7 7 Satisfy Minimum Stock Quantity 2 2 e 7 8 Fulfill All Production Orders 2 2 een 7 10 Fulfill Selected Production Orders 2 a ee 7 10 Order Number s i s val eri BQ b be Se Se ee es 7 11 Wale E Bo ah te Ss es a A ae ee 7 11 Priority 2 clack o EA E A Se 7 11 Queries and Reports ue ib ae a a a a a 7 12 Production Order Validity Report 7 12 viii ER CIM USER S MANUAL 9502 Inventory Reports oti do A dr E ace Soe Ph e a E Raw Material Production Requirements Queries Order Number S o 2 a e aa gt ag h DIS a a BR A OS Be oe pa A ws O AR eG a O A File Manager os Uo ate EA A e a EE Ge o EGE PIG Age ty ie hc A aaah eros Meee Ea E at ate a ott CHAPTER 8 CIM Graphic Tracking Software User s Guide Introduction 2 areen mop a Ee A e S
209. the current versions of the CIMDEF and CIM ACL system programs this station should be the same as the Assembly station Updated automatically according to the target station definition User remarks for this part The Order Entry menu lets you enter view or modify orders Orders are numbered from 1 to 1000 thus up to 1000 different orders can be defined at a time You can define even more orders by using other order entry files refer to the File Manager section for more details To define or view an order you must select it enter its ID number After you have selected an order you can modify or view it Each order can contain up to 40 lines thus you can specify up to 40 different parts in one order 3 12 CIMDEF ER CIM USER S MANUAL 9204 9502 Order entry Order Priority Order date Delivery date ll _ lt 3 H a 2 3 O OO H o Fi Select an order F5 Report F2 Save current order PqUp PgDn Scroll up down F3 Delete current order Esc Previous menu Figure 15 Order entry Screen The information displayed in this screen is Order The number of the selected order Priority Define the priority of the selected order The priority is a number between 1 to 10 1 is the highest priority 10 is the lowest This field will be used later for the MRP Material Resource Planning analysis Order date Date order was entered Delivery date Planned date f
210. the positions from the controller s memory it will be downloaded to the station n controller during initialization Barcode Scanner Programming Setup Make sure the barcode scanner s internal programming has been setup as described in the appendix Preparing the LS 6x20 Barcode Scanner for Operation 1 8 Installation ER CIM USER S MANUAL 9308 9502 CHAPTER 2 The CIM Menu The CIM Menu allows direct access and activation of all available CIM software ER CIN Computer Integrated Manufacturing Version 1 72 Copyright C 1992 Eshed Robotec Main menu CIN definition Production ASRS MAP Reports Graphics menu Communication menu Setup menu Exit 47t Pick option Enter Activate option Figure 1 Main CIM Menu Activated from Central CIM Computer Use the arrow keys to highlight each field and lt Enter gt to make your selections Or simply press the appropriate function key If you activate CIM from a secondary central CIM computer or a station computer that is connected to the Ethernet LAN some options will be displayed within parentheses and you will not be able to select them This is discussed in the section Using the CIM Menu at a Secondary Central CIM Computer or a Station Computer From the main menu selecting the following function keys activates the various CIM software modules Fl Activates CIMDEF Software CIMDEF is used to set up the CIM structure materials processes and orders
211. tion It is used by the Station Setup Initialize controller option xx 5 5plus 7 9 14 MK2 the type of robot Replace the existing file in the directory with the PARxx CBU file from the ATS diskette which was supplied with the robot installed at the station If you change the controller parameters for example when accessories are added backup the newly established parameters to the file PARxx in the directory H CIMSYS ST n ER CIM USER S MANUAL ER CIM version 1 84 UPDATE Xix 9407 9502 CONFIG ACL This file contains the station controller configuration It is created by Station Setup Station setup definition and used by the Station Setup Initialize controllers to configure the controller You may make changes to this file However you will lose these changes the next time you use Station Setup Station setup definition unless you have locked the file To protect your changes do the following 1 Change the current directory to H CIMSYS ST from the H gt prompt type STATION 2 Make the CONFIG ACL a read only file type LOCK n where nisthe station number To change the CONFIG ACL back to a read write file type UNLOCK n REPORT DLD This file is created during each controller initialization All data sent to and from the controller during the initialization is recorded in this file in order to facilitate troubleshooting in the event of a failed initialization Sample SMP File
212. tion includes a quality control inspection these variables can be used to mark the parts and to inform the system what to do with the part when it is unloaded from the buffer for example TASK The machine task which will perform the subprocess STATUS The status of the buffer The possibilities are EMPTY No template on the buffer WAITING Waiting for work in the machine to be completed IN MACHINE Template on the buffer is waiting for the part in the machine DONE Work on the part in the machine is finished EMPTY TEMPLATE The frame in the lower portion of the screen provides a description of all the activity at the station MACHINE 1 STOPPED ROBOT PUTTING TEMPLATE ON PALLET PALLET 4 IN STATION In this example only one machine is located at this station 10 18 REPORTS ER CIM User s Manual 9209 9502 MACHINE The currently activity of each machine at the station The possibilities are STOPPED WORKING TURNING The part in the machine is being turned around LOADING PROGRAM Machining programs are being downloaded from a computer to the machine ROBOT The current activity of the robot at the station Many messages are possible They describe the movement of the robot in taking and returning parts and templates to and from the pallets buffers and machines A few examples are GETTING TEMPLATE FROM PALLET PUTTING TEMPLATE ON BUFFER ASSEMBLING PART LOADING PART TO MACHINE
213. tion is to fulfill selected production orders Issue Purchase Orders Menu To satisfy minimum stock quantities To fullfill all production orders This will issue separate purchase orders to ensure sufficient raw material to produce a range of orders selected according to the following criteria e production order number e production order date e production order priority The MRP software accesses the CIMDEF database to determine the production order requirements for the selected range and accesses the ASRS database to check the quantities in stock This information is used to generate the purchase orders 7 10 MRP ER CIM USER S MANUAL 9204 9502 When this option is chosen the following window asks the user to choose the selection criteria By priority Order Number When a selection according to order number is chosen the next window asks for the range The default values of 1 to 1000 will always appear Change these numbers to suit your needs pressing lt Enter gt after each change In the example shown below a range of 1 to 20 was entered Enter order range From 1 To 20 Date When a selection according to date of production order is chosen the following window asks for the range The default for the start and end of the range is the current date Enter suitable dates pressing lt Enter gt after each entry Enter date range From 02 06 91 To 02 06 91 If the dates you entered are not accept
214. tral controller transmits data such as part ID task to perform machine to use When production starts the central controller also uses point to point connections to give commands to the ASRS for raw material inflow station During production each of the station controllers communicates with the central controller for real time on line production commands and updates RS232 peripherals such as the barcode unit may also be connected in this manner for immediate on line communication Switched RS232 Network The switched RS232 network allows the operator from one computer to fully interact with any station or machine in the CIM cell This communication network links all elements of the cell starting from the central computer and reaching all stations and machines including CNC and robot controllers During the development of various station programs the switched RS232 network allows the central computer to work with selected machines It is then used for preloading the machines with production data and for downloading production commands and programs The following diagrams describe the various RS232 communication connections ER CIM USER S MANUAL RS232 Connections B 1 9204 9502 STATION are T STATION CONTROLLER CENTRAL DESK maln computer STATION Ml CONTROLLER STATION 3 CONTROLLER STATION 4 STATION 5S Legend Figure 1 Direct Controller RS232 Network crossed par
215. used to select an option from a menu In most screens pressing lt Enter gt activates your choice Alternatively you can select and activate an option by pressing the corresponding function key listed in the menu In screens that require you to supply information in a number of fields you must press lt Enter gt after each entry or the previously saved value will remain Pressing lt Enter gt also moves the cursor to the next field To simply move the cursor between the fields use theT and J keys When a report option is listed at the bottom of the screen it is activated by pressing lt F5 gt Pressing lt Esc gt returns you to the previous screen 7 2 MRP ER CIM USER S MANUAL 9204 9502 Reports and Production Orders The MRP software allows you to generate various types of reports and purchase orders Each time you activate one of these options the following series of screens will appear 1 Ifa partial report is available the first menu will ask you to choose between a full and a partial report as shown below When a partial report is chosen the next window prompts you for the range The particular range depends on the type of report you have requested In the example below a raw material information report was requested and the user is prompted for the range of part numbers Type of Report Partial Full Enter raw range From 1 To 1000 2 The next window or the first if a partial report is n
216. ve position CIM 1 In some cases however the relative definition may cause these positions to be out of the robot s range of motion If this problem occurs record these positions as absolute positions Backing Up Positions to Disk After recording station positions you should always backup the positions using the Backup Controller Points option in the Station Controller Setup This will ensure that the next initialization includes the updated positions Part Manipulation Programs The application programs for each station must include the programs that follow The ER CIM system activates these programs at run time to transfer parts between the buffers and the machines at each station The programs should be written by the user at a PC using the ACL Off Line tool and copied into the USERn DNL n station number files in the directory H CIMSYS ST at the central CIM computer Once the programs are written you must initialize the station controller as discussed previously If they suit your needs you can copy the programs contained in the files USERx SMP x LATH MILL ASSM as given in the section ER CIM Sample Applications These programs may be modified to suit your application The user may also write additional programs as needed The programs should refer to the buffer number stored in the global variable BFR Note The programs WTLn and SFLPn exist as system programs and are available for the user if required The u
217. y after you have selected an order You are prompted to confirm whether or not you want to continue Production setup menu Select production order Download production data Verif Are you su Figure 7 Pre downloading verification Window After you press Y Yes to confirm PROD starts to process the selected order and the data associated with it and to compile the production data to be downloaded Production setup menu Select production order Download production data Status Processing line 03 of selected order Figure 8 Processing order Status Window 5 6 PROD ER CIM USER S MANUAL 9204 9502 If an error occurs during the processing stage an error message will be displayed and the processing and downloading will stop If this happens note the line number which was being processed when the error occurred and the nature of the error To correct such an error you will have to correct your order or sometimes exit PROD and enter CIMDEF to adjust the associated definitions Production setup menu Select production order Download production data Status Processing line 01 of selected order Part 1 is Figure 9 Error while processing an order Message Figure 9 shows an example of an error that can be corrected from within PROD Changing the part number in line number 1 of the selected order will correct this error When downloading begins a status window will appear showing the percentage

ER-CIM - intelitek

Contents

Download Pdf Manuals

Related Search

Related Contents