Project 3: Assembly, programming and commissioning of a production line with Handling station withelectrical drive and magazine and Turning station

Transcription

1 Project 3: Assembly, programming and commissioning of a production line with Handling station withelectrical drive and magazine and Turning station Weighting (points out of total) 41/100 time max 360 min Szenario You are responsible for the delivery of a production line purchased by a customer in China to be used in the partial automation of its production process. Task Assemble, wire and tube the production line on the profile plate according to the documentation. Develop a program and commission the production line. Your task is complete when: 1. The production line has been mechanically assembled, correctly wired and connected and its correct operation is guaranteed (based on evaluation using the simulation box). 2. Correct execution of the program with PLC activation (based on evaluation/plc board) is guaranteed. 3. The system meets the specifications (in accordance with the 'Agreement on Professional Practice'). The system will be sent to China as soon as you are finished. You will have no opportunity to make improvements later. WorlSkills Germany Mechatronics Competition

2 Production line layout: Handling station 2 Turning station Initial position: No workpieces at the system Handling Staiton Magazine ejector retracted (Cylinder extended) Gripper unit over magazin, Gripper open, Gripper up Turning Station Conveyor off Stopper extended Gate open Gripper module at slide position and up Gripper open, Gripper is turned clockwise (regarding from the actuator side) turned clockwise WorldSkills Germany Mechatronics Competition

3 Details Turning station: 3 A WorldSkills Germany Mechatronics Competition

4 Conveyor (1), Sensor for checking the orientation (2), Stopper (3), Turning module (4), Slide small (5), Gate (6) Details: Opt.Sensor (2) Stopper (3) and Turning module (4) B Stopper (3) Gate (6) A WorldSkills Germany Mechatronics Competition

5 Turning module: turning unit Gripper Input terminal Output terminal / Valve terminal Swivel - linear cylinder WorldSkills Germany Mechatronics Competition

6 Adjust the stoppers behind the cover Position for sensors WorldSkills Germany Mechatronics Competition

7 Screws to adjust the stoppers (fine-tuning) Lock screws Angle of the orientation sensor WorldSkills Germany Mechatronics Competition

8 Swivel - linear cylinder One cylinder with 3 possibilities. Select the right one for the application swivel linear movement of 90 in a clockwise direction (Fig. 2) swivel linear movement of 90 in an anti clockwise direction (Fig. 3) linear movement (with CLR to CLR 63..., see Fig. 4). Fig. 2 Fig. 3 Fig. 4 F Guide bolt for motion control of the linear and swivel movements 1. Unscrew and remove the guide bolt. 2. The piston rod can then be turned freely to the desired groove. 3. Screw the guide bolt in again. WorldSkills Germany Mechatronics Competition

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10 According to the colour and the orieentation the workpiece will be transported to different positions. (A), (B), (C) Separating Turning Position A (Conveyor end) Position B (Slide at Turning module) Position C (Slide small) Red, silver X Red, silver X X black X black X X transparent X transparent X X Control panel Start lamp Start button Stop button Reset lamp Reset button Q1 Q2 Auto Man WorldSkills Germany Mechatronics Competition

11 Motor controller: A1 : move to right side / A2 : move to left side 1, 2 : Motor VCC: 24 V / GND: 0V A3 and I-OUT are not used WorldSkills Germany Mechatronics Competition

12 Wireing of the control panel Additional wireing for extra signals to - X7 (pin 5-8 Input; pin Output) Outputs of the control panel Input oft he control panels WorldSkills Germany Mechatronics Competition

13 Pin allocation for 15-pin Sub-D Valve Terminal PIN Core Colour Coil Output Function 1 White 0 5 Turn gripper anti- clockwise 2 Brown 1 6 Glose gripper Green 2 3 Move gripper unit up 4 Yellow 3 4 Move gripper unit down Brown green 0V 15 White - yellow 0V Pin allocation for 15-pin Sub-D Input Terminal Pin Core Colour M8 plug/ Pin Input Function White 0 / 4 5 Gripper unit is up 2 Brown 1 / 4 6 Gripper unit is down 3 Green 2 / 4 7 Gripper is turned anti-clockwise 4 Yellow 3 / 4 4-CP Gripper is turned clockwise 5 Grey 4 / 4 6-CP Gripper is open 6 Pink 5 / 4 7-CP Gripper is closed 7 Blue 6 / 4 Not used 8 Red 7 / 4 Not used White - green 0-7 / 1 24V DC 14 Brown green 0-7 / 3 0V 15 White - yellow 0-7 / 3 0V CP: Control Panel WorldSkills Germany Mechatronics Competition

14 Wireing of the I/O-Terminal in Turning Station Connector I/O Terminal (IN) Comment 1 signal if: Connector I/O Terminal (OUT) Commen 1 signal set DI 0 Part at belt input DO 0 Conveyor forwards DI 1 Part at optical sensor DO 1 Conveyor backwards DI 2 Part at belt end DO 2 Retract stopper DI 3 Orientation at optical sensor DO 3 Move gripper unit up DI 4 Part at stopper DO 4 Move gripper unit down DI 5 Gripper is up DO 5 Turn gripper anti clockwise DI 6 Gripper is down DO 6 Close gripper DI 7 Gripper is turned anticlockwise DO 7 Glose the gate Wiring of the control console X7 (see also circuit diagram) Anschluss E/A Terminal (IN) Kommentar 1 Signal angeben Anschlusse E/A Terminal (OUT) Kommentar 1 Signal geben DI 0 DO 0 DI 1 DO 1 DI 2 DO 2 DI 3 DO 3 DI 4 Gripper is turned clockwise DO 4 DI 5 DO 5 DI 6 Gripper is open DO 6 DI 7 Gripper is closed DO 7 No changes at the wireing of the Handling station WorldSkills Germany Mechatronics Competition

15 Evaluation sheet Project 3: Assembly, programming and commissioning of a production line with Handling station withelectrical drive and magazine and Turning station Team: Verification of acceptance by experts (names, signatures): _ Time max.: 360 min. Time: Points max.: 41 Description Evaluation Maximum evaluation Function to be checked using simulation box in the Handling station if there is not full function with PLC Done Max points (Output 0 7: Signal 1 or 0) Preparation: Insert a workpiece into the magazine, connect the simulation box to the I/O terminal. (Output 0 7: signal 1 or 0) Open gripper (Out 3: 1) 0,2 Eject workpiece from magazine (Out 4: 1) 0,2 Gripper unit to position magazine (Out 1: 0; Out 0: 1) 0,2 Retract ejecting arm (Out 4: 0) 0,2 Gripper down (Out 2: 1) 0,2 Close gripper (Out 3: 0) 0,2 Gripper up (Out 2: 0) 0,2 Gripper unit to position next station/slide 2 (Out 1: 1; Out 0: 1) 0,2 SimuBox Handling station 1,6 WorldSkills Germany Mechatronics Competition

16 Description Evaluation Maximum evaluation Function to be checked using simulation box in the Turning station if there is not full function with PLC Done Max points (Output 0 7: Signal 1 or 0) Preparation: Put on the belt, connect the simulation box to the I/O terminal. Station in Initial position ((Out 6: 1); (Out 4: 0; Out 3: 1) Transport workpiece to the stopper (Out 0: 1) 0,5 Conveyor of (Out 0: 0) 0,5 Retract stopper (Out 2: 1) 0,5 Move turning module to pick up position (Out 4: 1; Out 3:0) 0,6 Glose gripper (Out 6: 0) 0,5 Move turning module to slide (Out 4: 0; Out 3:1) 0,6 Open Grippper (Out 6: 1) 0,5 Extend stopper (Out 2: 0) 0,5 Put a workpiece on stopper and close the gate (Out 7: 1) 0,6 Transport workpiece tot he small slide (Out 1: 1) 0,6 Open gate (Out 7: 1) 0,5 Conveyor OFF (Out 1: 0) 0,5 SimBox Turnning station 6,4 SimBox total 8,0 WorldSkills Germany Mechatronics Competition

17 Description Evaluation Maximum evaluation Function check with PLC Done Max. Points Preparation: Remove all workpieces from the stations, connect the PLC boards to the I/O terminals and the control panels, switch key to the position AUTO, start the PLCs, no programming cable / WLAN between PC and PLC, valve for air opened, Handling linear drive between sensors, Turning module Gripper at position belt. Function START Signal lamp RED ON ** 0,4 Turning station Lampe Reset AN (Turning Station) Switch key to the position MAN (Turning Station) then signal lamp YELLOW ON ** Press Reset button (Turning Station) then system moves to initial position Lamp Reset OFF if system is in the initial position Switch key to the position AUTO (Turning Station) then lamp START ON (Turning station) Handling station Lamp Reset ON (Handling Station) Switch key to the position MAN (Handling Station) Press Reset button (Handling Station) then system moves to initial position Lamp Reset OFF if system is in the initial position Switch key to the position AUTO (Handling Station) then lamp START ON (Handling station) And signal lampe GREEN flashing with 1 Hz** Put a number of pots (min 6) into the magazine of the Handling station* as instructed by the evaluation team Press the START button (Handling Station) then lamp START OFF (Handling Station) (no movements) Press the START button (Turning station) then Signal lamp GREEN ON ** and lamp START OFF (Turning station) A: Eject workpiece if pickup position empty Transfer pot to the next station 0,6 WorldSkills Germany Mechatronics Competition

18 Partial points 5,2 If workpiece red or silver with hole Done Max. Points If workpiece red or silver with Done Max. Points on top hole down Transport to conveyor end Workpiece stops at stopper If workpiece at conveyor end*** then flashing lamp Q2 with mit 2 Hz (Turning station) Take of the workpiece from the belt by hand, then Q2 OFF Continue automaticaly with A: if the belt is free until the Magazin is empty The turning module pick up the workpiece The turning module turns the workpiece 0,4 The turning module put the workpiece back on the belt The turning module moves to its initial position 0,4 Transport to conveyor end If workpiece at conveyor end*** then flashing lamp Q2 with mit 2 Hz (Turning station) Take of the workpiece from the belt by hand, then Q2 OFF Continue automaticaly with A: if the belt is free until the Magazin is empty 0,4 Partial points 1,3 Partial points 2,9 If workpiece black with hole on top Done Max. Points If workpiece black with hole down Done Max. Points Workpiece stops at stopper Workpiece stops at stopper Glose gate The turning module pick up the workpiece Transport workpiece onto the small slide Continue automaticaly with A: if the belt is free until the Magazin is empty The turning module turns the workpiece 0,4 The turning module put the workpiece back on the belt The turning module moves to its initial position 0,4 Glose gate Transport workpiece onto the small slide Continue automaticaly with A: if the belt is free until the Magazin is empty 0,4 Partial points 1,3 Partial points 2,6 WorldSkills Germany Mechatronics Competition

19 If workpiece transparent with hole Done Max. Points If workpiece transparent with Done Max. Points on top hole down Workpiece stops at stopper Workpiece stops at stopper The turning module pick up the workpiece The turning module put the workpiece onto the slide The turning module moves to its initial position Continue automaticaly with A: if the belt is free until the Magazin is empty The turning module pick up the workpiece 0,4 The turning module turns the workpiece The turning module put the workpiece back on the belt 0,4 The turning module moves to its initial position Continue automaticaly with A: if the belt is free until the Magazin is empty 0,4 0,4 Partial points 1,7 Partial points 2,0 If pot magazine empty Q1 ON (Lamp at Control panel) 0,2 Ejecting arm retraced Gripper stops at basic position if the previous job is finished Lamp Start ON (Handling station) Signal lamp YELLOW flashing with 2 Hz ** Put a pot into magazine n Press the START button (Handling Station) then lamp START OFF (Handling Station) And signal lamp GREEN ON ** And Lamp Q2 OFF 0,2 And Continue with A automatically 0,5 ** At any time only one lamp of the signal column is on Partial points 3,0 PLC board total 20 * Red, black, silver or transparent workpiece will be chosen by the evaluation team. *** Stop at conveyor end max 1 mm WorldSkills Germany Mechatronics Competition

20 Description Evaluation Maximum evaluation Professional practice List of Professional Practice will be checked in samples PP item no. Not fullfiled * -1,0 * -1,0 * -1,0 * -1,0 * -1,0 Professional Practice total 5,0 * Each deviation will result in 1 points being deducted Description Evaluation Maximum evaluation Time evaluation (only if the maximum number of points is achieved for PLC board and simulation box function and at least 6 points for professional practice) Points for time = (max. time actual time) x max. points /(max. time min. time) = ( ) x 8 Points / ( ) 8 Total evaluation Project 3: Description Evaluation Maximum evaluation Points for operation based on simulation box 8 Points for operation based on PLC board 20 Points for professional practice 5 Points for time evaluation 8 Total points 41 WorldSkills Germany Mechatronics Competition