1.

0 INTRODUCTION

Since the dawn of civilisation, man has been continuously trying to ease
and improve his work by developing better tools. This process started with the
development of stone tools and will culminate into development of a totally
automated factory. This factory would be able to do all the things associated with
a product, right from designing it to packaging. Since the human operator tends
to be the weakest link in the production process, the need for automation has
been felt throughout the industry. A Flexible Manufacturing System (F.M.S.) is a
part of this process and a step towards complete automation of the factory. This
system automates the metal cutting part of the product manufacturing. A F.M.S.
is a form of flexible automation in which several machine tools are linked together
by a material-handling system, and all aspects of the system are controlled by a
central computer.

2.0 OBJECTIVE

The objective of this report are :

• Know the bases of a Flexible Integrated Assembling System.
• Operate with a Flexible Integrated Assembling System.
• Know the theory bases of the electropneumatics.
• Identify and operate with sensors.
• Identify and operate with actuators.
• Analyze of the configuration and connections of controllers.
• Load and unload of controllers programs.
• Make and modify controllers programs.
• Understand and make technical documentation.
• Troubleshooting diagnosis and repair of different types.

1
STATION 7 ( FMS – 207)
3.0 SAFETY,HEALTH AND ENVIRONMENTAL DOCUMENTS AND
STANDARDS

GENERAL SAFETY PRECAUTIONS

• Once the process has begun, care must be taken to avoid adding pieces to, or
removing pieces from, the respective stores or pallets in circulation.
• In general, the stations should not be manipulated with whilst the machine is
running.
• When proceeding to the disassembly of the mechanism, do not leave any
pieces behind inside the main body.
• Under no circumstances must the protection and safety devices described
below be tampered with.
• If the stations have to be physically dealt with after a halt, to extract a fallen
piece. For instance, always press the emergency stop mushroom head down
until the intervention is completed. If some damaged element has to be
replaced, we must open either the sectionalising switch on the button pad or
the one the transfer unit, as circumstances require.
• In order to safeguard the cell components, care must be taken to stop foreign
bodies or obstacles from entering the stations.

PROTECTION AND SAFETY DEVICES

All the stations and the transfer unit are equipped with emergency stop
mushroom heads for stopping the process at any moment in order to prevent
accidents. If the emergency stop mushroom is used, once the incident that caused the
stop has been overcome, make sure, before reactivating the cell or station, that the
situation will not recur, by taking appropriate measures. Furthermore, it is advisable
to take away pieces that are in the middle of a cycle whenever possible. After freeing
the emergency stop mushroom it will be necessary to press button so that the
components return to their starting mode positions.

2
 There is also a pneumatic device at the general air input, which causes a
gradual increase in air pressure when the air is connected, thus avoiding accidents
produced by the sudden input of air in the circuit.
Stations 3 (press) has a protection fairing to prevent accidents occurring with
the press. It descends when the latter is working and goes up when the task is
finished.
Stations 7 and 8 (robot and store, respectively) there is a protection fairing
that covers the entire station. We must be sure that all the gates are closed before
running these stations. The gates should never be opened with the station running.

MAINTENANCE PROCEDURES

PNEUMTIC COMPONENTS

• In general, the pneumatic components of the FMS200 are lubricated for life
and there is no need to carry out any maintenance of this kind on them. It is
possible that, over a long period of time, the internal gaskets of the cylinders
may suffer from attrition. In this eventually, if the cylinder is detachable the
gaskets have to be replaced. If it is not detachable it will to be replaced by
another cylinder.
• It is recommendable every so often to carry out periodic bleeding of the water
that accumulates in the cell’s air conditioning units. The filter condensate
level should never go the maximum indicated on the filter bowl.
• If the filter pressure drop higher than a bar is detected, the cartridge filter must
be replace with a new one.

ELECTRICAL SHAFTS

The electrical shaft on station 8 require periodic inspection : after every six
months of continuous work or after a month at standstill. This inspection must
involve a check on the unit holding elements, such as screws and nuts, in case they
are loose. It is also necessary to clean the feed shaft with the right kind of grease,

3
moving the carriage backwards and forwards. The linear guide runners hav to be
greased as well, using an appropriate tool. Important Note : The grease used must not
contain fluorine.

CLEANING

For the periodic cleaning operations on the FMS200 a clean cloth that leaves
no fibre traces can be used, whilst it is not advisable to use any cleaning product, in
particular those containing alcohol, solvents or chlorinated compounds.

SAFEGUARDING

Safeguarding includes the use of safeguards such as interlocking guards,

awareness means in addition to the safeguards, and safe working procedures to
reduce the possibility of injury while performing an assigned task.
Here, the guidance on safeguards and awareness means are provided for customers to
check their safeguarding

SAFEGUARD

1. Fixed guards must be installed outside the maximum space of the robot.

2. Fixed guards must be constructed to withstand foreseeable operational and

environmental forces.

3. Set the fixed guard to prevent entry into the protection region (inside the safety
fence) from entrances other than those provided with an interlock device or presence
detection device. (So that an operator cannot climb over, go under or get the fence.)

4. Fixed guards must be permanently fixed in position and only be removable with
the aid of a tool.

4
5. Fixed guards must be free of sharp edges and projections and must not themselves
be a harzard.

6. The interlocking guard with guard should be designed so that the guard remains
locked until the guard is closed. The closure of the a deliberate action at the control
station.

7. The interlocking guard with guard should be designed so that the guard remain
locked closed until the risk of injury from the hazard has passed or that the guard
while the robot system is working gives a stop or emergency stop instruction. Where
the hazard cannot be eliminated immediately by power interruption, the interlocking
system must need to include a guard locking or a braking system.

8. When the operator’s entire body can enter the safety protection region (inside the
safety fence) from the door with interlock, install a device so that the door cannot be
closed unintentionally.

9. The interruption, re-establishment after an interruption of fluctuation in whatever

manner of the power supply to the safeguards must not lead to a dangerous situation.

10. Guard and protection devices must cause minimum obstruction to the view of the
production process.

11. Guards and protection devices must enables essential work to be carried out in
installation and/or replacement of tools and also for maintenance by restricting access
only to the area where the work has to be done, if possible without the guard or
protection device having to be dismantled.

12. Re-establishing the interlocked gate or presence sensing device field must not in
itself restart automatic operation.

5
13. A presence sensing device must be installed and arranged so that persons cannot
enter and reach into a hazardous area without activating that device or cannot reach
the restricted space before the hazardous conditions have ceased.

14. Barrier used in conjunction with the presence sensing device may be required to
prevent persons from passing the device.

15. The operation of presence sensing device must not be adversely affected by any
of the environmental conditions for which the system was intended.

16. Resumption of robot motion must require the removal of the sensing field
interruption. This must not be the control to restart automatic operation.

17. Where laser ray equipment or other harmful ray equipment is used, guards and
protection devices must prevent any accidental radiation as well as reflection and
diffusion that may damage health.

AWARENESS MEANS

1. An awareness barrier must be constructed and installed so as to prevent inadvertent

entry into the restricted.

2. An awareness signal device must be constructed and located such that it must
provide a recognizable audible or visual to persons of an approaching or present
hazard.

3. When awareness signal in the form of light are used warn of hazards in the
restricted space, sufficient devices must be used and located so that the lights can be
seen by all persons in the proximity of the space.

4. Audible awareness devices must have a distinctive sound of greater intensity than
the ambient noise level.

6
SYSTEM DOCUMENTATION

The robot system documentation to be supplied by the robot system

manufacturer shall contain the document of all the components included in the
system with their identification e.g. robot, associated equipment, safeguards. ( It shall
also as a minimum include the following :

1. A clear, comprehensive description of the robot system and its installation

including mounting and connection to external power resources.

2. A description of foreseeable hazardous conditions and how to avoid them.

3. A description including interconnecting diagrams (of the safeguards, interacting

function, and interlocking of guards with hazardous conditions particularly with
interacting installation.

4. Any further instructions for use specific to the system.

TRAINING

Personal who perform maintenance or repairs on robot systems must be

trained in the procedures necessary to perform safely the required tasks.
Therefore, the user must have an inspection and maintenance program and ensure
those personnel are adequately trained and demonstrate competence to perform their
include, but is not limited to, the following:

1. A review of applicable standard safety procedures and the safety

recommendations of the robot manufacturer (s) and the robot system designers.

2. A clear definition of assigned tasks and responsibility of each person.

7
3. Identification and explanation of all control devices and their functions used in
performing the assigned task.

4. Identification of the hazards associated with the assigned task.

5. The designated method (s) of safeguarding including the safe working procedures
from the identified hazards.

6. The method for testing or otherwise ensuring the proper functioning of the
safeguards and interlock.

4.0 PROCESS AND LAYOUT INFORMATION

PROCESS INFORMATION

The seventh FMS-200 station integrates robotics as technology which is

widely used in automated environments. In this case, a robot is used to screw in the
four bolts supplied by the previous station. The robot has a tool attached with a
pneumatic gripper and an electric screwdriver and the station table includes two
warehouses for material (with capacity for 6 lids and 6 shafts in different materials,
colors and heights). These components allow the user to screw the four bolts in the
work in process as well as to carry out operations such as the change in material,
insertion and extraction of material in the assembly and the exchange of material
between warehouses. These applications give way to an extensive range of programs
for the robot's controlling unit thus extending significantly its didactic capacities.

8
THE INTEGRATION OF ROBOTICS

The control of the robot's movements is carried out using a controlling

element which can also be used to program the movements it has to carry out. The
programming is carried out from a PC with the robot's own software.

The station also has a programming console from which the commands must be
entered.

9
 In order to avoid risks from uncontrolled movements by the robot, the station
is equipped with a protection guard in its programming. We have a wide variety of
robot versions which can be customized to our clients' needs. Consult availability.

LAYOUT INFORMATION
Technical Data

Dimensions:
Table of slotted aluminum section, 900 x 540 Trim. Height 900 min.

Pushbutton control:
Start, stop, and reset pushbuttons. Emergency button and error pilot indicator.

Station elements:
MOVEMASTER EX MELFA RV-M1 MITSUBISHI 5-axis robot. Speed 2.1 m/s,
2500 storable positions, 0.02 mm accuracy, 10 speeds, 2 kg payload, 19 kg arm
weight, parallel (centronics) and series (RS-232) interfaces, 16 inputs (3 switches)
and 16 outputs, 1 emergency stop input.

Electric screwdriver 3.6 V.

Methacrylate screening for user protection.

10
Input/ Output module:
Device Net module 8 inputs/ 8 outputs.

Electrical control panel:

Mounted on perforated mesh 550 x 400 mm.
Accessible terminal plate with supply connections and coded I/Os.
Thermal overload switch incorporated.
I/0 station: 7 inputs/ 7 outputs.
Relay for screwdriver supply.
Supply source: 24V/ 0.6A.
Supply source: 5V/ 2.5A
MITSUBISHI robot driver.
MITSUBISHI robot programming console.
PLC Control:
Omron model CPM2C- S I I 0C-DRT
Digital Card 8 inputs CPM2C- 8EDC
Digital Card 8 outputs CPM2C- 8ER

5.0 FACTOR THAT INFLUENCE SAFETY, HEALTH AND

ENVIRONMENT
FACTOR/SYMPTOM

STATION 7
No Symptom Possible Cause Remedy
7.1 The station will 1.) The station is unplugged or 1.) Plug in supply
not start when the classroom is without voltage classroom with voltage.
the start button supply. 2.) Close the switch
has been 2.) Magnetic circuit breaker (ON), if it breaks again
pressed. open. when restarted the power
3.) The emergency stop button is installed is insufficient.
locked. 3.) Unlock emergency
4.) Line breaker open. stop button and press
5.) Cell unplugged. reset.
6.) Transfer unit magnetic circuit 4.) Shut down line
breaker open. breaker.
7.) The emergency stop button 5.) Plug cell in.

11
 on the transfer unit is locked. 6.) Close the transfer
8.) Cell air not connected or unit switch (ON), if it
transfer air valve is open. breaks again when
restarted the power
installed is insufficient.
7.) Unlock emergency
stop button.
8.) Connect air intake or
close transfer air valve.
7.2 The station will 1.) The station is not operating 1.) Press start.
not start when under start mode conditions. 2.) Unlock emergency
the start button 2.) The emergency stop button is stop button and press
has been locked and the station is not reset.
pressed and the operating under start mode
defect pilot conditions.
light on the
button pad is
blinking.
For faults associated with the robot consult the robot manual.

12
6.0 STRUCTURAL COMPONENTS

13
7.0 DIMENSION STRUCTURE

14
8.0 DETERMINE MOUNTING/CONNECTION FOR COMPONENTS/
ASSEMBLIES

HANDLING AND PACKAGING

The packing is designed to protect the modules from physical, chemical or

mechanical attack that might be produced during handling and transportation.

For transoceanic transportation, the packaging is treated with waterproofing

and dehydrating elements so as to provide protection against the effects of steam, salt
spray, dust and other external agents that might damage module components.

Details are given below of the packaging characteristics for each module :

BASE HEIGHT VOLUME

STATION 7 1000 x 700 2010 mm 1.407 m³

When handling, loading and unloading the packaging, it is advisable to

employ appropriate equipment such as lift trucks. Once unloaded the stations can be
transported by a minimum of two people, while the transfer requires a minimum of
four. The boxes must be kept vertical at all times and must, under no circumstances,
be piled one on top of another or have other objects placed on top.

When proceeding to unpacking, it is advisable to observe the following

procedure :

1. In the first place, make sure there is enough room to carry out the unpacking
process. We recommend, as a minimum, that there be a free surface area more than
three times the space occupied by each packaging.

2. Next, it is necessary to cut the straps that fasten the four seals at the bottom of
the box. These are then raised so as to be able to lift the lid.

3. Two or more people must raised the lid that covers the station and store it
where it will not get in the way of the following phases.

4. The next move is to loosen the wood pieces that secure the station to the
bottom of the packaging. The best idea is to loosen only the top pieces, as the station
can be extracted without freeing all the others: it can also prove useful to keep them
for possible transportation in the future. In this operation suitable tools will be
required for taking out the coach screws or nails that hold the wood in place.

5. When this operation is complete, the station must be transferred from the base
of the packaging on the floor of the space where the unpacking operation is taking
place : at least two people are required to do this. It is advisable to check that all the
components listed on the station delivery note are included.

15
6. The station has wheels, which means that it can be transported easily and
effortlessly to place where it will be used.

INSTALLATION

Individual Station

If there any individual, they come with a tray with a pallet for placing the
pieces. In order to avoid problems in the transportation process, the tray with the
supporting pallet for the piece to be assembled has been in the position indicated in
figure 1.

When installing the station, the tray has to be disassembled so that it can then
be placed with the pallet facing upwards, as shown in figure 2.

16
 The next step is to proceed to establish the electrical and pneumatic
connections for the station. Before doing this we must make that the classroom meets
the pneumatic and electrical requirements mentioned above.

For greater safety, it is wise to cut off voltage to the station using the isolating
switch on the button pad before any electrical connection is made. This is done by
connecting the station plug to the appropriate classroom socket.

In the same way, it is recommendable to carry out the pneumatic connection

with the station air tap turned off. A six-diameter pipe must be connected from the
classroom socket to the air treatment group intake for the station.

START-UP
STATION 7 (ROBOT) :

1. Carry out a visual inspection of the station to check that there are no elements
that might distort the functioning of the system.
2. Make sure that the fairing protection gates are closed.
3. The robot drive switch at the back of the unit and the magnetic circuit breaker
situated on the electrical control panel must be in the "on" position.
4. Set the cycle switch on the button pad to step-by-step mode.
5. Move the load switch on the button pad to the "on" position.
6. Check that the emergency stop mushroom head on the button pad is unblocked.
7. Press the reset button on the button pad to ensure that the process begins in
start mode conditions. Each time the process is halted, either during start-up or
during a cycle, if the station is not in start mode condition the defect pilot light
on the button pad will start blinking. In addition the drive unit error led lights
up accompanied by the sound of a buzzer.
8. When the start button is pressed the first step in the process will be executed.
Since we will be working in step-by-step mode, it will be necessary to press the
start button each time we wish to take a new step.
9. If any imbalance in the unit is detected, take appropriate corrective action and
repeat the cycle until it functions correctly. It is quite likely that slight
modifications have to be made to the robot's screwing movements so that it
performs its duty correctly. To do this the robot manual must be consulted.

17
 10. When the cycle is over, set the cycle switch on the button pad to continuous
mode. When the start button is pressed it will now execute an uninterrupted
cycle.
11. The process can be halted at any time by pressing the stop button or the
emergency stop mushroom head. If the latter is pressed, once it has been
deactivated it will be necessary to return to initial mode conditions (reset
button on the button pad and drive unit). After this we only have to press the
start button on the button pad.

PROCEDURE FOR USE

STATION 7 (ROBOT) :

1. Carry out a visual inspection of the station to check that there are no elemens that
might distort the system’s performance.

2. Ensure that the fairing protection gates are closed.

3. The switch at the back of the robot drive unit and the magnetic circuit breaker on
the electrical control panel must be in the ‘ON’ position.

4. Set the cycle switch on the button pad to the desired mode.

5. Move the load switch on the button pad to the ‘ON’ position.

6. Make sure that the emergency stop mushroom head is unblocked.

7. Press the reset button on the button pad to ensure that the process will begin in
starting mode conditions. Each time the process is halted, whether during start-up or
during a cycle, if the station is not in starting mode conditions the defect pilot light
on the button pad will start blinking. In addition the unit’s drive error led will light
up, accompanied by the sound of the buzzer.

18
8. If the continuous cycle has been selected, when the starter button is pressed the
cycle will be executed. If we are working in step-by-step mode, it will be necessary
to press the starter button each time we wish to perform a new step.

9. The process can be halted at any point by pressing the button or the emergency
stop mushroom. If the mushroom head is pressed, once it has been deactivated it
will be necessary to return to starting mode conditions (reset button on the button
pad and the drive unit). Afterwards it will e sufficient to press the starter button on
the button pad again.

9.0 PART LIST AND PART NUMBER

• ATORNILLADOR ELECTRICO REF : BLACK&DECKER KC9019 3.6Y,

180 rpm
• (1x) END WERA 840-4Z 5X50
• 243 (2X) SCREW ALLEN DIN 7991 M5X15 CINC.
• 244 (2x) SCREW ALLEN DIN 912 M5x30 CINC.
• 242 (4x) SCREW ALLEN DIN 7991 M3x30 CINC.
• ROBOT MITSUBISHI REF : RV-M1
• (4x) TORNILLO ALLEN DIN 912 M8x30 CINC.
• (4x) ARANDELA DIN 125 M8 CINC.
• (2x) TUERCA M8 REF : F-13

19
10.0 WORKSPACE LAYOUT (AIR/ELECTRICAL)
* Refer to the next page of this report*

11.0 TECHNICAL DRAWING

* Refer to the next page of this report*

12.0 CONCLUSION

The seventh FMS 200 (FMS 207) station integrates robotics as technology
which is widely used in automated environments. It help increase more productive
automation industry by saving more energy (people) to do work in production line.
By learning mechanical structure design of this components, will help workers or
technician of using this robotics for more efficiency and safety use. Without any
knowledge about this station may cause a lot of problem when using it.

20