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DL-MPS901A Flexible Manufacturing System Training Instructions

Dolang Technology Equipment Co., Ltd.

Contents Chapter One DL-MPS901A flexible manufacturing system brief

introduction ............................................................................................2 Chapter Two DL-MPS901A flexible manufacturing system main

components introduction and application.............................................4


Section 1 Sensor ........................................................................................................................4 1.1 Sensor introduction......................................................................................................4 1.2 Common sensor introduction ......................................................................................5 Section 2 PLC .........................................................................................................................11 Section 3 Pneumatic Technology ............................................................................................42 3.3 Pneumatic actuator ....................................................................................................44 Section 4 Motor.......................................................................................................................57

Chapter Three Station Introduction....................................................58


Section 1 Distribution Station .................................................................................................58 1.1 Components Contents................................................................................................58 1.2 Module Contents .......................................................................................................59 1.3 Working Contents ......................................................................................................61 1.4 Training Subjects.......................................................................................................62 Section 2 Testing Station .........................................................................................................64 2.1 Components Contents................................................................................................64 2.2 Module Contents .......................................................................................................65 Section 3 Processing Station ...................................................................................................72 3.2 Module Contents...................................................................................................73 3.3 Working Contents.................................................................................................76 3.4 Training Subjects .......................................................................................................77 Section 4 Handling Station......................................................................................................78 4.1 Components Contents................................................................................................79 4.2 Module contents ........................................................................................................79 4.3 Working order............................................................................................................81 4.4 Training Subjects .......................................................................................................81 Section 5 Buffering Station .....................................................................................................82 5.1 Components Contents................................................................................................83 5.2 Module Contents...................................................................................................83 5.3 Working Contents ....................................................................................................85 5.4 Training Subjects .......................................................................................................86 Section 6 Pressing station........................................................................................................89 6.1 Component contents ..................................................................................................89 6.2 Module Content .........................................................................................................90 6.3 Working Contents ......................................................................................................92 6.4 Training Subjects .......................................................................................................93 Section 7 AS/RS Station..........................................................................................................94 7.1 Component Contents .................................................................................................95

DL-MPS901A flexible manufacturing system

7.2 Module contents ........................................................................................................95 7.3 Working Contents.................................................................................................97 7.4 Training Subjects .......................................................................................................97 Section 8 Robot Station...........................................................................................................99 8.1 Component Contents .................................................................................................99 8.2 Module Contents .....................................................................................................100 8.3 Working Contents ....................................................................................................102 8.4 Training Subjects .....................................................................................................103 Section 9 Sorting Station.......................................................................................................104 9.1 Components Contents..............................................................................................104 9.2 Module Contents...................................................................................................105 9.3 Working contents.....................................................................................................109 9.4 Training Subjects .....................................................................................................109

Chapter Four Operation Instruction ................................................ 111

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Chapter One DL-MPS901A flexible manufacturing system brief introduction


1. Describes DL-MPS901A flexible manufacturing system is composed of distribution station and testing station, processing station, handling station, buffering station, robot station, press station, AS/RS station, sorting station. Each station of this system is installed aluminum board with groove, each station is easy to connect together and form to an automatic processing line. In the station is composed of all sorts of modular form, it is easy to build, remove and maintenance between each module, it can be combined at will between each workstation. 2. Working Principle
Distribution Press AS/RS

Testing

Buffering

Robot

Sorting

Processing

Handling

The workpiece in the bunker according to the order supply, chuck send the workpiece material from distribution station to the testing station. Sensor detect workpiece color and the material,improve cylinder (rodless cylinders) rise, height measurement cylinder drop, after photoelectric sensor measured the work piece height, height measurement cylinder rise, ascension cylinder decline. After optical fiber sensor confirms workpiece of reach turntable, turntable rotated 45 degrees send the workpiece to the corresponding processing position, drilling processing module machining diameter. Then turntable rotate workpiece to another position, this position judge whether the workpiece drilling qualified, testing cylinder, testing inner diameter,if cylinder forward to the end which shows processing is normal, or it is defective. After completed the work of the processing station, works of handing station begin. Buffering station is composed of two buffer cylinders in the left and right direction and a double belt conveyor institution. When supply power to buffering station, the belt conveyor is transmission and put the tray down on the top of the belt conveyor, when tray operate at the
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top of the right buffer cylinder, and right buffer cylinder detect tray, brake withdraw, right buffer cylinder decline in position, the belt transmission will continue to send tray to left buffer area, then left buffer cylinder test to tray, brake withdraw, belt transmission stop, left buffer cylinder rise in position, waiting handing station bring the workpiece, testing the tray has work, belt transmission start, send workpiece in the tray to right buffer area. Robot from the buffering station grab workpiece, place workpiece fixed on the processing station. From robots we get material signal and OK signal (when work independent, use start button instead of), according to the material X, Y axis move, the Z axis rise, and prepare to up the tray, the Y axis rise to up the tray, the Z axis fall to start move, waiting the signal that the robot take the materials, put empty tray in its place waiting for the next signal. From robots we get material signal and OK signal (when work independent, use start button instead of), the workpiece cover was delivered to pressure tank, Using hydraulic converter do pressure homework for workpiece cover, Use the cylinder and the cylinder to slot the workpiece push to another slot 3. Knowledge points The application of the test switch The application of various sensors The application of Pneumatic and hydraulic components PLC application The application of automatic warehouse management the application of Two dimention designated take things Pneumatic circuit wiring and electrical wiring Assembly and disassembly of mechanical parts and pneumatic part System fault diagnosis and maintenance Notes: This book had said 1 # station is distribution station, 2 # station is testing station, 3# station is processing station, 4# station is handing station, 5# station is buffering station,6 # station is pressing station, 7 # station is AS/RS station,8 # station is robot station, 9 # station is sorting station.

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Chapter Two DL-MPS901A flexible manufacturing system main components introduction and application
In automatic line usually use sensor technology, motor technology, pneumatic technology, control technology, servo drive technology, communication technology, just like the person sensory system, sports system, the brain and nervous system. Here DL-MPS901A flexible manufacturing system as the carrier to expound the above key technology . It is the so-called "preceded the things, you will have to have the its machines". PLC is like the brain; software is like central nervous of the brain; Photoelectric sensors, capacitance sensor, inductance sensor like people's eyes; Magnetic switch like people's touch sense;Motor and belt is like the legs; Robotic device as man's hands and arms; Electromagnetic valve set is like people's muscle; communication bus is like the nervous system;

Section 1 Sensor 1.1 Sensor introduction 1. Classification of sensor At present sensor has no a unified classification method, but more commonly used has the following three: (1) according to the classification of the sensor physical quantities, it can be divided into displacement, force, speed, temperature,flow, and the gas components,etc sensors; (2) according to the classification of sensor work principle, can be divided into resistor, capacitor, inductor, voltage, hall, photoelectricity, optical grating sensor and thermocouple, etc sensors ; (3) according to the nature classification of the sensor output signal , can be divided into: output is the switch quantity (" 1 "and" 0 "or" on "and" off "switches type sensor;) Output is simulation type sensor; The output is the digital sensor of pulse or code. 2.Common sensor diagram

Photoelectric sensor
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Inductance sensor

Capacitor sensor
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Optical fiber sensor

Magnetic switch

1.2 Common sensor introduction 1.2.1 Magnetic switch and application a. Magnetic switch introduction Magnetic type approximate switch (in short the magnetic switch) is a non-contact position detection switch, this kind of non-contact position detection do not wear and damage detection object content, the response speed is high. The commonly approximate switch on production line also has induction type, static capacity type, photoelectric type,etc approximate switch. Induction type approximate switch used the existence of test metal objects, static capacitive proximity switch type used the existence of detection metal and non-metallic objects, magnetic switch used the existence of test magnet; Installations method have wire leads type, connectors type, connectors relay type; According to the requirements of the installation place environment, approximate switch can choose shielding type and non- shielding type. When magnetic material close to magnetic switch sensor, the sensor act and output switch signals. In practical applications, in the tested object (such as the piston and cylinder piston rod) installed on the magnetic material, and in the both end of the outside cylinder cylinder install a magnetic type approximate switch, it can use the two sensors to mark two limit position of cylinder sports respectively.

Brown line

Tongue reed switch

Blue line

Magnetic switch internal circuit diagram

In order to prevent damage the magnetic switch because of wrong connections, usually in the use of magnetic switch, all series connect the current limiting resistor and the protection diodes. So even though lead wire polarity reversed, magnetic switch also will not burned, only the magnetic switch can't work normally. b.The application example of magnetic switch in the DL-MPS901A flexible manufacturing system
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magnet

Magnetic switch

The figure shows the automatic storage station magnetic switch detection magnet.

c. Installation and debugging of magnetic switch In the automatic control of production line, can use this signal judge cylinder motion state or the location, to determine whether the workpiece was launched or whether the cylinder returned. 1Electrical wiring and inspection We emphasis on consider the influence which the sensor's size, position, installation way, wiring craft, cable length and work around environmental factors to sensor work. . In magnetic switch settings are LED, to display the sensor signal state, for when debugging and running monitor to observe. When the cylinder piston close, proximity switch output to act, output "1" signal, LED bright; When there is no cylinder piston close, proximity switch output do not move, output "0" signal, the LED not bright. 2Installation and adjustment of magnetic switch in the cylinder When magnetic switch and cylinder used together, if not installed reasonable, may make the cylinder action is not correct. When the cylinder piston move to the magnetic switch, and close to a distance, magnetic switch has a "perception", switch will act, usually call this distance is "detection distance". When install the magnetic switch on the cylinder, the first is put the magnetic switch installed on the cylinder, the installation position of the magnetic switch adjusted according to the requirements of the control object , the adjustment method is simple, as long as after the magnetic switch arrives the specified position, with a screwdriver tighten screw (or nut), magnetic switch usually used to test the position of the cylinder piston, if detect other types of workpiece position, such as a light color plastic workpiece would then choose other kinds of sensors, such as photoelectric switch. 1.2.2 Optical fiber photoelectric proximity switch and application a. Optical fiber photoelectric proximity switch profile Structure: fiber photoelectric switch is composed of optical testing head and optical fiber amplifier, fiber amplifiers and optical testing head is the two parts of the separation, the end part of optical testing head is divided into two optical fiber, when using, inserted the two optical fiber hole of amplifier respectively . The output of the optical fiber photoelectric
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switches connected to the PLC. Optical fiber photoelectric switch is also a kind of optical fiber sensors, optical fiber sensors sensing part does not have the circuit is connected, do not produce heat, only using a few light, these characteristics make optical fiber sensor become ideal choice in the dangerous environment . Optical fiber sensor can also be used for the key production equipment's long-term high reliability and stability monitoring. Compared with the traditional sensors, optical fiber sensors have the following advantages: anti-electromagnetic interference, working in the bad environment, the transmission distance, long service life, in addition, the head of the optical fiber has smaller volume, so can be installed in the small place. Optical fiber amplifier according to the need to hold. For example, electric spark fireworks in the production process may cause an explosion and fire, and light will not become fire sources, not cause an explosion and fire, so the fiber optical detection head set in dangerous places, will put amplifier unit set up in the dangerous places to use. Optical fiber sensor is composed of optical testing head and fiber optic amplifiers , amplifiers and optical testing head is the two parts of separation . Optical fiber sensor classified sensor type and the light-transmission type . The sensor is based on optical fiber itself as sensitive components, make optical fiber both have the role of feelings and passed tested information. The light-transmission type is to be measured through the output terminal light signal processing by the light signal input optical fiber which modulate by tested objects , the work principle of light-transmission type optical fiber sensor is similar to photoelectric sensors'. b. The application example of optical fiber photoelectric switch in the DL-MPS901A flexible manufacturing system.

Optical fiber sensor

Silo is a cylindrical organic glass tube,c in the lower end of the silo has a fiber optic sensor, to detect whether has the workpiece. 1Electrical and mechanical installation In the installation process, first fix the fiber optical detection head, put the fiber amplifiers install in guide rail, and then two optical fiber that at the end of optical testing respectively inserted into the two optical fiber hole of amplifier, when you wiring, please pay attention to judge polarity and signal output power line according to the connection wire color. Sensitivity adjustment Optical fiber photoelectric switch is applied more and more in the production line application, but in some application place where there is more dust, and easy access to organic solvent and need higher performance, actually can choose some other sensors instead, such as capacitive switch, electricity eddy proximity switch.
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1.2.3 Photoelectric switch and application a .Photoelectric switch introduction Photoelectric switches usually use in some situations that environment condition is very good and no dust pollution. The photoelectric switch almost has no effect on tested objects when it is working. Therefore, it is widely used in production line. Using the tiny beam, amplifier built-in type diffuse photoelectric switches. Diffuse photoelectric proximity switch is working which use the reflected light that use light to illuminate the tested objects , because the reflected light is diffuse light , so it is called the diffuse photoelectric switch. It consists of light (launch light) and photosensitive components (receive light) , light emitter and light receiver are on the same side. When is is working, light emitter always emission testing light, and if proximity switch within a certain distance ahead did not appear object, there is no light is reflected to the receiver, photoelectric switches are in normal state and not move; And if proximity switch within a certain distance ahead appear objects, as long as the reflected light enough strength, the receiver receive enough diffuse light and will make proximity switch act and change the output state . Besides has diffuse type photoelectric switches in the production line, also have cast type (DuiShe type) and regression model (mirror reflection), all composed of emitting light source and photosensitive components that accept the light, if Cast light is covered or reflected because of the difference of detection object , the amount of light that arrive receiver part will change. The receiver part will detect this change, and convert to electrical signals, running output. According to properties, installation of tested object in the production line. b. The application example of photoelectric switch in the DL-MPS901A flexible manufacturing system

light projector

Regression reflex plate

In this production line, return type optoelectronic switch uses the test that workpieces are put full in the classification station slippery slot. 1 Electrical and mechanical installation The photoelectric switch has power source polarity and output reverse connect protection function. Photoelectric switch has self diagnosis function, when the environment change (temperature, voltage, dust) redundant that was set meet the requirements, the stable indicator light display (if redundant is enough, the light bright,). When the receiver's photosensitive components receive effective light signal, the transistor that control output will conduct,
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and at the same time action indicator light display. The photoelectric switch can detect its own light axis deviation, lens face (abnormal and failure of the sensor pollution, the influence of earth, the external dry state of the sensor and so on), it is easy to conserve, so that equipment can work stably. In the sensor wiring process ,attention to avoid the electromagnetic dry on, don't be direct illuminate by sunshine or other light source, don't use in some place where produce corrosive gas, contact with organic solvent and has larger dust. 2 Installation adjustment and debugging Photoelectric switch has advantage that long detection distance, the small limits of the test object , fast response speed, high resolution, and easy to adjust, etc. But in the process of photoelectric switch installation , we must ensure that the distance from sensor to the tested object must be within range of the "detection distance", at the same time, considering tested object's shape, size, surface roughness and movement speed, and other factors. Photoelectric switches adjust position does not reach the designated position, not sensitive to the workpiece reflection, action light not bright; Electric switches ' work position adjust right and is sensitive to the workpiece reflection, action light and stable light are bright ; When no workpiece close to the photoelectric switch, photoelectric switch has no output. Debugging photoelectric switch position, after right locking set screw nut. The light source of photoelectric switch adopts green light or blue light can discriminate color, according to the different reflectivity characteristics of surface color, photoelectric sensor can sort the products, 1.2.4 Capacitive and electric eddy type proximity switch Capacitance sensor working principle is use the method that mechanical quantity change make the one of the parameters of capacitor change to achieve signal transformation. According to the different tested object in the production line, the different installation environment , to choose capacitive or inductive proximity switch. Capacitive proximity switch also belong to position sensor that has switching quantity output, its measurement head usually is a polar of capacitor, and the other polar plate is the object itself, when objects move to proximity switch, the object and polar distances of proximity switch or dielectric constant will change, cause static capacity change, state circuit that connect to measurement head will be change, too. which will be control switch on and off. This test object of proximity switch, is not limited to metal conductor, also can be the liquid or powder objects of insulation.

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Detection body

One side of sensor

Electricity eddy proximity switch to belong to one of the inductance sensor, is position sensor which has switch quantity output and use the eddy current effect to make. it consists of LC high frequency oscillators and amplification processing circuit, when using metal objects to close to this oscillation induction head that can produce electromagnetic field, make the object internal generate electricity eddy current. The eddy current react on proximity switch, make proximity switch oscillation capacity attenuate, internal circuit parameters change, thus identify whether has metal objects close to it, and then control switch's lead or broken. The project that can test by this proximity switch must be metal objects. No matter what kinds of proximity sensors, when using must be pay attention to tested object's materials, shape, size, and movement speed, and other factors. During the sensor install and choose to use, have to seriously consider detection distance, setting distance, ensure the sensor reliable action of the production line.

B signal line lack

B signal line lack

B n( V row

B V lue

B n V row

Be lu V

B n row

B V lue

C apacitanceand inductance

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Electrical symbols of the sensors pictured above. 1.2.5 Application of sensors in the DL-MPS901A flexible manufacturing system

Inductive sensor

Photoelectric sensor sensor

Capacity sensor

This picture is testing station in DL-MPS901A flexible manufacturing system, using the sensor test components materials and state

Inductive sensor

Inductive sensor

Capacity sensor Photoelectric sensor

This picture is the sensor test that used in the buffering station

The more knowledge of the sensor, please refer to the relevant books. Applicable occasion of each sensor is different with requirements ,detection distance, installation way, output interface electrical characteristics are different, this needs to consider comprehensively in the installation and debugging with execution structure, the controller, etc.

Section 2 PLC 2.1 PLC Introduction 2.1.1 PLC structure and function of various parts. PLC English called Programmable Controller short of PC because the PC easy confuse But with Personal Computer (Personal Computer) , so people still used to use PLC as
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programmable controller's abbreviations. It is a electronic system device of digital computing operations that a microprocessor as core, specially designed for the industrial field application, it uses programmable memory, in its internal storage to perform the logic operation, sequence control, regular/count and arithmetic operation instructions, and through the digital or analog input, output interface, control the various types of machinery or the production process. PLC is product that microcomputer technique combine with traditional relay contact control techniques, it overcomes the complex wiring, lower reliability, high power consumption , the poor universality and flexibility in the mechanical contacts relay contact control system, make full use of the advantages of the microprocessor, and take care the skills and habits of site electrical operation maintenance personnel, especially PLC programming, don't need a special computer programming language knowledge, but using a set of simple instruction form based on relay ladder diagram, make the user programming visual, intuitive and easy to learn; The commissioning and check wrong is also very convenient. After users bought PLC that what they need, just according to the hint of introduction book, do a small amount of wiring and simple user programming work, you can be flexible and convenient applied PLC to the production practice. 1. PLC structure and function of various parts There are various types of PLC, function and command system are also different, but the structure and the working principle is the same, usually is composed of main machine, input/output interface, power supply expand device interface and external devices interface and so on. PLC hardware system structure as below:

1) Main machine The main machine includes the central processing unit (CPU), system program memory and the user program and data storage. The CPU is the core of PLC, it used to run the user program, monitoring input/output interface state, make logical judgment and data processing, that means read input variables, completing various operating that the user instructions rules, and send the results to the output terminal, and respond to external device (such as computer, printer, etc) request and do various internal judgment, etc. PLC internal memory has two kinds, one kind is system program memory, it main storage system management, monitoring program and the program that do compile processing to user's program, the system program has been fixed by manufacturer, users can not change; Another kind is the user program and data storage, main storage application program that the user compile and all kinds of temporary data and intermediate results. 2) Input/output (I/O) interface
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The I/O interface PLC and input/output devices connected components. Input interface accept input device (such as buttons, sensors, contacts and stroke switch, etc) control signals. Output interface is main machine modification, debugging program and PLC monitor work state. Through the special cable wire connect to PLC and computer, and use special software to do computer programming and monitoring. 3) Input/output expansion unit The I/O expansion interface use for connect expand unit of expand external input/output terminal to the basic unit (namely main machine) together. 4) External device interface The interface can connect printer, bar code scanner, inverter and other external equipment to main machine, and to complete the corresponding operation. The experiment device providing main machine model are Siemens S7-300 312-1AE13-OAB0. Input points is 8, output points is eight. 2. PLC working principle PLC is using the "order scanning, continuous cycle" way to work. That is when the PLC operating, CPU according to the program storage in user memory that the user according to control requirements compiled, according to command step serial number (or address date) do periodic cycle scanning, if no jump instruction, then from the first instruction began executing user program according to the sequence, until the program end. And then returned to the first instruction start the next round of the new scanning. During every scanning process, also must finish sampling to the input signal and refresh work to output state, etc. PLC scan cycle must have input sampling, program execution and output refresh three stages. PLC in the input sampling stages: first read into input terminal hige state or enter data that storage temporary in the input latches by scanning mode according to the order, and write them in the corresponding input status register, which is refresh input. Then close input ports, into the program execution stage. PLC in program execution stage: according to user program instructions stored order scanning executes every instruction, after the corresponding operation and treatment, the results were wrote output state register, all the content in the output state registers changes along with the program execution. Output refresh stage: when all the instruction execution, the hige state of output state register in the output refresh stage sent to output latches, and through a certain way (broken appliances, transistors or thyristor) output, drive the corresponding output devices work. PLC programming Programming components PLC is used in the software programming to achieve control requirements. When programming uses all kinds of programming components, they can provide countless move closes and move off contacts. Programming components is refers to the input registers, output registers, bit memory, timer, clock, general-purpose registers, data register and special function memory, etc. The role of these memories PLC internal is similar to role of relay that using in the relay contact control system, also have "coil" and "triggers", but they are not "hard" relay, is storage units of PLC memory. When the logic state is "1" in the unit, means the corresponding relay coil get electricity, its move close contacts closed, move break contacts disconnect. So, these internal relay are called "soft" relay.
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2) Programming language The programming is that users according to the control object requirements, use programming language provided by PLC manufacturers, describe the process of a control . Ladder diagram language and instructions statement table language is the most commonly used PLC programming language, and both of them always used joint . a. Ladder diagram language Ladder diagram is a graphic language that demonstrates from relay contact control circuit diagram. It is lent the move close, broken contacts, move coil and series and parallel terms and symbols that similar to a relay, according to the control requirements, connect and into graphics that show a logical relationship between PLC input and output , straightforward and easy to understand. In the ladder diagram always use graphic symbols to show PLC programming components' move close and dynamic broken contact; Use ( ) show their coil. Ladder-diagram programming's types use graphic symbols and labeled letters or several to distinguish. Contacts and coils consisted independent circuit called network, use programming software generated ladder diagram and statement to show there are network numbers in the table program, allow taking network as unit to comment ladder diagram. Ladder diagram design should pay attention to the following three points: The ladder diagram according to from left to right and top to bottom to order. Each logical lines (or says cascade) started in left bus, and then the contact's series, and parallel connection, and the last is the coil. Each step of the ladder diagram flows is not the physical current , but "concept current", from left to right, its both ends not have power . The "concept current" is used to describe visually the coil through conditions that should meet in the user program execution. Input registers uses to receive external input signal, but not drive by PLC other internal relay touch points. Therefore, ladder diagram only appears input register contacts, and don't appear the coil. Output registers are output program execution results to the external output devices, and when the ladder diagram output registers coil to electricity, then there is signal output, but not direct drive output devices, and through the relay, transistors or thyristor of output interface to realize. Output register contacts also can be used by internal programming b. Command statements table Command statements table is a language that uses mnemonic runes to compile PLC program, it is similar to the computer assembly language, but easy to learn and to understand than assembly language, some instruction program is composed of instruction statement tables. An instruction is composed of step sequence, instruction language and function device numbers three parts. 2.2 Basic directive introduction

1 Bit logical instruction 1.1 Bit logical instruction overview Introductions Bit logical instruction processes two numbers, "1" and "0". The two digital form the foundation of the binary Numbers system. The two figure "1" and "0" called the binary number or binary. In the contacts and coil field,
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"1" means the action or electricity, "0" means no action or not powered. Bit logical instructions scanning signals state 1 and 0, and according to the Boolean logic combine. In these combinations born results 1 or 0, called "logic operation results (RLO)". Boolean logic applied in the following basic instructions: A "and" AN "and not" O "or" ON "or not" X "exclusive or" XN "exclusive or not" O "before and after or" You can use the following instruction nested expression: A (" and "operation nested began AN (" and not "operation nested began O (" or "operation nested began ON (" or not "operation nested began X (" exclusive or "operation nested began XN (" exclusive or not "operation nested began You can use the following instructions to end a Boolean logic string: = assignment R reset S setting You can use the following one of instructions, change the logic operation results (RLO) : NOT RLO not SET RLO setting (= 1) CLR RLO clear (= 0) SAVE put the RLO deposited in the BR registers Other instructions response to positive edge and negative edge: FN negative edge FP positive edge 1.2 A "and" Format A <Bit> Address data type storage area < Bit > BOOL I, Q, M, L, D, T, C Introductions Use "and" instructions can check whether the signal state of be addressed was for "1", and will examine the results and logic operation result (RLO) and do "and" operation. Use "and" instructions, also can use the following address, direct check the status word: = = 0, < > 0, > 0, < 0, > = 0, < = 0, OV, OS, UO, BR. Status word BR CC 1 CC 0 OV OS OR STA RLO/FC 1.3 AN "and not" Format
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N <Bit> Address data type storage area <Bit> BOOL IQMLDTC Introductions Use "and not" instructions can check whether the signal state of be addressed was for "0", and will examine the results and logic operation result (RLO) and do "and" operation. Use "and not" instructions, also can use the following address, direct check the status word: = = 0, < > 0, > 0, < 0, > = 0, < = 0, OV, OS, UO, BR. Status word BR CC 1 CC 0 OV OS OR STA RLO /FC 1.4 O "Or" Format 0 <Bit> Address data type storage area <Bit> BOOL IQMLDTC Introductions Use "or" instructions can check whether the signal state of be addressed was for "1", and will examine the results and logic operation result (RLO) and do "or" operation. Use "or" instructions, also can use the following address, direct check the status word: ==0 <>0>0<0>=0<=0OVOSUOBR Status words BR CC 1 CC 0 OV OS OR STA RLO /FC 1.5 ON "or not" Format ON <Bit> Address data type storage area <Bit> BOOL IQMLDTC Introductions Use "or not" instructions can check whether the signal state of be addressed was for "0", and will examine the results and logic operation result (RLO) and do "or" operation. Use "or not" instructions, also can use the following address, direct check the status word: = =0<>0>0 <0>=0<=0OVOSUOBR Status words BR CC 1 CC 0 OV OS OR STA RLO /FC 1.6 X "exclusive or" Format X <Bit> Address data type storage area <Bit> BOOL IQMLDTC Introductions Use "exclusive or " instructions can check whether the signal state of be addressed was for "1", and will examine the results and logic operation result (RLO) and do "or" operation. You can also use for several times "exclusive or" instructions. If there is signal status of
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unpaired seized address is "1,"


The logic operation results for each other is "1".

Use "or not" instructions, also can use the following address, direct check the status word: = =0<>0>0 <0>=0<=0OVOSUOBR Status words BR CC 1 CC 0 OV OS OR STA RLO /FC 1.7 XN "exclusive or not" Format XN<Bit> Address data type storage area <Bit> BOOL IQMLDTC Introductions Use "exclusive or not" instructions can check whether the signal state of be addressed was for "0", and will examine the results and logic operation result (RLO) and do "exclusive or" operation. Use "exclusive or not" instructions, also can use the following address, direct check the status word: = =0<>0>0 <0>=0<=0OVOSUOBR 1.8 O Before "and" after "or" Format O Introductions "Before and after or (O)" orders according to the following rules, perform logic "or" operation to "and" operation: before "OR (OR)", "AND (AND)". 1.9 A"and" Operation nested began Format A( Introductions A( andoperation nested beganCan stored RLO and OR bit and a instruction code in nesting stacks. Up to seven nesting stacks input items. 1.10 ANand notoperation nested began Format AN( Introductions AN( and not operation nested began stored RLO and OR bit and a instruction code in can nesting stacks. Up to seven nesting stacks input items. 1.11 Ooroperation nested began Format O( Introductions O( or operation nested began) can stored RLO and OR bit and a instruction code in nesting stacks. Up to seven nesting stacks input items.
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DL-MPS901A flexible manufacturing system

1.12 ONor notoperation nested began Format ON( Introductions ON( or notoperation nested begancan stored RLO and OR bit and a instruction code in nesting stacks. Up to seven nesting stacks input items. 1.13 Xexclusive oroperation nested began Format X( Introductions X( exclusive or operation nested began stored RLO and OR bit and a instruction code can in nesting stacks. Up to seven nesting stacks input items. 1.14 XNexclusive or notoperation nested begin Format XN( Introductions XN(exclusive or notoperation nested begincan stored RLO and OR bit and a instruction code in nesting stacks. Up to seven nesting stacks input items. 1.15 Nested close Format ) Introductions Use )nested closeorderscan delete a input item from nesting stacks, reset OR bit, according to the instruction code, make RLO that the stack input items contains relate to the current RLO, and assign result to RLO. If instruction code is "AND (AND)" OR "AND NOT (with not)", it also includes OR bit. Use the statement of parentheses combination: U (" and "operation nested began UN (" and not "operation nested began O (" or "operation nested began ON (" or not "operation nested began X (" exclusive or "operation nested began XN (" exclusive or not "operation nested began 2.3 STEP7 V5.4 Programming Software Applications 2.3.1 Overview Open Computer> Desktop > S7tgtopx Application Program > S7tgtopx . As shown in figure is found and opened S7tgtopx software.

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Programming software interface:

Click on the new files to create a new folder, and named 11

2.3.2 Build hardware configuration 1, Click on Insert menu >Station > Simatic 300 Station insert 300 station. As below: 2, Then double-click the "Hardware" hardware icon, into the hardware configuration screen, on the right figure box found 300 installation guide Rail, click open the "+" icon of " Simatic 300" find "Rack-300" -> "Rail" , hold this figure to the left margin, as below:
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3, the picture after insert guide rail is as follows:

2.3.3 Set up the path of the editor file First should be set file path, all user documents access in this path. Hypothesis D: \ PLC * set to file access path. Operation steps: Firstly, open Windows interface into "my computer", select D dish, create a new folder, named for [PLC1] confirmation, and then into the programming software.

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2.3.4 Edit document right entry and access 4, Insert 300 host model in the guide rail NO. 2 slot : first click open the "+" icon of "Simatic 300" and find "CPU312"-> "6 ES7 312-1-1AE13 OAB0" module-> insert the corresponding version V2.6

Double click "6ES7 312 1AE13-0AB0" iconso CPU312 will be inserted into the guide rail, as shown in figure:

5,Then establish input and output module in the guide rail, insert input/output module in NO.4 slots , the "+" icon of "Simatic 300" finds "SM300" -> "DI/DO-300" -> "SM323 DI8 / DO8 X.D C24V / 0.5 A" double click this icon establish input/output hardware configuration.
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After build all hardware configurations, and then build MPI address 6, Double click CPU312 in the NO.2. Pop up the following drawing:
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Then click propertiescan change MPI address and Baud ratesystem default address is 2, Baud rate is 187.5, as below:

1,Assume first time program design: first open programming software, click on "engineering > submenu < create new engineering > or click on the common toolbar pop-up [engineering make] dialog box, for choose model. After finish file editing and save: click on the" engineering > submenu < save as engineering for >, pop-up [save as engineering for] dialog box, This can enter the programming picture. 2.3.5 Programming 1, How to establish a programming screen, back to the hardware configuration initial screen as the chart:
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DL-MPS901A flexible manufacturing system

Double click CPU 312diagram, find Blocks, then double click this block, showOB1. Then double-click on the block, into the programming interface, as below:

2, After the data block established, began to programming:

3,In programming interface mouth, find the "View" change the program mode, change "STL" programming mode to "LAD" program mode, as below
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DL-MPS901A flexible manufacturing system

4,Write the programming that you need, and save

5, programming download Find a root of Siemens 300 MPI programming cable, choose to download hardware into the CPU , and then download programming into the CPU, switch gear to "RUN" , such PLC can be used. 2.3.6 The document preservation 1, Choose the driver of the engineering, after input the engineering name, click save. 2, open the existing file: first click programming software, in the main menu < engineering > ,choose < open engineering > pop up [open engineering ] dialog box, select the correct drive, file types and file name, click on the "ok" button to enter edit program before. 2.3.7 The document editing program When right into the programming system, the edit of document programming can be used two edit state form: 1Instructions table edit 2) ladder diagram edit
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1, Instructions table edit programming Instruction tableedit statecan let you use instructions table form edit the general procedure. Now input a program for example:

2, ladder diagram edit

2.3.9 communication set 1, set communication mouth parameter First set MPI address and Baud rate, also can through the MPI cable directly to find the address. 2.3.9 The running and debugging of the program 1, Program running When the program is written to the PLC,it will be running in PLC. First the PLC in RUN state (use hand dial the PLC "RUN/STOP",switch to "RUN" file, then through input switch of the experiment system to give PLC input commond signal, observe PLC output indicator light, verify whether to conform to the circuit logical relationship of edit programming, if there is a problem, but also through the debugging tool that S7tgtopx software provides to determine and solve problems. 2.3.10 log out system After finish program debug and before log out system, you should approve program name, then save it.then close GX DEVELOPER all application submenu graph, exit system.

2.4 S7-200 Programming software application


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DL-MPS901A flexible manufacturing system

S7-200 Programming system using introduction This chapter describes how to build a S7-200 programming system, it includes: A set of S7-200 CPU A set of PC or programming console equipped with STEP 7-Micro/Win32 A root of connection cables (PC/PPI) Installation of V4.0 STEP 7 MicroWIN SP6 software First Unzip the software package

, then double-click

icon installS7-200

software, As shown in figure 3-5, click "ok" do the next step installation, then appear as shown in figure 3-6 shows picture, click "Next" to continue to install, Appear icon as shown in figure 3 -7, and then click "Yes" do the next step installation, appear shows icon as shown in figure 3-8, choose installation path, general install into C tray, build a SIMES folder, click

continue to install.

Figure 3-5

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DL-MPS901A flexible manufacturing system

Figure 3-6

Figure 3-7

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DL-MPS901A flexible manufacturing system

Figure 3-8

Figure 3-9

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DL-MPS901A flexible manufacturing system

Figure 3-10

Figure 3-11

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DL-MPS901A flexible manufacturing system

Figure 3-12

After click

, appear the following figure, as shown in figure 3 - 13, figure 3 - 14

and figure 3-15 software was complete installed, restart your computer.

Figure 3-13
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DL-MPS901A flexible manufacturing system

Figure 3-14

Figure 3-15

After software installation is complete,then open the desktop icons as shown in figure 3-16, double click V4.0 STEP 7 MicroWIN SP6, appear picture in figure 3-17

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Figure 3-16

Find the toolbar

, modify the General in the Options, as shown in figure 3-18

and figure 3-19 shows, modify the shows language to Chinese, click "OK", and then close the programming interface, reopened programming software appear Chinese interface as shown in figure 3-20 shows, and then build a new construction, can write programs.

Figure 3-17

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DL-MPS901A flexible manufacturing system

Figure 3-18

Figure 3-19
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DL-MPS901A flexible manufacturing system

Figure 3-20

programming cable (PC/PPI cable) A head is 9 core D type male port, a head is 9 core D type female port, Insert the port PORT1 or PORT0 of PLC into male head, insert serial (RS232 port) of computer into female port, please don't inserted cable with charge, otherwise it will cause the damage of the COM port.

Other functions as shown in the S7-200 Chinese system manual

2.5 Touch Screen Control 2.5.1 TPC_PLC Wiring

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After complete equipment debugging, Before start communication testing of mcgsTpc and the actual equipment, first we need to verify communication wiring of TPC and PLC equipment, and in the equipment window change the "serial port" of "universal serial port father equipment" to the TPC corresponding serial number that been choosed, to ensure the next step communication test smoothly. Choose RS232 MPI cables and touch screen-communication. 2.5.2 Download engineering communication test After confirm and correct do McGsTpc and PLC communication wiring, Engineering can be downloaded into the TPC and do practical communication test. The specific procedure as follows: First connect the USB programming line: insert the USB flat port into the computer USB port, the micro interface port was inserted into the USB2 port of TPC.

Click on the download button in the toolbar, do download configuration. Choose "machine operation", connection mode ,then to choose "USB communication", and then click "communication test" button, after communication test become normal, click "engineering download".

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DL-MPS901A flexible manufacturing system

After download, you can start operation engineering in the TPC7062K and do the communication test of practical and equipment. 2.5.3 Mainstream PLC wiring picture 1.TPCDL01 wiring pictureSiemens S7200PPI

2.TPCDL02 wiring pictureSiemens S7300MPI

2.6 Industrial Control Network DL-MPS901A flexible manufacturing system mainly forms is PROBUS-DP network. The PROFIBUS DP communication link introduction between S7300 and S7-200
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Through DP cable connect 200PLC and S7300PLCrealize DP communication of 200PLC and S7300PLC. S7-300 and S7-200 through the EM277 do PROFIBUS DP communication, need to do S7-300 station configuration in the STEP7, in S7-200 system do not need do configuration and programming to communication, only need to make up and store the communication data in V storage area and correspond to hardware I/O address of S7-300 configuration EM277 slave station. Insert a S7-300 station:

Select the menu Option in the STEP7 hardware configuration window Install new GSD, import SIEM089D. GSD files, install EM277 slave station configuration files, as the below diagram:

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There is GSD file of EM277 in the SIMATIC folder:

After Import GSD file, you can find EM277 slave station in the right equipment choice list, PROFIBUS DP Additional Field Devices PLC SIMATIC EM277, and according to your communication bytes, choose a kind of method of communication, in this example, choose the way of 8 bytes into / 8 bytes out, the following graph:

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According to DIP SWITCH on the EM277 to set station address of above EM277 slave station, as the chart:

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After configure hardware configuration of the system, download the hardware information into S7-300 PLC:

After download S7-300 hardware, switch EM277 DIP SWITCH to the same with the setting value of above hardware configuration, in the S7-200, write program and store the

exchange data in VB0-VB15, corresponding S7-300 PQB0-PQB7 and PIB0-PIB7, open the variables list in the STEP7, and monitor STEP7 MicroWin40 state table, their data exchange results as below:

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Note: VB0-VB7 is the date that wrote from S7-300 to S7-200, VB8-VB15 is read values from S7-300 to S7-200. DIP SWITCH position in the EM277 must be same with S7-300 configuration address value. Each newsletter address mapping table in the delivery U disk Section 3 Pneumatic Technology 3.1 Pneumatic technology brief introduction In the DL-MPS901A flexible manufacturing systems, installed a lot of pneumatic components, including air pump, gas processor, flow control valves, two-way electric control valves, one-way electric control valve, the converge-wires, cylinder. Among them cylinder
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DL-MPS901A flexible manufacturing system

use the thin shape cylinders, fingers cylinders, pen type cylinder, rotating cylinder, rodless cylinders, etc. In the DL-MPS901A flexible manufacturing system, common use part pneumatic components graph:

Rotating cylinder Double-acting cylinder with proximity switch

Single-acting cylinder

The vacuum valve with chuck one-way gas control valve

5/2 way double-acting gas control reversing valves

3/2 way

Air treatment

Gas liquid converter

3.2 The Characteristics of Pneumatic Device A pneumatic device is composed of the actuators that generate straight lines and rotation action through compressed air, the valve of control actuator action, and the energy components that provide the energy for pneumatic device. Pneumatic, hydraulic and electrical are used in the operation medium of the industrial site. Through the analysis of advantage condition and disadvantage condition of effective operation medium, decided to an effective operating medium.
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3.3 pneumatic actuator Pneumatic actuator produces straight lines and rotation through the compressed air. The pneumatic actuator is composed of cylinder that produces line action, the device that produces the rotation. Cylinders including the single-acting cylinder, it use compressed air produce one way action, the double-acting cylinder, it use compressed air to produce two way action. Rotating device include concussion device, it limits rotation angle, pneumatic motor with limited rotation angle. 3.3.1The single-acting cylinder Piston the single-acting cylinder The single-acting cylinder through the use of compressed air produce one way action, and using a built-in spring and external force to produce other direction action. In the return process, built-in spring is not strong enough for load, can only finish the cylinder back. In return action, because spring force only equivalent to compressed air pressure 0.3-0.5 KGF/cm2, so if loading act on cylinder, cylinder cannot back.

Figure 3.1 Control principle of single-acting cylinder The biggest stroke of the single-acting cylinder with built-in spring is within 100 mm. Due to the bigger the volume of the cylinder, the longer the compressed air emissions time and spring return response time, the biggest diameter was also limited to maximum 50 mm. The single-acting cylinder need simple lines between the valve and cylinder, and consumes half compressed air of double-acting cylinder. The single-acting cylinder is mainly used for clamping, injection, extrusion and up and down, do not need powerful force to return.
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Figure 3.2 Structure of piston single-acting cylinder 3.3.2 Double-acting cylinder Double-acting cylinder use compressed air cylinder produce back and forward actions. Not different with the single-acting cylinder, the use of double-acting cylinder no specific condition, therefore, double-acting cylinder has been widely used. Although double-acting cylinder is no limit on their stroke, considering the piston rod bending, their stroke in general set within 2000 mm. Inner size scope of double- acting cylinder between 4 mm-320 mm.

Figure 3.3 structure of double-acting cylinder Double-acting cylinder mainly used items operation, including transportation, conversion, clamping and injection. Rodless cylinders
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There is no piston rod in the rodless cylinders, outside of the air tube, cylinder move with the piston. Rodless cylinders have two different types: one is use permanent magnet, another use tube aperture (forming wedge between the sheet) to move follower. In magnetic rodless cylinders, strong magnetic force of follower may make internal and external magnet fault movement, and air may be leakage in the gap in the tube aperture rodless cylinders,. Figure 3.4 is rodless cylinder, its magnetic make follower move with piston. Form strong magnetic the outside and inside of cylinder barrel.

Figure 3.4 Rodless cylinder 3.3.3 Pneumatic rotating device Swing device Swing device has limited rotation angle, between the two places has intermittent movement swinging. Swing device has two kinds of type: rack and pinion, blade 1. Rack and pinion rotating cylinder A rack and pinion rotating cylinder use rack and pinion device mechanically convert linear action of a double-acting cylinder to rotating action. The piston rod nc-copy theory driving gear converts linear action of the piston rod to gear rotation action. Although in some commercial rack and pinion rotating cylinder, the rotation angle can be up to 720 degrees, but in the market, rotation angle mainly is 180 degrees. The stroke of piston rod adjusts rotation angle through a rotating button. Rack gear rotating cylinder quite expensive, need more installation space, but it has more softening movement and the longer service life relative to the cylinder blade rotation

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Figure 3.5 Rack and pinion rotating cylinder

2. Blade cylinder Blade cylinder uses compressed air direct rotating blades. Compressed air accessories that installed in the cylinder limit the rotation angle. Rotating angle can be effectively to 300 degrees, but mainly in the market is 180 degrees. Because of simple structure, low cost cylinder, little installation space, but because its brittle structure, only small size cylinder within 50 mm diameter is effective.

Figure 3.6 Blade rotating cylinder

4.4 Pneumatic control valves Pneumatic control system is composed of signal components, control components and actuators. As a signal and control component, valve influence the operation sequence and state of actuators. Actuator itself can't work. In the bus, drive control a stem behind the wheel to open or close automatic door. The action of cylinder and valve is consistent, the state of valve through the pole to operate, to close and open the door. Valve only use for signals, including the operation of stem, control direction, speed, and the force of actuator.
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Through the valve can control start, stop, direction, flow rate and fluid pressure. Rotary piston, ball valve and plug valve is common form of valve, and in the international mainly used in industrial settings. According to the function, valve can be classified into four groups: Direction control valve or pass valve Flow control valve one-way valve Pressure control valve 3.4.1 Structure and operation principle of direction control valve Direction control valves can be divided to lifting direction valve and slide valve on the structure. Based on how to seal, lifting direction valve is divided into ball seat valve and board seat valve. Lifting direction valve use a ball center, board or vertebral closed or open port. Through a flexible seat to seal, can increase service life, to block the foreign material or dust enter, and to promote the operation reliability. On the other hand, because of the complex structure, to create enough strong operating force against reset spring force and compressed air force, so the price is very high. Slide valve use slide of spools open or close port. Not like lifting direction valve need to resist reaction of compressed air, slide valve structure is simple, small. Because it move successively in valve body, the valve can't be sealed up, reduce the service life, and easy to receive damage of foreign material or dust. Ball seat valve Because of its simple structure and small size, the price of ball seat valve is low. The built-in spring will push ball to seat place, to cut off the air flow that from supply line P to operation line A. Press the piston to separate ball and seat, in order to make the compressed air from P terminal into the operation terminal A. The pressure on the piston need strong enough to block spring reaction and force that compressed air promote to the ball. When the piston rod is released, the spring pushes the ball and makes the valve back to the initial position. The ball seat structure can only applied in small size valve, and the normal size is 1/8 inches. Disc seat valve
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Disc seat valve is tight, and have high reliable operation. Because of cross parts of the air, even in short distances can get it fully, the reaction time is short. The lifting valve has the self-cleaning function; it can clear dust in the compressed air. It is not affected by the outside subjects and greatly increases the reliability of operation, and increase the service life. On the other hand, complex structure makes its price increased, and need more driving force. Slide valve Compare with lifting valve, slide is cheap than the lifting valve, and structure is simple, only need small operation force. Because a line axis slide in the valve body, seal of valve is not strict, thus, decrease the service life, and easily damaged by the foreign material. If supply end P and vent R exchange function mutual, and a NC type slide valve can be used as NO type slide valve. If R as the compressed air supply end , P as vent hole, the valve can be used as a NO type valve. Lifting valve can't convert from NC type valve into NO type valve.

Figure 4.1 Slide valve3/2 way valve

3.4.2 Direction control valve application Direction control valve is a basic valve, it control beginning, stop and direction of airflow through control cylinder. Direction control of a single acting cylinder Figure 4.2 show the circuit diagram of back and forward action that control a single-acting cylinder. Using 3/2 way valve control a single acting cylinder. After press the button on the 3/2 way valve (1.2) and electromagnetic valve P communicate with A, single-acting cylinder move forward. When loosen button, the built-in spring reset to the normal position of valve,
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and air of single-acting cylinder was vent out through the vent R, make cylinder move backward. If 1.0 cylinder is small or the distance between cylinder and control valve is short, cylinder can directly be control by hand valve, as shown in figure 4.2 shows. The bigger cylinder requires controlled by a bigger 1.2 valve. Big flow manual valve can be difficult to find and search. If the distance between the cylinder and the valve is far, after operation cylinder move backward, and when the valve has been returned to normal position, the 1.0 cylinder need to spend a long time to drop the compressed air. So the cylinder backward action needs longer response time. If that's the case, we will introduce a institutions that direct control, as shown in figure 3.12.

Figure 4.2 single-acting cylinder control Indirect control of single-acting cylinder Figure 4.3 shows other circuit diagrams that control the single-acting cylinder. And the difference with indirect control circuit that figure 4.2 describes is indirect control circuit use 1.2 manual control valves make 1.4 valve control the cylinder. Because 1.0 cylinder is generally located on the machine's operation, the distance between 1.0 cylinder and 1.2 valve is very long. If the distance is long between 1.0 cylinder and 1.2 manual operation valve, the direct control structure is disadvantage to longer cycle time, because gas consumption increase, return reaction time of air cylinder increase. On the other hand, the indirect control structure that described in figure 3.12 is 1.4 valve near cylinder installed, avoid the problems within direct control structure.

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Figure 4.3 Indirection control of single-acting cylinder

Direction control of double-acting cylinder Use 4/2 way valve or 5/2 way valve, has two operating lines, to control double-acting cylinder. Press the button on the valve, connect P and A, and B and R make double-acting cylinder forward. When loosen button, build-in spring make valve reset to the initial position, connect P and B, A and R make cylinder back 4/2 way valve and 5/2 way valve have the same function and results. The two operations lines A and B on the 4/2 way valve are vent hole R to blow off the gas, and A in the 5/2 way valve deflated through R, B put gas through S. Most 5/2 way valve are sliding type, and most 4/2 way valve are lifting type. Because of its simple structure, low price advantage, 5/2 way valve was widely used in the industrial area.

Figure 4.4 Double-acting cylinder controls

Indirection control of double-acting cylinder Figure 4.5 shows circuit diagram of indirect control double-acting cylinder. Similar to indirect control of the single-acting cylinder, indirect control of the double-acting through the valve as the main valve (or total valve), make the cylinder move as the need speed, and use small
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valve (1.2 and 1.3) provide control signal.

Figure 4.5 Indirection control of double-acting cylinder

3.5 Flow Control Valve Flow control valve control the flow speed. Hydraulic or pneumatic equipment control fluid speed to adjust to the speed of actuator. Pneumatic valve that Influent actuator speed including 2-way flow control valves, one-way throttle valve and quick-discharge air valve. Although in science only 2-way flow control valve is called the flow control valves, and one-way throttle valve and quick-discharge air valve was classified as one-way valve, we will classify all the valves that impact speed as flow control valves. Two-way flow control valve A 2-way flow control valve control the air quantity into the two directions Noted that if the valve is installed between cylinder and direction control valve, the valve will influent the speed of the cylinder back and forward. Figure 5.4 shows structure of 2-way flow control valve.

Figure 5.4 2-way flow control valve

One-way throttle valve


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One-way throttle valve will connect 2-way fluid valve and check valve together. Check valve only make one way air flow, to control flow velocity of a direction. When the gas into the direction of the test valve closed, the velocity is adjustable, and when gas into the check valve opened direction, velocity can not be adjusted, because the across parts size of check valve is greater than the control flow valves, and make the air flow through the check valve. This valve is mainly used to control the speed of the pneumatic actuators, known as the speed control valves. Figure 5.2 shows structure of a one-way throttle valve

Figure 5.2 one-way throttle valves

The valve has two control structures: inlet throttle control and its control will supply gas to cylinder, Deflated throttling control, and its control gas deflated from the cylinder. Inlet throttle speed control Figure 5.3 show inlet throttle circuit diagram, Can adjust the air amount of supply cylinder and to control the forward speed of cylinder. Open 1.1 direction control valves, make 1.0 cylinder forward. Cylinder forward speed can be adjusted through 1.02 speed control valves, speed control valves can control the air amount of supply cylinder. Back speed of cylinder is not adjustable, because the supply gas could not be controlled, when the cylinder back, the gas on the piston rod on can free emission through the one-way valve. In order to adjust the cylinder back speed, need to install another speed control valves to control gas of supply piston rod.

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If exert force in the same direction of cylinder action, inlet throttling control structure has no effect. The structure is rarely used, because the change rates of load rise and fall in a wide range.

Figure 5.3 inlet throttling speed control

Deflated throttling speed control Figure 5.4 shows deflated throttling circuit diagram, it adjusts gas amount from cylinder expulsion, to control the forward speed of cylinder. And the compressed air is a lot of supplied to the piston end; the gas that total piston end expulsed can be adjusted through the speed control valves, to control the cylinder forward speed. When cylinder acting, maintain stress that role in the piston and on the piston rod, and compared with the inlet throttling control structure, can obviously control speed. Deflate throttling speed control structure mostly used in the pneumatic device. Need to install another speed control valve in the piston to control the cylinder back speed.

Figure 5.4 Deflate speed control

Quick-discharge air valve


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Quick-discharge air valve is mainly used to increase speed of the cylinder. Figure 5.5 shows the structure and operation principle of quick-discharge air valve. Supply the A end of compressed air flow valve in the P end. When P end loses pressure, the gas in A end rapidly be put off through deflate hole, and installed together with cylinder, the valve simplified and shorten the put gas path, and thereby reducing the reaction. Rapid deflated increases the speed of the cylinder.

Figure 5.5 rapid deflated valve

Pressure sequence valve The operation principle of pressure sequence valve and the pressure reducing valve is the same. If pressure of compressed air role in the Z end to the spring setting pressure, the valve will send a output signal to A. This valve is mainly used for particular pressure to convert control position that pneumatic control pneumatic. Figure 5.6 shows the structure and operation principle of pressure sequence valve.

Figure 5.6 pressure sequence valve


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Pressure sequence valves are 3/2 way that compressed air signal control through the spring pressure simple external control. This valve is used in the limit switch environment, alternate limit switches to test whether cylinder finishes back and forward movement. Figure 5.7 is the application that use pressure sequence valve testing whether the order finished the forward movement. 1.1 valve change direction by 1.2 valve, make the cylinder forward. Set the operation pressure of the 1.3 pressure sequence valve higher than cylinder forward pressure, so that when the 1.0cylinder finished forward movement, operate 1.3 valve. The order of the cylinder pressure valve control position limit switch control as reliable, so it is recommended for use in the special device inside. The position of the pressure sequence valve control cylinder are not reliable than limit switch control, so it is recommended for use in the special device.

Figure 5.7 use pressure sequence valve test position

3.6 Brief introduction of one-way control valves and two-way control valve The difference between dual electronic control and single electric solenoid valves is that, for single electric solenoid valves, when no electric control signal, valve heart in the role of spring will be reset, and for double electric solenoid valves, there is no electric control signal in both ends, the position of the valve heart is depend on the electric control signal before. Note that the two electric control signal of dual electronic control cannot are "1" at the same time, that is, in the control process not allowed two wire get the electricity at the same time,

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otherwise, they can cause electromagnetic coils burned down, and of course, in this case the position of the valve heart is uncertain 3.7 Exchange and install solenoid valves If there is electromagnetic valve damage, need to replace a solenoid valve, can according to the following steps install solenoid valves: cut off air source, use screwdriver remove solenoid valves that have been damaged Insert electric control joint to solenoid valves Insert pneumatic tube into the fast connection of solenoid valve. connect to air source, debugging with the hand control switch, inspect cylinder action situation. Section 4 Motor 4.1 Use the of DC motor In the DL-MPS901A flexible manufacturing system, we mainly use DC gear motor, use main axis drive ball screw transmission structure of motor, do clockwise or counter clockwise rotation.

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Chapter Three Station Introduction


Section 1 Distribution Station 1. Technical parameter 1, Electric control cabinet main circuit power supply: single phase AC220V 10% 50Hz. 2, Electric control cabinet control circuit power suppliy: DC24V 3, Temperature-1040; environment humidity 90%25 4, Overall dimension: 750mm750mm1000mm 5, Air pressure: 0.4~0.6Mpa 6, Whole machine capacity: 1KVA 2. Working principle Module station of the workpiece supplied according to the order in the silo is the first station of the whole system also is the most basic modules in the whole works. 1.1 Components Contents Distribution module

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Rotating transmission module

Figure 1.1 Distribution station

1.2 Module Contents 1.2.1 Distribution module Storage workpiece in silo The workpiece of optical fiber sensors sense and store Distribution cylinder pushes workpiece in the silo out according to order, after the first silo finished, the second silo continue Main components Double acting cylinder (flow regulator, With proximity sensors) The workpiece induction: optical fiber sensor Proximity sensor 5/3 way single acting solenoid valves

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Figure 2.1 Distribution module and pneumatic circuit

1.2.2 Rotating transmission module Rotary cylinder and vacuum generator, combined chuck together transmitte the workpiece out. Vacuum generator and chuck transmiss the workpiece from distribution module to the next station. Main Components Rotating cylinder Proximity sensors of attached to the cylinder Vacuum induction pressure sensor Cylinder speed controller (flow regulator) Rotary cylinder: 5/3 way solenoid valves Vacuum generator: 5/2 way solenoid valves

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Figure 2.2 Rotating transmission module

Vacuum chuck

Rotated actuator

Figure 2.3 Rotating transmission module pneumatic circuits

Rotating cylinder uses 5/2 way solenoid valve. The vacuum system is composed of rotating cylinder, 5/2 way solenoid valve, rapid exhaust valve and pressure sensor. 1.3 Working Contents 1.3.1 Order requirements Begin condition There are workpiece in the distribution module silo (optical fiber sensor induction) All transmission mechanism initial state Begin condition Distribution cylinder retract Rotating cylinder turn to silo direction (left)
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Vacuum generator closed There are workpiece in the silo Working order Rotating cylinder turn to the next direction (right) Silo sense and move Distribution cylinder forward Vacuum generator begin to act Rotating cylinder turn to silo direction (left) Distribution cylinder retract Rotating cylinder turn to the next direction (right) Vacuum generator closed Rotating cylinder turn to silo direction (left) System initialization 1.4 Training Subjects Training subject 1

SubjectDebugging Mitsubishi PLC (hardware) AimDebugging Mitsubishi PLC Training contents:FX series)NPN connection Training subject 2 SubjectDebugging Mitsubishi PLC (software) AimDebugging Mitsubishi PLC Training contents Install GX Develop and make new program, set CPU type and communication terminal, and then test all the connection. Training subject 3 SubjectPLC wiring Aim Refer to I/O table and connection figure finish PLC wiring.
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Training contentsReference the wiring diagram and the I/O distribution table complete PLC NPN wiring and testing all terminal. Training subject 4 Subject: The motor turning/reverse control Aim Master method that control motors turning and reverses Training contentsUse two signal control motors turning and reverse. Think again what circumstance will appear if both sides signal exist side by side, and draw the appropriate circuit diagram. Training subject 5 SubjectReplace silo control Aim: Replace silo Training contentsEvery time press the start button silo 1, silo 2, silo 3 according to the order in place. Need to confirm whether the distribution cylinder is in indented state. Training subject 6 Subject: Material feeding action control Aim: Finish material feeding action Training contentsPress the start button material feeding cylinder forward to finish material action, then silo confirmed its position. Training subject 7 SubjectTransmission action control Aim: After the material feeding end, do transmission action Training contentsPress the start button, first identify the workpiece position and then do transmission action. Action steps: begin button => sensor position confirm => adsorption & rotary cylinder silo direction => adsorption workpiece => cylinder indented & rotary cylinder transmission direction => adsorption stop
Note: Example program in the shipping U disk.

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Section 2 Testing Station 1. Technical parameter 1, Electric control cabinet main circuit power supplies: single phase AC220V10% 50Hz 2, Electric control cabinet control circuit power supplies: DC24V 3, Temperature: -1040; Humidity: 90%25 4Dimension750mm750mm950mm 5Air pressure0.4~0.6Mpa 6Capacity1KVA 2. Working principle Testing induction sensor of metal, the optical fiber sensor using reflect principle test and capacitance sensor that inspect whether has workpiece test workpiece color and texture, and then using photoelectric sensor judge height of three workpiece. 2.1 Components Contents Lifting module

Transmission belt convery module

Figure 1.1 Testing station

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2.2 Module Contents 2.2.1 Lifting module It is composed of the inspection module that discriminate workpiece material and color, modules of measuring height, and lifting module of rodless cylinders vertical up. Main components Rodless cylinders Workpiece height measure module Workpiece texture testing module

Height test

Material test

Lifting cylinder Figure 2.1 lifting module

Lifting module

Lifting cylinder module components Rodless cylinders Proximity sensor 5/2 way double acting solenoid valves Cylinder speed controller (flow regulating valve)

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Figure

2.2 lifting cylinder and pneumatic circuit

Workpiece material testing module components Capacitive sensor Inductive sensor Direct reflection type optical fiber sensor Lifting tray Workpiece detrusion cylinder 5/2 way single acting solenoid valves Cylinder speed controller (flow regulating valve)

Figure 2.3 Workpiece texture test module components

According to the different combination of sensor detection signal to judge the material Each sensor according to the different workpiece, judge whether there is signals to judge the state of material.

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Figure 1 The function of the sensor that according to different workpiece classify

Workpiece Black texture Sensor workpiece type 1Optical sensor 2.Capacitive sensor 3.Inductive sensor (black red write) non-ferrous workpiece

Metal workpiece

Module components of measure workpiece height Measure height device Photoelectric sensor Measure height device delivery cylinder (double) 5/2 way single acting solenoid valves Cylinder speed controller (flow regulating valve)

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Figure

2.4 Measure height module and pneumatic circuit

The following diagram each module has two sensors, according to test signal of different sensor measure height of workpiece

low

middle

height

figure 2.5 according to different signal combination of the sensor to measure the workpiece height Workpiece is the middle height condition Sensor S1,S2 are no acting Workpiece is low or high condition Sensor S1,S2 are acting Measure height cylinder forward, test device decline measurement workpiece height

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Figure 2.6 measure high device

2.2.2 Transmission belt convey module Belt type transmission device, is controlled by DC gear motor

Main components Tension adjusting device Belt type transmission belt device DC gear motor Relay

Figure 2.7 Transmission belt convey module

2.2.3 Defective goods loaded slide rod Main function is load defective workpiece. Main components Slide rod base platestents
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Figure 2.8 Defective goods loaded slide rod

2.3 Working contents 2.3.1 Order requirements Begin condition Lifting cylinder decline Detrusion cylinder retract Transmission belt stop Height test cylinder retract (rise) Begin condition All the parts are reset condition. Working order Judge workpiece of tray. (Texture, color) Lifting cylinder rise. (redness cylinder) Height measurement cylinder decline. Height measurement sensor measure height. After measure height, cylinder rise.. Finished product (low, and the middle height) condition Transmission belt start. Cylinder back and forth one time.(to transmission belt) Lifting cylinder decline Workpiece arrive to processing station transmission and stop Back to intinal position Defective goods (high) condition, Lifting cylinder decline. Cylinder back and forth one time. (put on the slide rod) Back to intinal position
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2.4 Training Subjects Training subject 1 Subject Debugging Mitsubishi PLC (hardware) AimDebugging Mitsubishi PLC Training contents:FX series)NPN connection Training subject 2 SubjectDebugging Mitsubishi PLC (software) AimDebugging Mitsubishi PLC Training contents Install GX Developand make new program, set CPU typeand commucation terminal, and then test all the connection. Training Subject 3 SubjectPLC wiring Aim Refer to I/O table and connection figure finish PLC wiring. Training contentsReference the wiring diagram and the I/O distribution table complete PLC NPN wiring and testing all terminal. Training Subject 4 SubjectSensor AimKnow the features of sensor Training contentsUnderstand the sensors position in the testing station; study the characteristics of different sensors, and master discriminant method of workpiece material. (Kinds: capacitive, inductive, optical fiber sensor) Training Subject 5 SubjectDetect workpiece control AimComplete detection workpiece action Training contentsPress the start button, improve loading up to inspect workpiece. The initial condition is elevating load decline, cylinders indentation, transmission belt stop. Action steps: begin button=>sensor detection => elevating load up => inspect workpiece => cylinder forward &transmission belt operate => cylinder indente => elevating load decline => transmission belt stop
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Training Subject 6 SubjectDetection defective control AimFinish detection defective action Train contentsPress the start button, hoister rise detects defective. The initial condition is elevating load decline, cylinder indented, transmission belt stop. Action steps: begin button=>sensor detection => elevating load up => inspect defective workpiece => elevating load decline => transmission belt stop=> cylinder forward => cylinder indented Note: Example program in the shipping U disk. Section 3 Processing Station 1. Technical parameter 1, Electric control cabinet main circuit power supplies: single phase AC220V10% 50Hz 2, Electric control cabinet control circuit power supplies: DC24V 3, Temperature: -1040; Humidity: 90%25 4Dimension750mm750mm950mm 5Air pressure0.4~0.6Mpa 6Capacity1KVA 2. Working principle After optical fiber sensor confirms workpiece of turntable, turntable rotated 45 degrees send workpiece to the corresponding processing position. [workpiece arrive drilling hole detection workpiece push ]

Drill processing module machine workpiece diameter. Then turntable rotate workpiece arrive to the next module, this module judge whether workpiece is drilling, and then through testing cylinder test inner diameter whether drilling qualified, if cylinder forward to end show processing normal, or it is defective.

3.1 Components Contents Turntable module

Drilling module
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Hole processing detection module

Transmission module

Figure

1.1 Turntable processing station 3.2 Module Contents

3.2.1 Turntable module

Main components
DC gear motor Motor control use relay Middle position detection induction sensor 45testing inductive sensor Workpiece arrive testing optical fiber sensor.

Figure 2.1 Turntable and pneumatic circuits controlled by gear motor 3.2.2 Drilling process module It is composed of DC motor, drill cylinder, clamping workpiece of facilitate process.
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Main components Drill process DC motor Motor control use relay Double acting cylinder

Figure

2.2 Drilling process module

Drilling process module components DC gear motor Cylinder belt proximity sensor Double acting cylinder Cylinder speed controller (flow regulating valve) 5/3 way double acting soleoid valve

Figure 2.3 Drilling device and circuit diagram

Fixed workpiece module components Double acting cylinder 5/2 way single acting soleoid valve Cylinder speed controller (flow regulating valve)
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Figure 2.4 Fixed workpiece module and circuit digram

Note the order, in order to avoid turntable rotate make workpiece and cylinder piston hit under testing cylinder not retract condition. 3.2.3 Hole detection module Workpiece drilling state after detection is drilled. Main components Hole detection double acting cylinder 5/2 way singal acting soleoid valve Cylinder speed controller (flow regulating valve)

Figure 2.5 Hole detection module and circuit digram 3.2.4

Slide rod module

Workpiece that previous station transfered deliver on the turntable. In order to ensure transmission in place, a small hole on the slide rod blow
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facilitate to workpiece slide down to work. Main components Slide rod, stents, and base plate of outline form.

Figure

2.6 slide rod module

3.3 Working Contents

3.3.1 Order requirements Begin condition All the parts are reset condition. Initial condition Drill process cylinder retract (rise) Testing cylinder retract (rise) Fixed cylinder forward Turnable wait No workpiece in turnable workpiece slot Working order Detect workpiece of first workpiece slot. Fixed cylinder retract Turntable rotates 45 degree. Fixed cylinder forward (fix) Drill prosess cylinder forward (deline) Drill prosess cylinder retract (rise) Fixed cylinder retract Turntable rotates 45 degree.
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Fixed cylinder forward (fix) Detect workpiece whether was processed (detect cylinder forward) Detect cylinder retract (rise) Fixed cylinder retract Turntable rotates 1/4 Fixed cylinder forward (fix) Back to initial position 3.4 Training Subjects Training subject 1 SubjectDebugging Mitsubishi PLC (hardware) AimDebugging Mitsubishi PLC Training contents:FX series)NPN connection Training subject 2 SubjectDebugging Mitsubishi PLC (software) AimDebugging Mitsubishi PLC Training contentsInstall GX Develop and make new program, set CPU type communication terminal, and then test all the connection. Training subject 3 SubjectPLC wiring Aim Refer to I/O table and connection figure finish PLC wiring. Training contentsReference the wiring diagram and the I/O distribution table complete PLC NPN wiring and testing all terminal. Training subject 4 SubjectWheel rotation control AimWheel rotation and

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Training contentsPress the start button, after sensors induct the workpiece, stop after rotate 1/8circle. Training subject 5 SubjectThe processing control AimProcessing workpiece Training contentsPress the start button, after wheel rotate 1/8 circle, do process workpiece action. Action steps: begin button => wheel rotate => process cylinder down & drilling => 3S => process cylinder up & drilling stop Training subject 6 SubjectProcess test control AimProcess test Training contentsPress the start button, after wheel rotate 1/8 circle, do process workpiece action. Action steps: begin button => wheel rotate => Hole detection cylinder decline=> Hole detection cylinder up.
Note: Example program in the shipping U disk.

Section 4 Handling Station 1. Technical parameter 1, Electric control cabinet main circuit power supplies: single phase AC220V10% 50Hz 2, Electric control cabinet control circuit power supplies: DC24V 3, Temperature: -1040; Humidity: 90%25 4Dimension750mm750mm950mm 5Air pressure0.4~0.6Mpa 6Capacity1KVA 2. Working principle After complete the processing station work, through the cc-link communication begin the handing station work.

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[processing work end handling station PTP move grab work workpiece convery ]

After the end of processing, the handing station send workpiece to transmission station, bad workpiece placed in the middle of the slide rod and back to the initial position again. 4.1 Components Contents Rodless cylinder

Grab module

Slide rod module

Figure 1.1 handling station

4.2 Module contents 4.2.1 Rodless cylinder

It is equipped with 0.5mm rodless cylinder and plays a role to connect processing station and transmition station. Place bad workpiece in the middle of the slide rod and back to the initial position again.

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Components Rodless cylinder Proximity sensor 5/3 way Double acting cylinders Cylinder speed controller (flow regulating valve)

Figure 2.1 Rodless cylinder

4.2.2 Grab module After grab the workpiece on the turntable and then deliver to transmission station.
Components

The cylinder with proximity sensors 5/2 way single acting solenoid valve Cylinder speed controller (flow regulating valve)

Figure 2.2 Grab module

4.2.3 Slide rod module Bad workpiece on the processing station place in the middle of the slide rod returned to the
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initial position. If the bad workpiece on the slide are full, the warning lights will light. Main components Contour structure slide rod, stents, base board, slide rod workpiece filled with sensors.

Figure 2.3 slide rod module

4.3 Working order 4.3.1 Order requirements Begin condition All the parts are reset condition. Initial condition Grab workpiece. Craw rise vertically. There are no workpiece in turntable workpiece slot. Working order Turntable workpiece slot claw deliver position induction workpiece. The Y axis claw cylinder declines. Grab workpiece. Deliver to transmission station. Place bad workpiece in the middle of slide rod. Craw open Return to intinal position. 4.4 Training Subjects Training subject 1 Subject Debugging Mitsubishi PLC (hardware)
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AimDebugging Mitsubishi PLC Training contents:FX series)NPN connection Training subject 2 SubjectDebugging Mitsubishi PLC (software) AimDebugging Mitsubishi PLC Training contents Install GX Develop and make new program, set CPU type and communication terminal, and then test all the connection. Training subject 3 SubjectPLC wiring Aim Refer to I/O table and connection figure finish PLC wiring. Training contentsReference the wiring diagram and the I/O distribution table complete PLC NPN wiring and testing all terminal. Training subject 4 SubjectDistribution and pressure control Aim Finish distribution work and stamping work Training contentsPress the start button, push the workpiece cover out to finish stamping work, in the work process, have a emergency stop signals would return to the safe place. Action steps: Begin button=> Workpiece distribution forward => stamping work => Stamping initial position=> Distribution initial position Section 5 Buffering Station 1. Technical parameter 1, Electric control cabinet main circuit power supplies: single phase AC220V10% 50Hz 2, Electric control cabinet control circuit power supplies: DC24V 3, Temperature: -1040; Humidity: 90%25 4, Dimension750mm750mm950mm 5, Air pressure0.4~0.6Mpa 6, Capacity1KVA 2. Working principle
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Provide workpiece that was transmitted from buffer station to robot, also has buffer role.

[provide workpiece transmission station robot waiting robot signal tray initialization]

5.1 Components Contents Up/down convey cylinder

Transmission belt

Workpiece induction sensor

Figure

1.1 buffer station

5.2 Module Contents

5.2.1

Send up and down cylinder module

Provide workpiece that was transmited from buffer sation to robot, also has buffer role. Main components Double acting cylinders (flow regulator attached type) The cylinder with proximity sensors Transmission in position sensor proximity sensors 5/2 way double solenoid valves The positive and negative transmission
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2.1 /( /)

5.2.2 Transmission module Tray transmission belt robot station is composed of two layer transmission belt. Main components Tension adjusting device, steps transmission, flow gear motor, electrical control

Figure 2.2 Belt type conveyor belt

5.2.3 Workpiece induction sensor module After judge the workpiece material send the signal to the next station. Discriminant out metallic and nonmetallic according to characteristics of the different sensor, non-ferrous workpiece and black workpiece to classific each workpiece Main components Capacity sensor, induction sensor, the direct reflect optical fiber sensor, cylinder speed controller (flow control valve)

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Figure 2.3 sensor module Workpiece material sensor type Black workpiece workpiece Non-ferrous Metallic workpiece

(Black red metal) 1.Optical fiber sensor 2.Capacitor sensor 3.Inductive sensor

5.3 Working Contents 5.3.1 Order requirements

Begin condition All the parts are reset condition. Initial condition Transmission belt stop Delivery cylinder decline Transmission belt internal brake rise Working order Left/right deliver cylinder rise. Handing station provide workpiece. (Use function key instead when work dependently.) Lauch transmission belt deliver to right transmission belt. Wait lauch signal from robot. Use function key instead when work dependently. Delivery cylinder deline, empty tray recycling.

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5.4 Training Subjects Training subject 1 Subject Debugging Mitsubishi PLC (hardware) AimDebugging Mitsubishi PLC Training contents:FX2N64MR series)NPN connection Training subject 2 SubjectDebugging Mitsubishi PLC (software) AimDebugging Mitsubishi PLC Training contents Install GX Develop and make new program, set CPU type and communication terminal, and then test all the connection. Training subject 3 SubjectPLC wiring Aim Refer to I/O table and connection figure finish PLC wiring. Training contentsReference the wiring diagram and the I/O distribution table complete PLC NPN wiring and testing all terminal. Training subject 4 ThemeThe motor turning/reverse control Aim Control motors turning and reverses method Training contentsUse two signal control motors turning and reverse. Think again what circumstance will appear if both sides signal exist side by side, and draw the appropriate circuit diagram. Training subject 5 Subjectreset Aimreset action (initialization) Training contentsPress the reset button equipment initialization. X, Y axis in the left lower part, the Z axis indented state.

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13 9 5 1 (ORG)

14 10 6 2

15 11 7 3

16 12 8 4 Robot positi on

Training subject 6 Subject Material feeding action 1 AimTray material feeding action Training contentsPress the reset button equipment initialization, press the start button take out 1 tray. Action steps Reset switch => Initialization => begin button => Z axis forward => Y axis up => 2S => Z axis indented => Y axisdown => 2S => Stop
13 9 5 1 (ORG) 14 10 6 2 15 11 7 3 16 12 8 4 Robot position

Training subject 7 Subject Material feeding action 2 AimTray material feeding action Training contentsPress the reset switch equipment initialization, press the start button take out 1 tray placed in robot grab position. Action steps Reset begin => Initialization => begin button => Z axis forward => Y axis up => 2S => Z axis indented => Y axis down => 2S => Stop => X axis move => robot position => Y axis up => 2S => Z axis forward => Y axis down => 2S

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13 9 5 1 (ORG

14 10 6

15 11 7

16 12 8 Robot

positio n

Training subject 8 SubjectTray in the robot to the warehouse. (1)

location transfers the case

AimTray in the robot location transfers the case to the warehouse. (1) Training contentsTray in the robot location transfers the case to the warehouse 1. Action steps Reset switch => Initialization => begin button => Z axis forward => Y axis up => 2S => Z axis indented => Y axis down => 2S => Stop =>X axis move => robot position => Y axis up => 2S => Z axis forward => Y axis down => 2S => Function switch => Y axis up => 2S => Z axis indented => X axis move => NO.1 position Training subject 9 SubjectTray in the robot location transfers the case to the warehouse. (2) AimTray in the robot location transfers the case to the warehouse. (2) Training contentsTray in the robot location transfers the case to the warehouse 2. Action stepsReset switch => Initialization => begin button => Z axis forward => Y axis up => 2S => Z axis indented => Y axis down => 2S => Stop =>X axis move => robot position => Y axis up => 2S => Z axis forward => Y axis down => 2S => Function switch => Y axis up => 2S => Z axis indented => X axis move => NO.1 position => X axis stop & Y axis up => 2S => Z axis forward => Y axis down => 2S => Z axis indented
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13 9 5 1 (ORG)

14 10 6

15 11 7

16 12 8 Robot positi on

Section 6 Pressing station


1. Technical parameter (1) Electric control cabinet main circuit power supplies: single phase AC220V10% 50Hz; (2) Electric control cabinet control circuit power supply:DC24V (3) Temperature:-1040environmental humidity: 90%25 (4) Dimension:750mm750mm1470mm (5) Air pressure: 0.4 ~ 0.6 Mpa (6) Capacity: 1KVA 2. Working principle From Robots get a signal make pressure homework for the workpiece cover, and provide the cover for robot. [robot OK single provide material pressure work robot waiting ] 6.1 Component contents Distribution module Pressure module& hydraulic converter Pressure slot module

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Delivery slot module

Figure 1.1 pressing station

6.2 Module Content 6.2.1 Distribution module

The silo store workpiece. Stored workpiece induct through the optical fiber sensor. There are more than two workpieces in the silo will work, it will work, it will alarm when there are no workpiece. Main compents Double acting cylinders (flow regulator attached type) Workpiece confirm optical fiber sensor The cylinder with proximity sensors 5/2 way single solenoid valves

Figure 2.1 distribution module and hydraulic circuit

6.2.2 Pressure module & hydraulic converter Pressure work need a lot of pressure, on the site also use hydraulic pressure. If use hydraulic
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system will improve the training effect but system is complex, so using the hydraulic converter

Main components

Double acting cylinders The cylinder with proximity sensors 5/2 way single solenoid valves Hydraulic converter Pressure cylinder stents

Figure 2.2 Pressure module & hydraulic converter

6.2.3

Pressure slot module

There is a slot that benefit to the pressure work on the module, after the operation, cylinder under the slot rise and push workpiece up to another slot.

Components

Double acting cylinders Workpiece confirm optical fiber sensor The cylinder with proximity sensors 5/2 way singal solenoid valves Launch cylinder fixed stents

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Figure 2.3 distribution module and pneumatic circuit

6.2.4

Delivery slot module

Robot graps workpiece directily put thwm on the slot after finished pressure works, this is for

more firmly to deliver robot to grab again


Figure 2.4 delivery slot module

6.3 Working Contents 6.3.1 Order requirements

Begin condition

All the parts are reset condition. Provide workpiece on the distribution module. Distribution cylinder retract Pressure cylinder retract Delivery cylinder retracted after the pressure works over.
Working order

From robot get material signal and OK signal.(when working independently start button
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instead ) Sense workpiece on the distribution module. Provide workpiece. Pressure work. Workpiece that finished pressure works provide upward workpiece Use delivery cylinder to deliver. 6.4 Training Subjects Training subject 1

SubjectMitsubishi robot Aim: operate Mitsubishi robot Training contentsThe data cables that connect controller to mitsubishi robot. Training subject 2 SubjectRobot wiring AimRefer to I/O table in the manual finish robot wiring. Training contentsReference the wiring diagram and the I/O distribution table complete PLC NPN wiring and testing all robot interface. Training subject 3 SubjectUsing the handle AimUsing the handle to operate robot Training contentsUse the handle and move the 6 axis up. Training subject 4 SubjectRobot action 1 AimMove from P1 to P2.
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Training contentsOperate robot from any P1 point move to P2. Training subject 5 SubjectRobot action 2 Aim: Use timer from P1 move to P2. Training contentsOperate robot from any P1 point move to P2. Action steps: P1 => 1s => P2 => 3s Training subject 6 SubjectRobot action 3 AimUse timer in P1 to claw ON in P2 to claw OFF Training contentsOperate robot from any P1 point move to P2. Action steps: P1 => claw ON => 1S => P2 => claw OFF => 1S Section 7 AS/RS Station 1. Technical parameter (1) Electric control cabinet main circuit power supplies: single phase AC220V10% 50Hz; (2) Electric control cabinet control circuit power supply: DC24V (3) Tempeture:-1040Environmental humidity: 90%25 (4) Dimension:750mm750mm1470mm (5) Air pressure: 0.4 ~ 0.6 Mpa (6) Capacity: 1KVA 2.Working principle From robot get signals and provide small workpiece and spring for robot.

[robot material & prepare signal provide material robot OK signal empty tray initialization ]

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7.1 Component Contents Axis drive

Loading workpiece

Tray and components

Figure 1.1 AS/RS station

7.2 Module contents 7.2.1 Axis drive module Use DC motor to deliver work pieces Pivot on the X, Y axis be equipped with sensors that can stop any position where it want to. Use motor controller control motor reversing. Main components DC gear motor, relay control, position proximity sensors

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Figure 2.1 X,Y axis ball screw driver

7.2.2

Workpiece loading module

Carrying 16 trays, the independent warehouse in the right side is the part of robot takes workpiece. Each tray attach with a little workpiece and a spring, a type tray to carry in 1 ~ 3 layer, B type tray carry in fourth layer.

Figure 2.2 loading warehouse and the robot convery module

7.2.3 Tray and little workpiece It can be adapted loading workpiece position program according to the design; in this program, the black, metal, non-ferrous workpiece position is different. Workpiece a distributed in the fourth layer of automatic storage (4), the rest 1, 2, 3 layer (12) distribute workpiece b.
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Figure 2.3 a) black workpiece (left) and b) non-ferrous and metal workpiece(right) 7.3 Working Contents

7.3.1 Order requirements condition Begin condition All the parts are reset condition. Initial condition Provide materials for tray (Type A, type B supply respectively) The Z axisis indented state. The X axis is in the most left side. The Y axis is in the most below side. Workpiece order From robot get material signal and OK signal.(when working independently start button instead ) According to the material X, Y axis move. Z axis forward prepare to lift the tray. Y axis rise to lift the tray. After the Z axis indented, began to deliver. Wait the signal that the robot taken materials Place the empty tray back, and wait the next signal.

7.4 Training Subjects


Training subject 1 SubjectDebugging Mitsubishi PLC (hardware) Aim: Debugging Mitsubishi PLC
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Training contents: Mitsubishi PLC (FX series ) NPN connection Training subject 2 SubjectDebugging Mitsubishi PLC (software) Aim: Debugging Mitsubishi PLC Training contents: install GX Develop make mew program, set CPU type and communication port and test all connection. Training subject 3 SubjectPLC wiring Aim Refer to I/O table and connection figure finish PLC wiring. Training contentsReference the wiring diagram and the I/O distribution table complete PLC NPN wiring and testing all terminal. Training subject 4 SubjectStorage action 1 AimFinish storage work Training contents: Press the start button in the first warehouse load workpiece. Action steps: begin button => convey belt ON & brake => switch 1 cylinder forward => storage finish => switch1 cylinder indented Training subject 5 SubjectStorage action 2 AimFinish storage work Training contentsPress the start button in the second warehouse load workpiece. Action steps: begin button =>convey belt ON & brake => switch 2 cylinder forward => storage finish => switch 2 cylinder indented Training subject 6 SubjectStorage action 3 AimFinish storage work
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Training contentsPress the start button in the third warehouse load workpiece. Action steps: begin button => convery belt ON & brake => storage finish

Section 8 Robot Station 1. Technical parameter (1) Electric control cabinet main circuit power supplies: single phase AC220V10% 50Hz; (2) Electric control cabinet control circuit power supply:DC24V (3) Tempeture:-1040Environmental humidity: 90%25 (4) Dimension:750mm750mm1470mm (5) Air pressure: 0.4 ~ 0.6 Mpa (6) Capacity: 1KVA 2. Working principle Robot clips the workpiece that transferred by the last station, and transmitted to the next station through the slippery rod. 8.1 Component Contents 6 axis multi-joint robot

Pneumatic claw module

Slide rod module

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Figure 1.1 Robot station

8.2 Module Contents 8.2.1 Vertical multi-joints (6 axis) robot According to the intention of the operator to grab and transmit workpiece freely. Main components Vertical multi-joints robot Robot controller Handheld programmer 5/2 way double-acting solenoid valves

Figure 2.1 Vertical multi-joints robot

Figure 38 Connection of robot and controller

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Figure 2.2 Connection of robot and handles

Robots are sophisticated equipment that used in the industrial site, so it is necessary to prepare and master the knowledge of robot before the use and need to periodically manage and maintenance. The more detailed about the robot can reference manuals provides by Mitsubishi manufacturers. Safety instructions Standard specifications Robot installation and maintenance Controller operation manual Command language manual 8.2.2 Pneumatic claw module Used for claw the workpiece Main components Double gas chuck Cylinder with proximity sensors 5/2 way single-acting cylinder Cylinder speed controller (flow regulator valve)

Figure 2.3 Glab module


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When the robot grabs workpiece, please reference below figure to avoid a collision with other parts.

Figure 2.4 Robot moving way

8.2.3 Slide rod module From the workpiece of robot transmit to the next station. Main components Slide rod, support, base plate of Outline form

Figure 2.5 Transmit slide rod 8.3 Working Contents 8.3.1 Order requirements Begin condition All the parts are reset condition. Robot should in a position that not occur interference with its components. Initial condition Robot should in a position that not occur interference with its components. Alarm on the robots controller should lift. Robot claw hand should be open. The fixed cylinder on the workbench should be fixed open
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Working order Fix workpiece body. Place in processing table. Assemble little workpieces and spring provided by automatic storage station together with workpiece. Assemble workpiece covers were provided by pression station. Deliver to sorting station. It was waiting for back to initial position. 8.4 Training Subjects Training subject 1 Subject Debugging Mitsubishi PLC (hardware) AimDebugging Mitsubishi PLC Training contents:FX series)NPN connection Training subject 2 SubjectDebugging Mitsubishi PLC (software) AimDebugging Mitsubishi PLC
Training contents Install GX Develop and make new program, set CPU type and

communication terminal, and then test all the connection. Training subject 3 SubjectPLC wiring Aim Refer to I/O table and connection figure finish PLC wiring. Training contentsReference the wiring diagram and the I/O distribution table complete PLC NPN wiring and testing all terminal. Training subject 4 SubjectTransmit workpiece
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AimTransmit workpiece Training contents: Press the start button and transmit the finished workpiece in the handling station to transmitting station.
Action steps: begin buttom => claw down => grab => claw up => transmit=> claw off

Training subject 5 SubjectSpare defective goods AimSpare defective goods Training contentsPress the start button from processing station detected defective goods loaded into slippery course handling station. Action steps: begin button => claw down => grab => claw up => rodless cylinder arrive => claw down=> claw off=> claw up =>move to initial position (handle direction) Section 9 Sorting Station 1. Technical parameter (1) Electric control cabinet main circuit power supplies: single phase (2) Electric control cabinet control circuit power supply:DC24V (3) Tempeture:-1040Environmental humidity: 90%25 (4) Dimension:750mm750mm1470mm (5) Air pressure: 0.4 ~ 0.6 Mpa (6) Capacity: 1KVA 2. Working principle Store the different workpiece in the corresponding slide rod. 9.1 Components Contents Transmission belt module AC220V10% 50Hz;

Buffering module

Convert cylinder midule

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Slide rod module

Workpiece test sensor module

Figure 1.1 Sorting station 9.2 Module Contents 9.2.1 Transmission belt module

Belt form transmission belt device. Vertical transfer workpiece, transmission belt controlled by a dc motor, the control use relay.

Main components Tension adjusting device Dc gear motor Relay control Optical fiber sensor test workpiece

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Figure 2.1 Transmission belt module

Induction components The workpiece that use optical fiber sensor induction into.

Figure 2.2Induction workpiece into

The operator arbitrary definite slide rod. For instance, NO.1 slide set as store black workpiece.NO.2 is blue workpieceNO.3 is aluminum workpiece

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Figure 2.3 Slide rod distribute different kinds of workpiece 9.2.2 Buffering module

Used to prevent the transmission workpiece, adjust transmission speed. Main components Single-acting cylinder 5/2 way single-acting solenoid valve

Figure

2.4 buffer module structure and role form Brake

Figure 2.5 Pneumatic circuit 9.2.3 Convert cylinder module

Push the transmission workpiece to the corresponding slide rod. Action form is convert the straight-line movement of the cylinder to the rotary motion. Main components Double-acting cylinder Cylinder with proximity sensor 5/2 way single-acting solenoid valve
Switch 1

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Figure .6 convert cylinder module and pneumatic circuit 9.2.4 Slide rod module

Store the default different workpiece in the corresponding slide rod. Main components Outline form slide rod, support, base plate

Figure 2.7 Slide rod module

9.2.5 Workpiece test sensor module Test the workpiece stored in the slide rod, when the workpiece on the slide rod under the condition of the full, no longer continue to work. Main components Reflective optical fiber sensor, sensor brackets and base plate

Figure 2.8 Reflective optical fiber sensor

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9.3 Working contents 9.3.1 Order requirements Begin condition All the parts are reset condition No workpiece on transmission belt No workpiece on storage slide rod Convert cylinder is retract state. Intinal condition Buffer cylinder is forward state Transmission belt stops. Convert cylinder is retract state. Working order Buffer cylinder at the forward state induct workpiece make brake retract and began to work. Transmission belt starts. Buffer cylinder retracts. According to the order of the default, workpiece is storaged to the corresponding slippery slot by convert cylinder. Workpiece on the slide rot stoped when they into transmission belt. The forward convert cylinder retract.

9.4 Training Subjects Training subject 1 SubjectDebugging Mitsubishi PLC (hardware) AimDebugging Mitsubishi PLC Training contents:FX series)NPN connection Training subject 2 SubjectDebugging Mitsubishi PLC (software)
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AimDebugging Mitsubishi PLC Training contents Install GX Develop and make new program, set CPU type and communication terminal, and then test all the connection. Training subject 3 SubjectPLC wiring Aim Refer to I/O table and connection figure finish PLC wiring. Training contentsReference the wiring diagram and the I/O distribution table complete PLC NPN wiring and testing all terminal. Training subject 4 SubjectThe motor turning/reverse control Aim Control motors turning and reverses method Training contentsUse two signal control motors turning and reverse. Think again what circumstance will appear if both sides signal exist side by side, and draw the appropriate circuit diagram. Training subject 5 SubjectTray sent to 1 AimSend tray to the second layer Training contentsPress the start button put the tray delivered to the second floor, then the tray initial position is middle position of a layer. Action steps: Begin button => transmission belt on => 1 layer brake down => left side module 2 layer => plase workpiece on the second layer. Training subject 6 Subject: Tray sent to 2 AimSend tray to the first layer Training contentsPress the start button put the tray delivered to the first floor, then the tray initial position is middle position of two layer.
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Action steps: Begin button => transmission belt on => 1 layer brake down => left side module 1 layer => place workpiece on the first layer.

Chapter Four Operation Instruction


I installation Notes 1, Avoid the damage of the small parts such as air cylinder when install equipment. 2, Do not use the old socket or the power supply wire, have get an electric shock and fire danger. 3, install in a clean, dry place, avoid overheating or abnormality. 4, Operating in the stabilizing voltage, in order to avoid the abnormality of equipment. 5, You must use the socket that connects ground wire, prevent leakage and get an electric shock. Near controller or sensor ban close to the object that with magnetic, to avoid serious error or fault. 6, When you open the power supply, first open the main source. 7, When you install and mobile quipment, first pulled out power and then moving. 8, Avoid object with water close to equipment. 9, Before start equipment, please check electrical and system, then start. 10,Before start the equipment,please confirm whether air pressure is 0.5 ~ 0.6 mpa. 11,When equipment act, avoid hand or other parts were clamped by cylinder or other components. 12, Do not use the hand with water touch plug or electronic/electrical components, to avoid shock. 13, when you operate robot, please avoid having obstacles within robot action ranges. 14, After use, please inspect equipment safety status and work state periodically in order to ensure the equipment performance and life. II Mechanical assembly
DLM PS- 900A - 6 DLM PS- 900A - 7 DLM PS- 900A - 1 DLM PS- 900A - 2 DLM PS- 900A - 3 DLM PS- 900A - 4 DLM PS- 900A - 5
DISTRIBUTION TESTING PROCESSING HANDLING BUFFERING PROCESSING AS/RS

DLM PS- 900A - 8 DLM PS- 900A - 9


ROBOT ASSENSLY

SORTING

Above figure are the arrangement sequence diagram You can put 9 stations in one line accord to the order, after use the installation fixed board fix every two station, tightened the nut in the fixed board, fixed the caster wheel in each station. Down gap between stations to least, lest cause the workpiece does not reach the designated position during the transfer process, or pull in does not reach the designated position,
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III Gas road connects With three-way joint connect the trachea of pump, intake end of first station air treatment, and the three-way connected joint of the second station, according to this method connect air road of several other station. Air Tube Adapter must be connected good and avoid a flat or gap gas and contact undesirable.

IV Circuit connection (network connection) 1, Profibus-dp head of 1 station and 9 station plasy to ON.

ON

ON

A1 B1 A2 B2

A1 B1 A2 B2

MPS900A-1 1
9

MPS900A-9

DISTRIBUTION
2, Connection way of ommunication line as below

SORTING

ON

Off

Off

Off

Off

Off

Off

Off

ON

A1 B1 A2 B2

A1 B1 A2 B2

A1 B1 A2 B2

A1 B1 A2 B2

A1 B1 A2 B2

A1 B1 A2 B2

A1 B1 A2 B2

A1 B1 A2 B2

A1 B1 A2 B2

MPS900A-1 1 2

MPS900A-2 3

MPS900A-3 4

MPS900A-4 5

MPS900A-5 6

MPS900A-6 7

MPS900A-7 8

MPS900A-8 9

MPS900A-9

DISTRIBUTION

TESTING

PROCESSING

HANDLING

BUFFERING

PROCESSING

AS/RS

ROBOT ASSENSLY

SORTING

There is a kind of purple cable in the packing bosex, it has nine profibus-dp head, only the DP
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head of 1 station and 9 station including purple cable that a root into, and the rest are all contain two purple cable that one into and one out. Put DP head from the control cabinet through the hole, connect the corresponding head to the corresponding DP interface of PLC, PLC of main station is S7-300, there is a EM277 in each local station, connect DP head to EM277 interface. V Equipment operation sequence 1, Sequence of convery power supply Open the equipment general supply and supply power to air pump, when air pump pressure is 0.4 MP ~ 0.6 MPa, open air pump valve, open one station air treatment processor (pressure valueis 0.4 ~ 0.6 MPa), switch on and transfer power to one station (convery power supply as following order) :
6 station 4 station 7 station 3 station 9 station 2 station 8 station 1 station 6 station 5 station

Emphasis: when 8 station transfer power suppy, should be paid attention to send robots power, then the power to PLC

Press on emergency stop button of each station, then releasing abrupt stop button of each station, press the reset button of each station, and press on start button after start light flesh, according to the above methods, the sequence of transfer power reset to each station 2, Power stop sequence
First stop power, and then turn off air supply

Stop power: press on emergency stop button (Power stop sequence as following):
1 station 8 station 2 station 9 station 3 station 7 station 4 station 6 station 5 station

Then switch off (Disconnect each circuit breaker). Shut air source: close air processor hand valve (stop gas order as following) :
1 station 6 station 2 station 7 station 3 station 8 station 4 station 9 station 5 station

Then total air valve (close air pump hand valve) VI The common problems and the processing method If appear this kind of problem, please click the following order for testing, if the problem cannot be solved or other questions, please contact with customer service center. symptoms solution

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-check the power switch. Check the electrical connection part Motor can't operate of the motor, see whether offer with polarity. -check out the chain and gear -check motor controller -detection ac 220 V is connected to the right. Power can't -detection green LED power supply. transfer -due to short circuit or overload power show mistakes -check sensor position Sensor doesn't work Electromagnetic valve does not work When there is a station appear incident or failure -with a metal object manually close to sensor test the response signal. See whether electromagnetic valve has electricity Whether supply gas Whether the corresponding magnetic switch has any signals Press od emergency stop button, and play PLC to STOP, after 1S to RUN , restart all stations equipment

VII 5-way shuttle valve electromagnetic valve classification and action theory

1, 2 single electronic control acting

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Two single electric solenoid valves When solenoid valves losing electricity 2, 2 double electronic control acting

When solenoid valves getting electricity

2 single electric solenoid valves. The left electromagnetic valve get electricity right electromagnetic valve get electricity 3, 5/3 middle seal type action

The

4, The regular maintenance of pneumatic components Every day (1) Before operate, please confirm whether the condensed water of the filter, tank and other place to discharge (2) Confirmation of important place pressure. Every week (1) Check air leakage status (2) Whether the press parts and connection parts are loose Every half year (1) Filter: whether filter is blocked?
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(2) The pressure reducing valve: check pressure adjustment is normal or not (3) Shuttle valve: whether the coil is buzzing? (4) Cylinder: whether it has a flat, and buffer is normal or not

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