Fms 200 Manual

TECHNICAL DESCRIPTION
FMS-200
FLEXIBLE AUTOMATED CELL TRAINER
10 REASONS FOR CHOOSING THE FMS-200

SYSTEM
1. The FMS-200 is manufactured entirely from industrial grade materials of maximum
strength and quality.
2. It complies with European safety directives in respect of both low voltage and
machine safety.
3. It includes a 4- metre line transfer system which integrates the various stations.
4. The process stations or layouts can work independently or integrated in the transfer in
cell mode, and can change position within the transfer.
5. The automatons needed for system control are included, with mains supply
connection, and users may design their own electrical control gear based on other,
different, PLCs.
6. Each of the stations incorporates a key-protected Fault Generation System which
makes it possible to work on diagnostic and repair capabilities, using the Switches
methodology and Virtual Repair.
7. The FMS-200 cell has been designed for assembly of a turning mechanism with a
total of 24 variants.
8. The pallets and transfer incorporate a magnetic coding system using inductive
detectors, which allow the Control System to identify the position of each pallet at
any time.
9. The Practical Activities drawn up from the modular concept of the system allow the
development
of
skills
such
as:
ANALYSIS,
INSTALLATION
/ASSEMBLY/IMPLEMENTATION, MAINTENANCE / DIAGNOSIS /FAULT
REPAIR,
START-UP/SET-UP,
DESIGN/LAYOUT,
PROGRAMMING,
PREPARATION OF DOCUMENTATION, DEFINITION OF PROCEDURES,
MEASURING,
ETC.,
integrating
different
technologies
including:
Pneumatics/Electro-pneumatics,
Hydraulics,
Electrical
Actuators,
Robotics/Manipulation, Industrial Communications, Control Systems, Electric
Automatisms, Safety Devices, Basic Mechanical Systems, and so on.
10. It has been conceived and designed using the pooled knowledge of two leading
companies: SMC (world leader in pneumatics and electro-pneumatics) and ALECOP
(leader in the world of training).
INDEX
1. TECHNICAL AND FUNCTIONAL DESCRIPTION....1
1.1 Programmable automaton with network communications system..3
1.2 Automaton programming software.3
2. PROCESS STATIONS....4
2.1 Body feed- positioning.4
2.1.1. Station function..4
2.1.2. Integral parts..4
2.1.3. Technical data5
2.2. BEARING HANDLING-FITTING LAYOUT..7

2.2.1. Station function..7
2.2.2. Integral parts..7
2.2.3. Technical data9
2.3. HYDRAULIC BEARING PRESSING LAYOUT...11

2.3.1. Station function11
2.3.2. Integral parts...12
2.3.3. Technical data..13
2.4. SHAFT HANDLING-FITTING-MEASUREMENT-SELECTION15

2.4.2. Integral parts15
2.5. COVER HANDLING-FITTING-SELECTION LAYOUT.21

2.5.1. Station function...21
3

2.6. SCREW HANDLING-FITTING..27

2.6.2. Integral parts...28
2.6.3. Technical data.29
2.7. ROBOT SCREWDRIVER..31

2.8. UNLOADING-STORAGE-PALLETIZATION OF COMPLETED ASSEMBLY.33

2.8.1. Station function....33
2.8.2. Integral parts....33
2.8.3. Technical data.....35
3. 4-METRE TRANSFER LINE WITH AUTOMATON AND PALLET ASSEMBLY...37

3.1. Transfer function and composition.......37
3.2. Technical details of transfer......38
4. INSTALLATION AND START- UP.40
4.1.
Prerequisites.40
Spatial requirements 40
4.1.2.
Electrical requirements 41
4.1.3.
Air requirements ..41
4.2.
4.1.1.
Handling and packaging ..43

4
4.3.
Installation ...44
Individual station .44
4.3.2.
Cell ..45
4.4.
4.3.1.
Start- Up ..46
Individual Station 46
4.4.2.
Cell ..48
4.5.
4.4.1.
PROCEDURE FOR USE 49

4.5.1.
Individual Station 49
4.5.2.
Cell ..50
5.
LOCATING AND CORRECTING FAULTS 51
6.
MAINTENANCE AND INSPECTION .67
6.1.
Introduction .67
6.2.
Inspection points .67

Daily inspection ...67
6.2.2.
Periodic inspection ..67
6.3.
6.2.1.
Maintenance procedures ..68

6.3.1.
Pneumatic components 68
6.3.2.
Electrical shafts ...68
6.3.3.
Cleaning ......68
7.
SAFETY ..69
7.1.
General safety precautions ..69
7.2.
Protection and safety devices ..69
8. FAULT SIMULATION SYSTEM..70
9. SETS OF PARTS FOR ASSEMBLY.....71
10. EC SELF- CERTIFICATION...72
11. SUPPORT MATERIAL....73
ANNEX A: FAULT GENERATION
ANNEX B: ELECTRIC DIAGRAMS
ANNEX C: PNEUMATIC DIAGRAMS
ANNEX D: GRAFCET AND CONTROL PROGRAMS
ANNEX E: MECHANICAL DIAGRAMS
ANNEX F: MANUALS
1.- TECHNICAL AND FUNCTIONAL

DESCRIPTION
From SMC, a world leader in Pneumatics, we introduce SMC International Training. Our
clear and wholehearted international vocation defines the objectives of this company: the
conception and marketing of training systems in the automation field to satisfy the training
needs of educative centres and companies all over the world.
An example of a Comprehensive Training System developed within the framework of this
project, constitutes the Flexible Assembly System FMS-200.
Figure 1: Flexible Automated Cell Trainer FMS-200
The flexible automation cell has been specially conceived for persons to acquire professional
capabilities in connection with the Occupational Groupings of Electricity/Electronics and
Maintenance, such as:
-
Installation, Electromechanical Maintenance and Line Transport.

Industrial Equipment Maintenance.
Automatic Control and Regulation Systems.
It enables the development of various skills associated with pneumatic, electro-pneumatic,

electrical, robotic and handling automatisms, programming and PLC technologies, industrial
communications, supervision, quality control and fault diagnosis and repair. It also allows the
study of a wide range of sensor types:
-
Magnetic detectors.
Inductive detectors.
Hall detectors.
Photoelectric detectors.
Reed detectors.
Photochromatic detectors.
Capacitive detectors.
Linear encoders.
Etc.
The system comprises a flexible automation cell which carries out an assembly process
involving a number of predetermined parts with a total of 24 different possibilities.
Figure 2: Turning mechanism
Figure 3: Turning mechanism components
Parts are transported between the different stations or layouts by an automated 4-metre
transfer line with corresponding stoppers and precision lifters-positioners. Parts are mounted
on pallets with a magnetic coding system.
The process stations or layouts function either independently of the transport system, or
integrated into it. The stations are situated around the transfer, and may be withdrawn for repositioning in a different order, moved for future extensions or work in a completely
independent and self-sufficient mode.
Each station has its own electrical panel, where the wiring system and automaton are fully
visible for study, while new elements may be fitted to the panel if desired. This electrical
control panel may be made entirely independent at each station for use in programmable
automaton training. In addition, students may design and build their own controls with
different automatons and subsequently integrate them in the station, thereby developing a
further series of skills envisaged in the Training Cycles for those persons who form the target
group for the Cell.
The front of each station incorporates the start, stop, and single and continuous cycle
pushbuttons.
The system is modular and may be extended, allowing future incorporation of other process
stations according to user needs.
The stations are mounted on aluminium sections, forming tables with a large surface area and
multiple slots to allow all types of extension and modification.
The assembly process performed (turning mechanism) is as follows:
Layout A: Feed body to which the other parts are assembled.
Layout B: Pick and Place bearing.
Layout C: Press bearing in hydraulically.
Layout D: Pick and Place shaft, and verify.
Layout E: Pick and Place cover.
Layout F: Fit screws.
Layout G: Robot screw driving.
Layout H: Unloading, storage and palletization of final assembly.
1.1. PROGRAMMABLE
AUTOMATON
COMMUNICATIONS SYSTEM.
WITH
NETWORK
The standard layout includes a programmable automaton, Omron model CPM2C, panelmounted via a DIN track.
The CPM2C automaton has 6 inputs and 4 outputs, timed and programmed interrupts,
internal PID, high-speed counter and 0.08us instruction time. It incorporates an RS-232 port
for programming, and an DeviceNet port for communication with other automatons or PCs.
The automatons which govern the cell stations communicate with each other via a network,
so that each station comes ready with the necessary adapter and communications module.
1.2. AUTOMATON PROGRAMMING SOFTWARE

This software enables programming of instructions and contact diagrams for all standard
OMRON automatons in any desired layout. It allows ON LINE contact diagram monitoring
and modification. There are options to generate listings with comments, data reports and
memory listings. It incorporates help advice in all functions. The software includes an
operating manual and works under the Windows environment.
2. PROCESS STATIONS
2.1. BODY FEED-POSITIONING
2.1.1. STATION FUNCTION
This first station feeds in the body which is the support for the turning mechanism, and
moves it to the pallet located in the transfer system.
This operation begins when the pallet is opposite the station, held in a determined location by
a stop on the transfer. Confirmation that the pallet is in the correct position is provided by a
microswitch which sends the appropriate signal to the automaton.
2.1.2. INTEGRAL PARTS

Station A, like the others, may be divided into a series of modules. Each sub-division has
been made by considering it as a set of components which performs a specific operation
within the process completed at the station. Starting out from this consideration, a description
is given below of the ordered sequence of actions performed for assembly of the body,
indicating the components involved in each operation.
-
Body feed:
The feeder which supplies the body is
of the gravity feed type, in that the
bodies are stored in a stack so that
when the bottom one is removed, the
next falls into place under the effect of
its own weight and that of the ones
above it.
The body is extracted by a pneumatic
cylinder which pushes against a pusher
shaped to match the profile of the
body.
Figure 4: Body-feed positioning
Position verification:
The body contains a housing in which the other components are fitted. This
housing must always be facing upwards when the base is placed on the pallet.
To check correct body orientation, a check is made by a cylinder which
advances and inserts a cylindrical part in the body housing. If the body is
inverted, this part cannot enter the housing, the cylinder cannot complete its
stroke and the magnetic detector on the cylinder is not activated.
A signal to this effect enters the PLC, resulting in an indication that the position
of the body is incorrect.
Movement to transfer point:

A cylinder with a pusher at its end is used to situate the body at the point from
which it is loaded onto the pallet.
4
The cylinder is rectangular, to prevent the pusher from turning.

-
Rejection of incorrect body:

If the verification process shows the position of the body to be incorrect, a
single-acting cylinder moves it towards a ramp, leaving the space clear for a
new body.
Placing body on pallet:

A two-axis manipulator is used to place the
body on the pallet lying on the belt
conveyor. Each axis carries a parallel rod
cylinder.
The terminal element is a vacuum holding
platform with four suction cups to absorb
possible lack of alignment in height.
Figure 5: Placing body on pallet
Suction is created by a vacuum ejector fitted with a vacuum switch

which sends a signal to the PLC indicating that the part has been
correctly clamped.
Figure 6: Vacuum Ejector
2.1.3. TECHNICAL DATA

Dimensions:
Table of slotted aluminium section, 900 x 540 mm.
Height 900 mm.
Air treatment unit:
Filter to 5 m, pressure regulator and pressure gauge.
Pushbutton control:
Start, stop, reset pushbuttons. Emergency button and error pilot indicator.
Composition of station modules:
Body feed module.
Magazine capacity: 12 bodies.
Actuators:
- Double-acting pusher cylinder 16, Stroke:100mm (CD85N16-100B), with flow
regulators and initial-end position detector. Controlled by 5/2 way monostable solenoid
valve.
Sensors:
- Reed type magnetic detectors (D-C73L).
5
Position verification module

Actuators:
- Double-acting cylinders 12, Stroke:50mm (CD85N12-50B), with flow regulators and
end position detector. Controlled by 5/2 way monostable solenoid valve.
Sensors:
- Reed type magnetic detector (D-A73CL)
Movement module
Actuators:
- Rectangular section pusher cylinder 25, Stroke:200mm (MDUB25-200DM), with flow
regulators and end position detector. Controlled by 5/2 way monostable solenoid valve.
Sensors:
- Reed type magnetic detector (D-A73CL).
Inverted body rejection module
Actuators:
- Single-acting ejection cylinder 10, Stroke:15mm (CJPB10-15H6). Controlled by 3/2
way monostable solenoid valve.
Pallet insertion module
Actuators:
- Horizontal axis: Parallel rod cylinder 20, Stroke:150mm (CXSWM20-150-XB11), with
flow regulators and initial-end position detector. Controlled by 5/2 way monostable
solenoid valve.
- Vertical axis: Parallel rod cylinder 15, Stroke:50mm (CXSM15-50), with flow
regulators and initial-end positio n detector. Controlled by 5/2 way monostable solenoid
valve.
- Holding plate: 4 telescopic suction cups 16 (ZPT16CNK10-B5-A10), with ejector to
generate vacuum (ZU07S). Controlled by 3/2 way monostable solenoid valve.
Sensors:
- Reed type magnetic detectors (D-Z73L)
- Vacuum switch PNP output (PS1100-R06L)
Input/ Output Module:
- DevideNet module 8 inputs/ 8 outputs
Electrical control panel:
- Mounted on perforated mesh 550 x 400 mm.
- Accessible terminal plate with supply connections and coded I/Os.
- Thermal overload switch incorporated.
- I/O station: 13 inputs, 10 outputs.
- Supply module: 24V/2.1A
- PLC control:
- Omron model CPM2C-S110C-DRT
- Digital Card 8 inputs CPM2C- 8EDC
- Digital Card 8 outputs CPM2C- 8ER
2.2. BEARING HANDLING-FITTING LAYOUT

The operation carried out by the second station consists of picking the bearing and placing it
inside the housing formed in the body.
Figure 7: Bearing Handling-fitting layout
The task of placing the bearing is performed on the pallet brought by the belt conveyor and
carrying the body located at the previous station. The bearing fitting operation requires the
pallet carrying the body to be precisely situated in a predetermined place. To achieve this
precision, once the pallet has been retained by a stop, it is lifted by a cylinder and centred at
the same time by four pins which fit inside housings formed for this purpose in the bottom of
the pallet.

Bearing insertion requires a series of operations which are carried out by the following
modules:
-
Bearing feed:
The bearings are held in a gravity feed
magazine. This consists of a column
magazine with a pusher cylinder at the
bottom which extracts the bearing at the
moment the cycle is to start.
Figure 8: Bearing feed
In this case, there is a bearing proximity sensor in

the form of a microswitch which allows the PLC
to verify that a bearing really has been extracted
following the feeding procedure. This makes it
possible to determine when the bearings loaded in
the feeder have run out.
Figure 9: Proximity sensor
Transfer to measuring station:

A manipulator is used to move the bearing from the feed point to the place
where the following operation is to be performed. The manipulator uses a rack
and pinion type rotary actuator which describes an angle of 180.
An arm is attached to the rotary actuator to move a two- finger parallel-opening
gripper which grips the inner part of the bearing. This arm houses a mechanism
consisting of a toothed belt and two pinions, the purpose of which is to change
gripper orientation throughout the turning moveme nt, so that when the bearing
reaches the point at which it is deposited, it has no angle of inclination
whatsoever.
Figure 10: Transfer to measuring station
Height measurement:
As the station caters for the
possibility of feeding bearings
of differing heights, a measuring
module
is
included
to
differentiate between them.
The bearing is deposited on a
platform, on a centring device
operated by a pneumatic
cylinder which locates it at a
very precise initial point.
Figure 11: Height measurement
This platform is lifted by a rodless pneumatic cylinder such that the bearing
contacts with a touch trigger and gives a height reading. The touch trigger
consists of a linear potentiometer with an output processed via an analogue
module included in the PLC.
After measurement, the lifter returns to its original position, at which time the
ejector cylinder pushes the bearing towards a collection bin if it is not of the
desired height.
-
Bearing insertion:
The final operation is performed by a manipulator comprising a rotary-linear
unit with an arm to which a two-finger gripper has been fitted. After picking up
the bearing, the arm is lifted, turns through 180 then drops down again to insert
the bearing in the housing formed in the body.
Figure 12: Bearing insertion

Dimensions:
Height 900 mm.
Air treatment unit:
Pushbutton control:
Bearing feed module
Magazine capacity: 38 bearings
Actuators:
regulators and initial position detector. Controlled by 5/2 way monostable solenoid valve.
Sensors:
- Reed type magnetic detector (D-C73L).
- Proximity detector: Microswitch OMRON V-166-1C5.
Measuring station transfer module
Actuators:
9
Rotary actuator: Double rack and pinion 50, ? max:180 ( MSQB50A), with flow
regulators and 0, 90 and 180 position detector. Controlled by 5/3 way solenoid valve,
mid position closed.
- Holding arm: Two- finger parallel-opening grippers (MHK2-16D). Controlled by 5/2 way
monostable solenoid valve.
Sensors:
- PNP type magnetic detectors (D-A93L).
Height measuring module
Actuators:
- Compact single-acting centring cylinder 12, Stroke:5mm (CQ2B12-5S). Controlled
by 3/2 way monostable solenoid valve.
- Vertical axis: Rodless cylinder 16, Stroke:250mm (MY1B16G-250), with flow
regulators and initial position detector. Controlled by 5/2 way bistable solenoid valve.
- Incorrect part ejection: Double-acting cylinder 10, Stroke:40mm (CD85N10-40),
with flow regulators. Controlled by 5/2 way monostable solenoid valve.
Sensors:
- Reed type magnetic detector (D-A93L).
- Linear potentiometer NOVOTECHNIK TR25.
Bearing insertion module
Actuators:
- Compact linear and rotary movement cylinder 32, Stroke:25mm (EMRQBS3225CB), with flow regulators and initial-end of travel detection for linear movement,
and 0 and 180 detection for rotary movement. Controlled by two 5/2 way monostable
solenoid valves.
- Holding arm: Two- finger parallel-opening grippers (MHK2-16D). Controlled by 5/2
Sensors:
- Reed type magnetic detectors (D-A73CL).
Input/ Output module:
- DeviceNet module 8 inputs/ 8outputs

- Supply module: 24V/2.1A.
- PLC control:
- Omron Model CPM2C-S110C-DRT
- Analogic Card 2 inputs/ 1 output CPM2C-MAD11.
10
2.3.
HYDRAULIC
LAYOUT
BEARING
PRESSING

Following the bearing insertion operation performed by the preceding station, this third
station carries out the task of pressing the bearing firmly into the body to fix it securely. In
actual fact, this pressing operation is not actually carried out; instead, it is only simulated so
that the finished assembly may be dismantled easily and the component parts reused.
In spite of this, the components included are all industrial grade and similar to those used in
numerous hydraulic applications. They allow the study of systems based on hydraulic
technology which incorporate real components integrated in an authentic application.
A complete hydraulic unit as required to supply the press cylinder with high pressure oil is
installed under the table, avoiding the need for any additional hydraulic installation other
than the electrical and pneumatic take-offs from the central transfer.
Figure 13: Hydraulic Bearing Pressing Lay-out
11

The pressing stage requires a number of operations to be performed, as detailed below.
-
Insertion / extraction of assembly:

The first operation consists of moving
the body with the bearing inside it
from the pallet retained at the transfer
to an unloading point inside the station.
This handling, and the reverse process
of unloading following pressing, are
performed by a pneumatic rotary
actuator.
Figure 14: Insertion/extraction of assembly
This actuator incorporates an arm with a set of four suction cups at its end,
whose job is to hold the part by means of an internal vacuum generated by
an ejector. To keep the body permanently horizontal throughout the turning
movement, this arm incorporates a pinion and toothed belt mechanism
similar to that used at the bearing insertion station.
Feed in to press:
The body to be fed in to the press is deposited on a platform fitted with two
double-acting pneumatic cylinders. The first effects the transfer from the
loading/unloading point to the press, while the second carries out the
reverse operation following the pressing operation.
Pressing the bearing:

When the body with the bearing inside has been positioned under the
hydraulic cylinder, a protective screen operated by a pneumatic cylinder
drops down. This protects the user against any risk of accident, and also
demonstrates a safety device widely used in this type of application.
By means of a hydraulic 4/3 way directional control valve, the pressing
cylinder now exerts a force which may be regulated using the pressure
limiting valve incorporated in the hydraulic unit. After pressing, the
cylinder returns to its original position, the screen is lifted and the assembly
is pushed to the unloading position.
Figure 15: Pressing the bearing
12

Dimensions:
Height 900 mm.
Air treatment unit:
Pushbutton control:
Assembly insertion/extraction module
Actuators:
- Rotary actuator: Double rack and pinion type 50, ? max:180 (MSQB50A), with flow
regulators and 0, 90 and 180 position detector. Controlled by 5/3 way solenoid valve,
mid position closed.
- Holding arm: 4 Suction cups 16 (ZPT16UN-B5), with ejector to generate vacuum
(ZU07S). Controlled by 3/2 way monostable solenoid valve.
Sensors:
- Vacuum switch PNP output (PS-1100-R06L).
Press feed module
Actuators:
- 2 Double-acting pusher cylinders 12, Stroke:125mm (CD85N12-125A), with flow
regulators and initial-end of stroke position detector. Controlled by 5/2 way
monostable solenoid valves.
Sensors:
Bearing pressing module
Actuators:
- Protector: Do uble-acting parallel rod cylinder 15, Stroke:100mm (CXSM15-100),
with flow regulators and initial-end position detector. Controlled by 5/2 way
- Pressing: Compact double-acting hydraulic cylinder 40, Stroke:50mm (CHDQH34050), with ATOS HQ012 flow regulators and initial-end position detector. Controlled
by ATOS DHI-0714 4/3 way solenoid valve, mid position closed.
Sensors:
- Reed type magnetic detector (D-Z73L and two D-A73CL).
- DevideNet module 8 inputs/ 8 outputs.
13

- Supply source: 24V/2.1A.
- Net filter.
- Frequency converter
- PLC control:
- Three-phase contactor for hydraulic unit operation.
Hydraulic unit:
- Three-phase motor 380V/1.4A 0.37kW 1400rpm.
- Pressure gauge.
- Pressure limiter.
14
2.4. SHAFT HANDLING-FITTINGMEASUREMENT-SELECTION

The fourth station follows the process needed to insert a
shaft into the bearing fitted at a previous station.
This station represents an increase in flexibility in that it
allows variety in the assemblies put together, in the form of
being able to fit shafts of different materials; aluminium or
nylon.
Figure 16: Shaft station
The existence of these variants means that the extra operations of checking the type of
material and extracting ones which are not of the desired material are added to the normal
operations of feeding, handling and insertion.

The extra operations to be carried out involve an increase in the complexity of the station,
which means that its structure is noticeably different from previous stations. In this case, the
components are arranged on an 8-station index plate.
Successive operations are performed at these stations, a description of which is given below:
-
Index plate:
This element is used as a system of
alternating rotary movement, in the sense
that each turning movement moves the
plate round by a number of degrees equal
to the circumference divided by the
number of defined positions.
To achieve this effect, the system
incorporates a pneumatic pusher cylinder
with back and forth movement giving the
required angular advance.
Figure 17: Index plate
There are a further two stop cylinders which function alternately, one moving
which holds the plate during the turn, and another fixed cylinder which locks
the plate in position when movement has ceased. In this way, the plate is held
firmly and the pusher cylinder can return to its initial position to await a new
cycle.
15
Shaft feed:
The shafts stored in a gravity type feeder are
deposited on the first plate station via a step-by-step
feed system involving two pneumatic cylinders.
These cylinders are in a permanent counterpoise
position, so that while the lower one releases the next
shaft from the feeder, the upper one holds the rest in
place.
F
Figure 18: Shaft feed
Shaft height measurement:

The shaft is not symmetrical and must therefore be
mounted on the assembly in a particular position.
The shaft is measured to check whether it has been
correctly inserted. A pneumatic cylinder fitted with
magnetic detector registers whether contact is made
with the shaft during outstroking, or whether the
cylinder is able to reach the end of its travel if the
shaft is not in its proper place.
Figure 19: Height measurement
Placing shaft in correct position:

If the second station on the index plate determines that the shaft has been placed
upside down, a manipulator has the job of turning it round. This is achieved by
holding the shaft between a two- finger gripper, lifting it by a parallel rod
cylinder, then turning it over using a 180 rotary actuator and replacing it in the
correct position in the housing.
Figure 20: Placing shaft in correct position
16
Shaft material detection:

The next operation at this station is carried out using two consecutive index
plate stations. The aim is to determine the material of which the shaft is made, it
being necessary to distinguish between aluminium and nylon. This is achieved
by inductive and capacitive detectors fitted to the third and fourth stations
which enable the two types of materials to be differentiated.
Figure 21: Shaft material detection
Removal of incorrect shaft:

As mentioned earlier, this station fulfils the potential to work at a higher level
of cell management by making a choice of shaft material to be used for the
various assemblies. This means a need for some element to reject the shaft if it
is not of the type indicated, an operation carried out at the fifth index plate
station and involving a manipulator which removes the shaft from the plate on
receiving the corresponding command.
This element takes the form of a two-axis
manipulator, at the extreme end of which is a
suction cup to hold the top part of the shaft.
Each axis comprise a parallel rod pneumatic
cylinder used to lift the shaft and carry it to a
removal ramp. The shaft is held by the
vacuum technique consisting of a suction cup,
ejector to create the necessary vacuum and a
vacuum switch which sends a signal to the
PLC to indicate that the shaft is securely held.
Figure 22: Removal of incorrect shaft
Shaft insertion in assembly:

Shaft insertion, carried out at the last of the index plate stations, is performed by
a rotary- linear type manipulator. This rotary- linear cylinder makes it possible
for a single component to pick up the shaft, take it to the unloading point and
insert it. The cylinder offers the possibility of independently commanding rod
instroking and outstroking as well as turns to left or right.
It is this cylinder which turns an arm fitted with a suction cup used to holds the
shaft throughout the movement. As in the case of the other manipulators using
the vacuum technique, an ejector and vacuum switch are provided for the
cylinder.
17
Figure 23: Shaft insertion in assembly
Given that the operation of inserting the shaft in the bearing calls for a certain
precision, the pallet supporting the components and lying on the belt is, after
being retained by a stop cylinder, lifted by a further cylinder which incorporates
centring pins for correct positioning.

Dimensions:
Height 900 mm.
Air treatment unit:
Pushbutton control:
Index plate module
Actuators:
- Compact double-acting pusher cylinder 25, Stroke:40mm (CDQ2B25-40D), with flow
- Stops: 2 Compact cylinders 16, Stroke:10mm (CQ2B16-10D). Controlled by 5/2 way
Sensors:
- Reed type magnetic detector (D-A73L).
18
Shaft feed module

Magazine capacity: 17 shafts.
Actuators:
- 2 Double-acting cylinders 10, Stroke:10mm (CD85N10-10B). Controlled by 5/2 way
Shaft height measuring module
Actuators:
- Double-acting cylinder 12, Stroke:50mm (CD85N12-50A), with flow regulators and
end position detector. Controlled by 5/2 way monostable solenoid valve.
Sensors:
Place shaft in correct position module
Actuators:
- Double-acting parallel opening two-finger gripper (MHK2-16D). Controlled by 5/2 way
- Vertical axis: Double-acting parallel rod cylinder 15, Stroke:50mm (CXSM15-50), with
flow regulators and initial-end position detector. Controlled by 5/2 way monostable
solenoid valve.
- Rotary actuator: Double acting ? max=180 (MSUB3-180S), with flow regulators.
Controlled by 5/2 way monostable solenoid valve.
Sensors:
- Reed type magnetic detectors (D-Z73L).
Shaft material detection module
Sensors:
- Inductive detector: OMRON E2EG-X5B1.
- Capacitive detector: OMRON E2K-C25MF1.
Incorrect shaft ejection module
Actuators:
- Horizontal axis: Double-acting parallel rod cylinder 15, Stroke:100mm (CXSM15100), with flow regulators and initial-end position detector. Controlled by 5/2 way
bistable solenoid valve.
- Vertical axis: Double-acting parallel rod cylinder 10, Stroke:50mm (CXSM10-50),
with flow regula tors and initial-end position detector. Controlled by 5/2 way
- Holding arm: Suction cup 8 (ZPT08UN-B5), with vacuum generating ejector
Sensors:
Shaft insertion in assembly module
Actuators:
solenoid valves.
- Holding arm: Suction cup 10 (ZPT10CNK10-B5-A10), with vacuum generating
ejector (ZU05S). Controlled by two 3/2 way monostable solenoid valve.
Sensors:
19
Reed type magnetic detectors (D-A73CL).

Vacuum switch PNP output (PS-1100-R06L).

- DeviceNet module 8 inputs/ 8 outputs.
- PLC control:
20
2.5. COVER HANDLING-FITTING-SELECTION

LAYOUT
The fourth of the components to be assembled is a cover which is fitted into a housing
formed on the body for this purpose. The cover serves to retain the turning mechanism shaft
mounted at the previous station.
While the preceding station saw the introduction of a variant in the form of different
materials for the shaft, this station increases the number of variants by offering the choice of
three different materials for the cover: aluminium, white nylon and black nylon, in addition
to a choice of two different cover heights, giving a total of six possible combinations for this
particular assembly task.
The need for appropriate checks to determine which type of cover is to be mounted at each
station cycle means that this station is the most comp lex in terms of the operations to be
carried out. It is also essential that the station control coordinates part selection operations in
accordance with the commands supplied by the master responsible for production
management in the FMS-200.

The structure adopted for the cover assembly process is
similar to that of the previous station. It is based on an 8station index plate to improve the method of working at
the station, as it saves space compared with other spatial
arrangements of work stations, and also means that all
handling operations may be carried out simultaneously to
optimize the process in question.
Figure 24: Cover station
The operations to be performed and the components involved are described below:
-
Index plate:
The 8-station index plate which moves round to effect the interchange of parts
between the different stations is of similar structure to that used at the
preceding station.
It is operated by two cylinders, one fixed stop and one moving, together with a
pusher cylinder which produces the turning movement as previously
described.
21
Feed module:
A gravity feeder is used to store and feed the covers. It is operated by a pusher
actuated by a pneumatic cylinder and which carries out the part extraction
process.
Figure 25: Feed module
Loading station:
The material feed described above supplies
the covers which will later be mounted on
the assembly lying ready on the pallet.
First, however, the cover must be loaded
on the index plate.
This is performed by ma nipulator
comprising a rotary-linear cylinder which
lifts and then turns an arm fitted with a
two- finger parallel opening gripper.
Figure 26: Loading station
The 180 turn effected by the manipulator leaves the gripper at the exact point
of unloading the cover at the first index plate station.
-
Material detection stations:

As described above, this station offers the possibility of working with
aluminium, white nylon and black nylon respectively.
Figure 27:Inductive sensor
Figure 28: Capacitive sensor
Figure 29:Photoelectric cell
To differentiate the first of these types, the second index plate station is fitted
with an inductive pick-up which supplies a signal to the PLC only if the cover
presented by the plate, as it turns, is of aluminium.
Detection of the nylon covers necessitates the use of a different type of sensor,
in this case capacitive, which supplies a signal when the part detected is not
made of metal.
22
The final cover differentiation process is that between black and white nylo n,
and for this purpose a photoelectric cell as in figure 31 is fitted. This component
only detects white-coloured nylon covers.
-
Cover measuring station:

The fact that covers of two different heights may
be used necessitates a height measuring device.
Owing to the teaching and training objective for
which the cell has been designed, various solutions
have been used to perform similar operations, so
that while components such as pneumatic
cylinders with correct height detectors or analogue
output touch probes have been employed at other
stations, this particular station uses a digital
transducer which provides a pulse output, as it is a
linear encoder.
Figure 30: Measuring station
The component used consists of a pneumatic cylinder which moves the probe
until it touches the cover. An integral linear encoder in the cylinder sends pulses
which are counted by a quick counter input at the PLC, making it possible to
determine the distance the cylinder advances until it makes contact with the
cover. This information allows direct determination of the height of the cover.
-
Rejection of incorrect cover:

If the cover reaches the last-but-one
index plate station, and the various
material or height sensors have
indicated that it is not of the material or
height indicated by the central controller
in charge of production, then it must be
rejected. This operation is effected at
this station by a two-axis manipulator,
which picks the cover off the index
plate and deposits it on a removal ramp
if the corresponding signal is received.
Figure 31: Rejection of incorrect cover
The manipulator comprises two pneumatic parallel rod cylinders, at the end of
which is a suction plate with three vacuum- holding cups.
23
Cover insertion:
As at the previous station, the final index plate station is where the cover is
fitted onto the assembly at a stop on the belt conveyor.
The manipulator used for this task is of identical characteristics to the one
which deposits the cover on the index plate. It has a parallel opening gripper to
hold the cover, which is lifted and turned towards the unloading point by a
rotary- linear pneumatic actuator.
Figure 32: Cover insertion

Dimensions:
Height 900 mm.
Air treatment unit:
Pushbutton control:
Index plate module
Actuators:
- Compact double-acting pusher cylinder 25, Stroke:40mm (CDQ2B25-40D), with flow
- Stops: 2 Compact cylinders 16, Stroke:10mm (CQ2B16-10D). Controlled by 5/2 way
Sensors:
24
Cover feed module

Magazine capacity: 19 covers.
Actuators:
regulators and final position detector. Controlled by 5/2 way monostable solenoid
valve.
Sensors:
- Reed type magnetic detector (D-C73L).
- Microswitch OMRON V-166-1C5.
Loading station module
Actuators:
- Compact linear and rotary movement cylinder 32, Stroke:25mm (EMRQBS3225CB), with flow regulators and initial-end of travel detection fo r linear movement,
solenoid valves.
- Holding arm: Two- finger parallel opening pneumatic gripper (MHKL2-16D).
Sensors:
Material detection stations module
Sensors:
- Inductive detector: OMRON E2EG-X5C1.
- Capacitive detector: OMRON E2K-C25ME1.
- Photoelectric detector: OMRON E3F2-DS30C4.
Cover measuring module
Actuators:
- Double-acting cylinder with stroke reading 20, Stroke:50mm (CE1B20-50), with
flow regulators. Controlled by 5/2 way monostable solenoid valve.
Sensors:
- Linear encoder integrated in cylinder.
Incorrect cover rejection module
Actuators:
- Horizontal axis: Double-acting parallel rod cylinder 15, Stroke:100mm (CXSM15100), with flow regulators and initial-end position detector. Controlled by 5/2 way
bistable solenoid valve.
with flow regulators and initial position detector. Controlled by 5/2 way monostable
solenoid valve.
- Holding arm: 3 suction cups 8 (ZPT08UN-B5), with vacuum-generating ejector
Sensors:
25
Cover insertion module

Actuators:
solenoid valves.
- Holding arm: Two- finger parallel opening gripper (MHKL2-16D). Controlled by 5/2
Sensors:
- DeviceNet module 8 inputs/ 8 outputs
- PLC control:
26
2.6. SCREW HANDLING-FITTING

This station carries out the final operation to fit components to the assembly under
construction, and involves the insertion of four screws in four threaded holes in the base body
of the turning mechanism.
The technology used to effect the movements at this station, based on different pneumatic
cylinders, means it is only possible to unload the screws at a single point. In consequence, an
additional component is needed for the transfer to give it successive turns, so that four
insertion cycles at this station will result in the four screws being fitted.
The components used for this particular operation are a pne umatic lifting cylinder on which a
similarly operated rotary actuator is fitted.
In contrast with preceding stations, where communication between the stations and
transfer was limited to sending start messages and end of cycle indications, here there
greater need for coordination between the units. As a result, more use is made of
possibilities offered by the automaton network for information exchange between
different stations.
the
is a
the
the
Figure 33: Screw handling-fitting station
27

The screw insertion function involves a series of operations which are described below.
-
Screw feed:
The screws to be inserted are stored in a
vertical gravity feeder, from where they are
unloaded onto a housing via a step-by-step feed
system involving two pneumatic cylinders
working in a permanent counterpoise position,
so that while the lower one instrokes to let the
next screw fall from the feeder, the upper one
outstrokes to hold the rest in place. Both
cylinders return to their original posit ion once
the screw has dropped down.
Figure 34: Screw feed
Transfer module:
The housing which receives the screws is situated on a double-acting parallel
rod pneumatic cylinder whose construction allows it to be fixed by plates at
each end so that it is the cylinder body which slides like a carriage.
This cylinder is used to transfer the screws from point at which they are fed in
to the point where the following module picks them up for fitting to the
assembly.
Screw insertion manipulator:

Once the items mentioned above have deposited a screw and transferred it to
the pick- up point, the pneumatic manipulator fits the screw into one of the holes
in the turning mechanism body retained on the transfer.
Constructed using two parallel rod cylinders, this manipulator has two degrees
of freedom corresponding to the horizontal and vertical axes. Its end effector is
a parallel opening two-finger gripper, used to hold the screws.
Figure 35: Screw insertion manipulator
28

Dimensions:
Height 900 mm.
Air treatment unit:
Pushbutton control:
Screw feed module
Magazine capacity: 38 screws.
Actuators:
- 2 Double-acting cylinders 10, Stroke:10mm (CD85N10-10-B). Controlled by 5/2 way
Transfer module
Actuators:
- Double-acting parallel rod cylinder 20, Stroke:100mm (CXSWM20-100), with flow
regulators and initial-end position detector. Controlled by 5/2 way bistable solenoid
valve.
Sensors:
- Photoelectric cell OMRON E3X-A41.
- Fibre optic OMRON E32-TC200.
Screw insertion manipulator module
Actuators:
- Horizontal axis: Double-acting parallel rod cylinder 25, Stroke:200mm
(CXSWM25-200-XB11), with flow regulators and initial-end position detector.
Controlled by 5/2 way bistable solenoid valve.
- Holding: Two-finger parallel opening pneumatic gripper (MHK2-16D) and openclosed position detector. Controlled by 5/2 way monostable solenoid valve.
Sensors:
29

- PLC control:
30
2.7. ROBOT SCREWDRIVER

All the preceding stations were of a design in which actuators based on fluid technology
predominated. These were primarily pneumatic components, although the study of hydraulic
technology was facilitated at the bearing pressing station.
With a view to matching the cell to all the most widely used techniques in industrial
automation, this station introduces a new though widespread technology, that of robotics.
The operation carried out by the robot consists of tightening the four screws fitted to the body
of the turning mechanism at the preceding station.
Figure 36: Robot screwdriver

Given the flexibility and numerous possibilities offered by the use of robots in automating
operations, at this station it is regarded as enough to use the element for the operations
needed to drive in the screws.
Control of the robots movements between the different points it has to reach is carried out
by a controller which has been specially designed for use with the particular robot used. It
performs the function of controlling all the movements of all of the motors incorporated in
the robot, so that the latter moves to the defined positions with great accuracy.
31
It is also possible to program the robots movements into the controller and thereby specify
what sequence of movements has to be followed for a particular process. Programming is by
means of specific software to be run on PC, which communicates the transfer of information
to the controller via a serial line.
There is also a programming console on which it is possible to enter a series of commands, or
to define the points to which the robot has to move.
The positional accuracy enables the tip of the electric screwdriver to be located on each of
the screws fitted in the body, before slowly screwing in the appropriate distance for the screw
to be properly fixed.
To avoid the possibility of uncontrolled movements during the programming phase causing
any type of accident, the station is protected by screening of aluminium section with
methacrylate see-through panels. This practically eliminates the risks involved in handling
components of this type.

Dimensions:
Height 900 mm.
Pushbutton control:
Station elements:
- MOVEMASTER EX MELFA RV-M1 MITSUBISHI 5-axis robot. Speed 2.1 m/s, 2500
storable positions, 0.02 mm accuracy, 10 speeds, 2 kg payload, 19 kg arm weight, parallel
(centronics) and series (RS-232) interfaces, 16 inputs (3 switches) and 16 outputs, 1
emergency stop input.
- Electric screwdriver 3.6 V.
- Methacrylate screening for user protection.
- I/O station: 7 inputs/ 7 outputs.
- Relay for screwdriver supply.
- Supply source: 24V/ 0.6A.
- Supply source: 5V/ 2.5A
- MITSUBISHI robot driver.
- MITSUBISHI robot programming console.
- PLC Control:
32
2.8. UNLOADING-STORAGE-PALLETIZATION
OF COMPLETED ASSEMBLY
One operation which is always present in flexible assembly systems, and to which all
operations lead, is that of storage. Once the turning mechanism put together by the cell has
been completed, at the final station it must be removed from the transport system, leaving the
now empty pallet to move towards the first belt to begin work on a new assembly.
This particular finished product store uses a system based on two coordinate axes, so that
assemblies picked off the transporting belt may be distributed at any point on the surface of
the table which constitutes the station.
Figure 37: Storage station

As mentioned, the storage system consists of two position-controlled axes which distribute
the assemblies along the surface of the table. Over these is supported a third vertical axis
with which to pick up the parts.
33
Vertical axis:
The system of holding the finished assemblies incorporates four suction cups
which use an ejector-produced vacuum to hold the assembly until it is
positioned at its storage point.
The vertical axis takes the form of a parallel rod cylinder on which the suction
cups are fitted.
Figure 38: Vertical axis
Figure 39: Pressure sensor
As at all the stations which make use of vacuum components, a pressuresensing element cons isting of a vacuum switch is fitted. This supplies a digital
signal indicating that the ejector has produced the level of vacuum needed to
hold the assembly firmly enough to ensure that it will not drop off when moved
by the other axes. In this case, however, a digital vacuum switch has been
incorporated which provides additional features such as displaying the
instantaneous value of pressure and vacuum, and the possibility of greater
accuracy than conventional units when programming the pressure value at
which the output signal is generated.
Positioning axes:
The first task in storing the finished assemblies is to situate the vertical axis
mentioned above over a fixed pick- up point over the place where the pallet is
retained facing the station.
The finished assembly is then picked and lifted by the pneumatic cylinder
forming the vertical axis. The assemblies to be stored must now be positioned at
various points over the surface of the station table before being unloaded at
these points.
The assemblies are moved and their position controlled by two linear motorized
axes, each of which consists of a motor-driven leadscrew-nut which translates
the rotary motion of the motor into linear displacement of the axis carriage.
The vertical pneumatic axis is attached to the first of these axes, this whole
assembly being mounted on the other motorized linear axis. The result is a
three-axis system, two of them being capable of positioning.
From the mechanical point of view, these components incorporate a precision
leadscrew with a recirculating ball system, together with two lateral linear
guides of high rigidity and precision, able to withstand the forces arising out of
the loads acting on the carriage.
34
Axis movement and movement regulation is effected by alternating current

servomotors, with an absolute encoder to provide instantaneous reading of
motor rotation. Control is via two drivers which set up a closed loop position
regulation system. This involves encoder feedback and the position setpoint
required at any particular moment supplied by the automaton governing the
station.
These components allow the study of electric motors used in applications which
call for position control, increasing further the number of technologies
associated with automation which are dealt with by this flexible cell.

Dimensions:
Height 990 mm.
Methacrylate screening for user protection.
Air treatment unit:
Pushbutton control:
Vertical axis module
Actuators:
- Double-acting parallel rod cylinder 20, Stroke:75mm (CXSWM20-75), with flow
regulators and initial-end position detector. Controlled by 5/2 way monostable
solenoid valve.
- Holding: 4 suction cups 16 (ZPT16CNK10-B5-A10), with vacuum generating
ejector (ZH10BS-06-06). Controlled by 3/2 way monostable solenoid valve.
Sensors:
- Digital vacuum switch PNP output (ZSE4B-01-65).
Positioning axes module
Actuators:
- Linear actuators (LJ1H20Y20SC-500-F-X1).
- Linear actuators (LJ1H10Y10SC-500-F-X1).
- Motors OMRON R88M-UE10030VS1 and R88M-U05030VAS1
Sensors:
35

- Linear actuator drivers R88D-UEP04V y R88D-UEP03V Omron.
- Driver programation console R88A-PRO3U Omron..
- PLC control (Omron):
- CPU Module: CQM1H-CPU51-NL.
- 16 input module CQM1-OC222
- Supply module CQM1-PA216
- Pulse generating card CQM1H-PLB21.
- DeviceNet slave Card for automaton network connection CQM1-DRT21.
36
3. 4-METRE TRANSFER LINE WITH

AUTOMATON AND PALLET ASSEMBLY
3.1.TRANSFER FUNCTION AND COMPOSITION.
The transport system is a line 4 metres long which links the layouts to facilitate the envisaged
assembly process.
The various layouts are linked up with the line by a quick assembly mechanical system.
The transfer follows a rectangular path, and is fitted with a control cabinet with integrated
automaton to organise and control the whole production sequence. This master automaton
controls the rest of the automatons connected into the RS-485 network.
Figure 40: Transfer
There is a longitudinal channel in the central area of the transfer to facilitate electrical
connections, air supply and connection between the transfer and the various handling
stations.
The transfer incorporates a pallet assembly to transport parts and assemblies between the
handling stations.
A safety button is fitted to the transfer to stop the whole system in case of emergency.
The central panel includes the master automaton which controls the entire process.
37
Figure 41: Transport system
All the transport system actuators, stoppers, lifters, positioners and pallet transfers are
operated by a system of solenoid valves connected to the central station.
Pneumatically-operated pushers unload the pallets from one section to another.
The stations are assembled using screwed joints incorporated for this purpose on both station
and transfer, enabling quick and precise assembly. In front of the station, there is a
mechanical stop to stop the pallets, an identification code reading system and, depending on
the particular process, a further series of elements for lifting, centring, turning, etc.
Both the pallet retention point and the relative position of the station may be varied, making
it simple to modify the distribution of the component bases of the cell.
3.2. TECHNICAL DETAILS OF TRANSFER

Dimensions:
2 sections 3900 x 130 mm. Height 970 mm.
Air treatment unit:
Filter to 5 m, pressure regulator and pressure gauge with incorporated pressure switch.
Drive:
2 Three-phase motors 230V/1.8A 0.37kW.
38
Composition:
Actuators:
- 8 Compact double-acting cylinders 32, Stroke:25mm (ECQ2B32-25D-XSE040).
Controlled by 5/2 way monostable solenoid valves.
- 3 Compact double-acting cylinders with guide 16, Stroke:30mm (EMGQM16-30),
monostable solenoid valves.
- Two-direction rotary actuator max:90 (MSUB3-90S), with flow regulators.
- 2 Rodless double-acting cylinders 20, Stroke:200mm (MY1B20G-200), with flow
regulators and initial-end position detector. Controlled by 5/2 way bistable solenoid
valves.
Sensors:
- Magnetic reed type detectors (D-Z73L and D-A93L).
- 24 capacitive detectors OMRON E2EG-X5MC1-M1.
- 2 capacitive detectors OMRON E2K-X8ME1.
- 8 microswitches OMRON V-166-1C5.

- Cabinet- mounted 700 x 500mm. Depth 230mm.
- DeviceNet inputs supply source.
- DeviceNet outputs supply source.
- Start, stop, reset pushbuttons. 2 emergency buttons, and error indicator pilot, on line
and emergency.
- 2 Three-phase motor supply contactors.
- Net filter.
- Frequency converter.
- PLC control (Omron):
- CPU CS1G-CPU42-EV1
- Digital inputs module (16) C200H-ID212.
- Digital outputs module (16) C200H-OC226-NNL.
- Supply source C200HW-PA204-JPN.
- DeviceNet Master Card CS1W-DRM21.
39
4. INSTALLATION AND START-UP

4.1 PREREQUISITES
4.1.1 SPATIAL REQUIREMENTS
The FMS200 cell is designed for working with a maximum of eight stations
plus the transfer unit. In figure 44 we are shown the dimensions of the complete cell
and the working space necessary in order to be able to use it. In addition, the figure
provides us with the dimensions of each statio n for cases where a different
configuration is used.
Figure 42
To get the best performance from the system, the following recommendations
should be followed:
- The floor should be level and have no ridging.
- In the vicinity there must be no heavy machinery producing noise or vibration.
- The working environment must be dust free, with no splashing of liquids.
- Humidity normal with no condensation.
- As far as is possible, keep EMI (Electromagnetic Incompatibility) sources at a
distance.
- Check out the quality of the earth connection.
- Atmospheric temperature must be moderate and extremes of temperature avoided.
40
4.1.2 ELECTRICAL REQUIREMENTS

-
FMS200 electrical supply must be in line with these requirements:

Full cell voltage: 220 V.
Minimum power necessary:
Statio n 1, 2 , 4 , 5 y 6 = 71 VA
Station 3 = 633 VA
Station 7 = 67 VA
Station 8 = 671 VA
Transfer = 1082 VA
Complete cell total = 2810 VA
4.1.3 AIR REQUIREMENTS

Details are given below of the air requirements for each station and for the
whole cell:
Station 1:
Element
CD85N16-100B
CD85N12-50B
MDUB25-200DM
CJPB10-15H6
CXSWM20-150-XB11
CXSM15-50
ZU07S
CYCLE TIME
STATION 1 TOTAL
Cycles
2
2
2
1
2
4
Diameter
16
12
25
10
20
15
Stroke
100
50
200
15
150
50
Consum.l/cycle
0.16
0.0144
0.7852
0.0044
0.3768
0.1412
19 l/min
10 sec
28.l/min
Station 2:
Element
CD85N16-100B
MSQB50A
MHK2-16D
CQ2B12-5S
MY1B16G-250
CD85N10-40
EMRQBS32-25CB
CYCLE TIME
STATION 2 TOTAL
Cycles
2
2
4
1
2
2
4
2
Diameter
16
16
12
16
10
32
-
Stroke
100
Consum.l/cycle
10
5
250
40
25
-
0.16
0.32
0.056
0.0022
0.4018
0.0125
0.3214
0.084
Stroke
Consum.l/cycle
20 sec
4.1 l/min
Station 3:
Element
MSQB50A
CD85N12-125A
CXSM15-100
ZU07S
CYCLE TIME
STATION 3 TOTAL
Cycles
2
4
2
Diameter
12
15
125
100
0.32
0.226
0.1413
19 l/min
22 sec
20.8 l/min
41
Station 4:
Element
Cycles
CDQ2B25-40D
CQ2B16-10D
CD85N10-10B
CD85N12-50A
MHK2-16D
CXSM15-50
MSUB3-180S
CXSM15-100
CXSM10-50
EMRQBS32-25CB
ZU05S
CYCLE TIME
STATION 4 TOTAL
Diameter
16
32
4
2
2
2
2
2
4
4
25
16
10
12
16
15
15
10
32
-
2
19 l/min
Stroke
40
10
10
50
10
50
100
50
25
-
Consum.l/cycle
1.256
0.2572
0.0125
0.0452
0.028
0.0706
0.0248
0.1413
0.0628
0.3214
0.084
4 sec
53.5 l/min
Station 5:
Element
CDQ2B25-40D
CQ2B16-10D
CD85N16-100B
EMRQBS32-25CB
MHK2-16D
CE1B20-50
CXSM15-100
CXSM10-50
ZU07S
CYCLE TIME
STATION 5 TOTAL
Cycles
Diameter
16
32
2
8
4
4
2
2
4
19 l/min
25
16
16
32
16
20
15
10
Stroke
Consum.l/cycle
40
10
100
25
10
50
100
50
1.256
0.2572
0.1607
0.6428
0.168
0.056
0.1256
0.1413
0.0628
6 sec
47.7 l/min
Station 6:
Element
CD85N10-10B
CXSWM20-100
CXSWM25-200-XB11
CXSM15-50
MHK2-16D
CYCLE TIME
STATION 6 TOTAL
Cycles
Diameter
4
2
2
4
10
20
25
15
16
2
30 sec
2.4 l/min
Stroke
10
100
200
50
10
Consum.l/cycle
0.0125
0.2512
0.785
0.1413
0.028
Station 8:
Element
CXSWM20-75
ZH10BS-06-06
CYCLE TIME
STATION 8 TOTAL
Cycles
Diameter
4
34 l/min
20
Stroke
75
Consum.l/cycle
0.3768
17 sec
35.3 l/min
42
Transfer:
Element
Cycles
ECQ2B32-25D-XSE040
EMGQM16-30
MSUB3-90S
MY1B20G-200
Diameter
16
6
4
4
32
16
20
Stroke
Consum.l/cycle
25
30
200
1.2861
0.1447
0.0496
1.005
CYCLE TIME
40 sec
TRANSFER TOTAL 3.7 l/min
COMPLETE CELL = 28 + 4.1 + 20.8 + 53.5 + 47.7 + 2.4 + 35.3 + 3.7 = 195.5 l/min
Considering that 100 l/min is equivalent to 1CV, a 1.95 CV or 1.43 kW

(which is the same) compressor is required.
4.2 HANDLING AND PACKAGING

The packaging is designed to protect the modules from physical, chemical or
mechanical attack that might be produced during handling and transportation.
For transoceanic transportation, the packaging is treated with waterproofing
and dehydrating elements so as to provide protection against the effects of steam, salt
spray, dust and other external agents that might damage module components.
Details are given below of the packaging characteristics for each module:
Station 1
Station 2
Station 3
Station 4
Station 5
Station 6
Station 7
Station 8
Transfer
Base
1000 x 700
1000 x 700
1000 x 700
1000 x 700
1000 x 700
1000 x 700
1000 x 700
1000 x 700
4200 x 1400
Height
1450 mm
1450 mm
1450 mm
1870 mm
1450 mm
2010 mm
2010 mm
1920 mm
1120 mm
Volume
1.015 m3
1.015 m3
1.015 m3
1.309 m3
1.015 m3
1.407 m3
1.407 m3
1.344 m3
6.586 m3
When handling, loading and unloading the packaging, it is advisable to

employ appropriate equipment such as lift trucks. Once unloaded the stations can be
transported by a minimum of two people, while the transfer requires a minimum of
four. The boxes must be kept vertical at all times and must, under no circumstances,
be piled one on top of another or have other objects placed on top.
43
When proceeding to unpacking, it is advisable to observe the following procedure:

1) In the first place, make sure there is enough room to carry out the unpacking
process. We recommend, as a minimum, that there be a free surface area more
than three times the space occupied by each packaging.
2) Next, it is necessary to cut the straps that fasten the four seals at the bottom of the
box. These are then raised so as to be able to lift the lid.
3) Two or more people must raise the lid that covers the station and store it where it
will not get in the way of the following phases.
4) The next move is to loosen the wood pieces that secure the station to the bottom
of the packaging. The best idea is to loosen only the top pieces, as the station can
be extracted without freeing all the others: it can also prove useful to keep them
for possible transportation in the future. In this operation suitable tools will be
required for taking out the coach screws or nails that hold the wood in place.
5) When this operation is complete, the station must be transferred from the base of
the packaging on to the floor of the space where the unpacking operation is taking
place: at least two people are required to do this. It is advisable to check that all
the components listed on the station delivery note are included.
6) The station has wheels, which means that it can be transported easily and
effortlessly to the place where it will be used.
4.3 INSTALLATION
4.3.1 INDIVIDUAL STATION
If there are any individual stations, they come with a tray with a pallet for
placing the pieces. In order to avoid problems in the transportation process, the tray
with the supporting pallet for the piece to be assembled has been placed in the
position indicated in figure 45.
Figure 43
When installing the station, the tray has to be disassembled so that it can then
be placed with the pallet facing upwards, as shown in figure 46.
44
Figure 44
The next step is to proceed to establish the electrical and pneumatic
connections for the station. Before doing this we must make sure that the classroom
meets the pneumatic and electrical requirements mentioned above.
For greater safety, it is wise to cut off voltage to the station using the isolating
switch on the button pad before any electrical connection is made. This is done by
connecting the station plug to the appropriate classroom socket.
In the same way, it is recommendable to carry out the pneumatic connection
with the station air tap turned off. A six-diameter pipe must be connected from the
classroom socket to the air treatment group intake for the station.
4.3.2 CELL
As for the cell, the first step is to proceed to installing the transfer unit. This
means following a similar process to that described above, as if we were dealing with
an individual station. In this case the pneumatic connection will have to be performed
using an eight-diameter pipe.
The stations are provided with anchoring angle brackets and a supporting leg.
The station must first be placed in front of the bars that project from the transfer unit
in the position in which it is going to be sited. The station is then lifted and placed
onto the outermost part of the bars, so that the table can be directly slid and pushed
until it touches the transfer unit.
The next move is to regulate the height of the table and immobilise it. This is
what the angle bracket is for, with its adjustable supporting leg screwed into the
bottom part of the table. This fastening must first be loosened and placed vertically,
then situated again, while the support leg has to be adjusted until it achieves a
horizontal position. In the case of station 8 (store), there is no need to put the station
onto the bars, although its four support legs do have to be adjusted.
45
The angle bracket anchoring pieces must now be screwed down to fix the table
to the transfer unit. When the assembly operations have been executed as indicated,
the wiring connection can be set up. The recommendation is to perform and complete
the wiring and assembly process on each single station before moving on to the next
one.
The transfer unit has connectors for communications, air and electricity,
located on the station positions. Before establishing the wiring connection it is
advisable to disconnect the transfer voltage and air (using the isolating switch on the
side of the unit for the former and the air tap for the latter).
4.4 START-UP
When installation is completed, we proceed to unit start-up. Shown below is
the procedure for each station. It is advisable to read the entire procedure prior to
carrying out these operations.
General procedure (Stations 1, 2, 3, 4, 5, 6 and 8):
1. As a result of incidents during the transportation of the unit, it is always possible
that mechanical components become unbalanced. This will be detected in the first
working cycle. Before starting, check that the fastening elements are properly
tightened.
2. Feed the loader with the pieces that correspond to each station (1, 2, 4, 5 and 6).
3. Set the air input pressure regulator at above 3 Kg/m3 . In the case of station 3
(press), the hydraulic supply regulator must also be set, in this case at 80 Kg/m3 .
4. Carry out a visual inspection of the station to verify that there are no elements that
might distort the functioning of the system. With station 8 (store), it is necessary
to check that the fairing protection gates are closed.
5. Ensure that the magnetic circuit breaker situated on the electrical control panel is
in the "on" position.
6. Set the cycle selector switch on the button pad at step-by-step mode.
7. Move the sectionalising switch on the button pad to the "on" position.
8. Make sure that the emergency stop mushroom head on the button pad is
unblocked.
9. Press the button pad reset but ton to ensure that the process begins in start mode
conditions. Every time the process is halted, either during start-up or during a
cycle, if the machine is not in start mode condition the defect pilot light on the
button pad will blink.
10. In the cases of stations 4 and 5 (shafts and covers), if there is a need to perform a
division plate evacuation cycle before beginning, the stop button on the control
pad must be pressed for five seconds.
46
11. When the start button is pressed the first step in the process will be executed.
Since we will be working in step-by-step mode, it will be necessary to press the
start button each time we want to take a new step.
12. If any imbalance in the unit is detected, take appropriate corrective action and
repeat the cycle until it functions correctly.
13. Once the cycle is over, set the cycle switch, situated on the button pad, in
continuous mode. When the start button is pressed it will now perform
uninterrupted cycles until the feeder runs out. At that point the pilot light will
come on to indicate that there is no material in place on the table (1, 2, 4, 5 and 6).
14. The process can be halted at any moment by pressing the stop button or the
emergency stop mushroom head. If the latter is pressed, once it has been
deactivated it is necessary to return to initial mode conditions (reset button). After
this we only have to press the start button.
Station 7 (robot):
1. Carry out a visual inspection of the station to check that there are no elements that
might distort the functioning of the system.
2. Make sure that the fairing protection gates are closed.
3. The robot drive switch at the back of the unit and the magnetic circuit breaker
situated on the electrical control panel must be in the "on" position.
4. Set the cycle switch on the button pad to step-by-step mode.
5. Move the load switch on the button pad to the "on" position.
6. Check that the emergency stop mushroom head on the button pad is unblocked.
7. Press the reset button on the button pad to ensure that the process begins in start
mode conditions. Each time the process is halted, either during start-up or during
a cycle, if the station is not in start mode condition the defect pilot light on the
button pad will start blinking. In addition the drive unit error led lights up
accompanied by the sound of a buzzer.
8. When the start button is pressed the first step in the process will be executed.
Since we will be working in step-by-step mode, it will be necessary to press the
start button each time we wish to take a new step.
9. If any imbalance in the unit is detected, take appropriate corrective action and
repeat the cycle until it functions correctly. It is quite likely that slight
modifications have to be made to the robot's screwing movements so that it
performs its duty correctly. To do this the robot manual must be consulted.
10. When the cycle is over, set the cycle switch on the button pad to continuous
mode. When the start button is pressed it will now execute an uninterrupted cycle.
11. The process can be halted at any time by pressing the stop button or the
emergency stop mushroom head. If the latter is pressed, once it has been
deactivated it will be necessary to return to initial mode conditions (reset button
on the button pad and drive unit). After this we only have to press the start button
on the button pad.
47
4.4.2 CELL
In the case of the cell, before proceeding to starting up the stations it is
necessary to start the transfer unit running, since both the electrical and pneumatic
feed for each station are obtained from their connection to it.
Start- up procedure
1. Due to incidents during the transportation of the unit, it is always possible that
some imbalance is produced in the mechanical components. Before beginning, it
is advisable to check that the holding elements are well tightened.
2. Set the air input pressure regulator at above 4 Kg/m3 : should the pressure drop
below this value the defect pilot on the transfer unit will start blinking.
3. Carry out a visual inspection of the system to be certain there are no elements that
might distort its functioning.
4. Check that the magnetic circuit breaker on the unit is in the "on" position.
5. Move the load switch on the side of the unit to the "on" position. The voltage
indicator pilot light in the transfer unit will light up.
6. Make sure that the emergency mushroom heads are unblocked.
7. When the start button is pressed the transfer unit will start to function.
8. Should any imbalance be detected in the unit, take the appropriate corrective
measures and repeat the cycle until it functions correctly.
9. The process can be ha lted at any time by pressing the stop button or the
emergency stop mushroom head. Afterwards we only have to press the start
button for the process to be renewed.
10. Once the transfer unit is running and the stations have been correctly installed, we
proceed to initiate the start- up of each station, ascertaining that each one is
functioning correctly, firstly in manual and then in automatic mode.
11. Finally, the functioning of the system must be checked with all the stations in
automatic mode, feeding the transfer unit with the pallets.
12. Due to reasons mentioned earlier, it is very likely that some imbalance be
produced between the transfer unit and the station: to resolve this problem slight
adjustments will have to be made before achieving optimum performance.
48
4.5 PROCEDURE FOR USE

The start-up procedure for the first cycle of functioning after installation has
been described above. We now proceed to explain the process for normal use.

General procedure (Stations 1, 2, 3, 4, 5, 6 and 8):
1. Feed the loader with the pieces that correspond to the station (1, 2, 4, 5 and 6).
2. See that the station's air input pressure regulator is registering above 3 Kg/m3 . In
the case of station 3 (press), check that the hydraulic supply regulator is indicating
above 80 Kg/m3 .
3. Carry out a visual inspection of the station to see that there are no elements that
might distort the functioning of the system. In the case of station 8 (store) check
that the fairing protection gates are closed.
4. Ensure that the magne tic circuit breaker situated on the electrical control panel is
in the "on" position.
5. Set the cycle switch on the button pad to the desired mode.
7. Make sure that the emergency stop mushroom head is unblocked.
8. Press the reset button on the button pad to ensure that the process begins in
starting mode conditions. Every time the process is halted, whether during startup or during the cycle, if the station is not in starting mode condition the defect
pilot light on the button pad will start blinking.
9. In the case of stations 4 and 5 (shafts and covers), if there is a need to perform a
division plate evacuation cycle before starting, the stop button on the button pad
must be pressed in for five seconds.
10. If the manual cycle has been selected, each time it is required to execute a step in
the process the start button must be pressed. If automatic has been selected it is
only necessary to press once.
11. If the feeder runs out, the warning pilot light will come on to indicate there is no
material in position on the table (1, 2, 4, 5 and 6).
emergency stop mushroom. If the mushroom is pressed, once it is deactivated it is
necessary to retur n to starting mode conditions (reset button). Afterwards it will
be sufficient to press the starter button.
49
Station 7 (robot):
1. Carry out a visual inspection of the station to check that there are no elements that
might distort the system's performance.
2. Ensure that the fairing protection gates are closed.
3. The switch at the back of the robot drive unit and the magnetic circuit breaker on
the electrical control panel must be in the "on" position.
4. Set the cycle switch on the button pad to the desired mode.
6. Make sure that the emergency stop mushroom head is unblocked.
7. Press the reset button on the button pad to ensure that the process will begin in
starting mode conditions. Each time the process is halted, whether during start-up
or during a cycle, if the station is not in starting mode conditions the defect pilot
light on the button pad will start blinking. In addition the unit's drive error led will
light up, accompanied by the sound of a buzzer.
8. If the continuous cycle has been selected, when the starter button is pressed the
cycle will be executed. If we are working in step-by-step mode, it will be
necessary to press the starter button each time we wish to perform a new step.
9. The process can be halted at any point by pressing the button or the emergency
stop mushroom. If the mushroom head is pressed, once it has been deactivated it
will be necessary to return to starting mode conditions (reset buttons on the button
pad and the drive unit). Afterwards it will be sufficient to press the starter button
on the button pad again.
4.5.2 CELL
Procedure for use
1. Carry out a visual inspection of the system to check that there are no elements that
might distort its performance.
2. Check that the defect indicator pilot light is not blinking (insufficient pressure).
3. Move the load switch on the side of the unit to the "on" position. Make sure that
the voltage indicator pilot light on the transfer unit lights up.
4. Make sure that the emergency stop mushroom heads are unblocked.
5. When the starter button is pressed the transfer unit will begin to function.
emergency stop mushroom. Afterwards it is sufficient to press the starter button
again in order for functioning to be renewed.
7. When the transfer unit is functioning, the running procedure for the stations is
carried out.
8. Feed the transfer unit with empty pallets, placing them at the beginning of the
cell.
9. When the units are stored in the last station, the empty pallets are re- fed, since the
transfer unit constitutes a closed circuit. The stations will stop when the material
from their stores finishes, this circumstance being detected by the desktop
warning pilot lights which will light up to indicate this. With the cell stopped, we
now move on to extract the assembled units, disassemble them and distribute
them among the different stores.
50
5. LOCATING AND CORRECTING FAULTS

No.
1.1
Symptom
The station does
not start after the
start button is
pressed
1.2
Station does not

start up after the
start button has
been pressed and
the defect pilot
light on the button
pad is blinking
The station will
not start when the
start button has
been pressed and
the desktop pilot
light comes on
The station starts
but after a short
time it stops
1.3
1.4
1.5
STATION 1
Possible cause
1) The station is unplugged or
the classroom is without
voltage
2) The magnetic circuit
breaker is open
3) The emergency stop button
is locked
4) The air intake is not
connected or the air valve is
open
5) The line breaker is open
6) Switch inside the fault box
producing the failure
activated
7) Cell unplugged
8) Transfer unit magnetic
circuit breaker open
9) Transfer unit emergency
stop button is locked
10) Cell air supply not
connected or transfer unit air
valve open
1) The station is not operating
under starting mode
conditions
is locked and the station is
not operating under start
mode conditions
1) The material feeder is
empty
clogged
1) Not enough air is reaching

the actuators
2) The pneumatic installation
in the classroom does not
meet minimum requirements
An actuator is
1) The speed controllers are
moving at excessive set at minimum
speed
Remedy
1) Plug the station in or
supply voltage to the
classroom
2) Close the switch (ON), if
it breaks again when
restarted then the power
installed is insufficient
3) Unlock the emergency
stop button and press reset
4) Connect the air intake or
close the air valve
5) Close line breaker
6) Close off the fault box
switch
7) Plug cell in
8) Shut off switch (ON) on
transfer unit, if it breaks
again when restarted then the
power supply installed is
insufficient
9) Unlock emergency button
10) Connect air intake or
close transfer unit air valve
1) Press reset
2) Unlock button and press
reset
1) Feed the station store with

the appropriate pieces
2) Unclog the feeder
1) Set the station air pressure

at 3 Kg/m3 and the cell air
regulator at 4 Kg/m3
2) Use a bigger compressor
or transfer to a more suitable
classroom
1) Regulate the flow until
reaching the desired speed
51
1.6
An actuator is
moving far too
slowly
1.7
The station always

stops when it
reaches the same
point
Piece to be set
wrongly placed by
one of the station
components
1.8
1.9
The vacuum pads

do not have
sufficient force to
hold the piece

set at maximum
2) The station air regulation
does not reach the minimum
value required
3) The cylinder gaskets are
worn
producing the failure activated
2) Detector faulty
3) Solenoid valve faulty
1) Detector faulty
2) Holding elements loose
3) Station pieces poorly
adjusted
1) Vacuum ejector damaged
2) Station air regulation does
not reach the minimum
required
1) Regulate the flow until it

acquires the speed desired
at 3 Kg/m3
3) Change gaskets or cylinder
as circumstances dictate
1) Shut off the switch in the
fault box
2) Replace detector
3) Substitute valve
1) Replace detector
2) Tighten loose screws
3) Adjust pieces
4) Shut off switch in fault box
1) Substitute ejector
at 3 Kg/m3
52
No.
2.1
Symptom
The station does
not start when the
start button has
been pressed
2.2
The station will not

start when the start
button has been
pressed and the
defect pilot light on
the button pad is
blinking
button has been
pressed and the
desktop pilot light
comes on
The station starts
but stops after a
short while
2.3
2.4
2.5
STATION 2
Possible cause
1) The station is unplugged
or the classroom is without
voltage
breaker is open
3) The emergency stop
button is locked
4) Air intake is not connected
or air valve open
activated
7) Cell unplugged
9) Transfer unit emergency
stop button locked
10) Cell air not connected or
transfer air valve open
1) The station is not

operating under start mode
conditions
button is locked and the
station is not operating under
start mode conditions
empty
clogged
1) Not enough air is getting

to the actuators
An actuator is
moving excessively set at minimum
fast
Remedy
1) Plug station in or supply
classroom with voltage
2) Shut switch off (ON), if it
breaks again when restarted
then the power supply
installed is insufficient
3) Unlock the emergency stop
button and press reset
4) Connect the air intake or
close air valve
6) Shut the fault box switch
off
7) Plug cell in
8) Shut off transfer unit
switch (ON), if it breaks
power supply installed is
insufficient
9) Unlock emergency stop
button
close off transfer unit air
valve
1) Press reset


2) Use a bigger compressor or
transfer to a more suitable
classroom

reaching the speed desired
53
2.6
2.7
2.8
An actuator is
moving far too slow set at maximum
2) The station air setting does
not reach the minimum value
required
worn
The station stops
1) Switch inside fault box
whenever it reaches producing the failure activated
the same point
2) Detector faulty
Piece to be set
1) Detector faulty
wrongly placed by
one of the station
3) Station pieces incorrectly
components
adjusted

at 3 Kg/m3
1) Shut off the fault box switch
2) Replace detector
3) Substitute valve
1) Replace detector
3) Adjust pieces
4) Shut off the fault box switch
54
No.
3.1
Symptom
button has been
pressed
3.2

button has been
pressed and the
the button pad is
blinking
The station starts
but stops again
after a short while
3.3
3.4
An actuator is
moving at
excessive speed
STATION 3
Possible cause
1) The station is unplugged or
voltage supply
breaker is open
is locked
4) Air intake not connected or
air valve is open
activated
7) Cell unplugged
on the transfer unit is locked
air valve on transfer unit open
Remedy
1) Plug the station in or feed
the classroom with voltage
supply
2) Close the switch (ON), if it
then the power installed is
insufficient
4) Connect up air intake or
close air valve
6) Shut down the fault box
switch
7) Plug cell in
8) Close the transfer unit
power installed is insufficient
button
close off air valve on transfer
unit
1) The station is not operating 1) Press reset
under start mode conditions
2) The emergency stop button button and press reset
is locked and the station is
not operating under start
mode conditions
1) Insufficient air is reaching
the actuators

2) Install a bigger compressor
classroom

set at minimum

55
3.5
An actuator is
moving far too
slowly
3.6
The station always

stops when it
reaches the same
point
Piece to be set
wrongly placed by
one of the station
components
3.7
3.8
The vacuum pads

do not have
sufficient force to
hold the piece

set at maximum
value required
worn
2) Detector faulty
1) Detector faulty
3) Station pieces wrongly
adjusted
2) Station air regulation does
required

at 3 Kg/m3
1) Close off fault box switch
2) Replace detector
3) Substitute valve
1) Replace detector
3) Adjust pieces
4) Close off fault box switch
at 3 Kg/m3
56
No.
4.1
Symptom
The station will no t
button has been
pressed
4.2

button has been
pressed and the
the button pad is
blinking
button has been
pressed and the
desktop defect pilot
light is blinking
The station starts up
but stops after a
short while
4.3
4.4
4.5
4.6
An actuator is
moving at excessive
speed
An actuator is
moving far too slowly
STATION 4
Possible cause
voltage supply
breaker is open
button is locked
4) Air intake not connected
or air valve is open
activated
7) Cell unplugged
button on the transfer unit is
locked
transfer unit air valve open
conditions
station is not operating in
empty
clogged
Remedy
insufficient
close air valve
5) Switch off line breaker
6) Switch off fault box switch
7) Plug cell in
8) Turn the transfer unit
switch (ON) off, if it breaks
button
1) Press reset

1) Insufficient air reaching

the actuators
2) The pneumatic installatio n

2) Install a bigger compressor
classroom

set at minimum

reaching the speed required

set at maximum

reaching the speed required
at 3 Kg/m3
57
4.7
4.8
4.9
4.10
4.11
value required
worn
The station always
stops when it reaches producing the failure
the same point
activated
2) Detector faulty
Piece to be set
1) Detector faulty
wrongly placed by
one of the station
3) Station pieces wrongly
components
adjusted
activated
The vacuum pads do 1) Vacuum ejector damaged
not have sufficient
2) Regulation of station air
force to hold the
piece
value required
Sometimes correct
1) Capacity detector
pieces are expelled
displaced
activated
The division plate has 1) Locking cylinders seized
stopped and will not
move despite
attempts to restart it

1) Turn off switch in fault box
2) Replace detector
3) Substitute solenoid valve
1) Replace detector
3) Adjust pieces
2) Set station air pressure at 3
Kg/m3
1) Adjust capacity detector
1) Manually activate the

corresponding slenoid valve so
that the cylinders return to
their position
58
STATION 5
Possible cause
voltage supply
2) Magnetic circuit breaker
open
button is locked
activated
7) Cell unplugged
locked
No.
5.1
Symptom
button has been
pressed
5.2

button has been
pressed and the
the button pad is
blinking
button has been
pressed and the
light is blinking
The station starts
but stops again after
a short while

conditions
station is not operating in
1) Material feeder is empty
2) Material feeder is clogged

actuators

classroom
An actuator is
moving at excessive
speed
An actuator is

set at minimum
1) Regulate flow until


set at maximum
2) The station air setting

3
59
5.3
5.4
5.5
5.6
Remedy
voltage to classroom
insufficient
4) Connect air intake or close
air valve
5) Switch off line breaker
6) Turn off switch in fault
box
7) Plug cell in
button
1) Press reset

2) Unclog feeder
5.7
5.8
5.9
5.10
5.11

required value
3) Cylinder gaskets are worn
The station always
the same point
activated
2) Detector faulty
Piece to be set
1) Detector faulty
wrongly placed by
one of the station
components
adjusted
activated
The vacuum pads do 1) Vacuum ejector damaged
not have sufficient
2) Station air setting does not
force to hold the
reach minimum value
piece
required
Sometimes correct
1) Capacity detector
pieces are expelled
displaced
2) Optical detector displaced
activated
The division plate has 1) Locking cylinders seized
stopped and will not
move despite an
attempt to restart it
at 3 Kg/m3
as dictated by circumstances
2) Replace detector
3) Substitute valve
1) Replace detector
3) Adjust pieces
2) Set station air pressure at 3
Kg/m3
1) Adjust capacity detector
2) Adjust optical detector
3) Turn switch in fault box off
1) Manually activate the

corresponding solenoid valve
so that the cylinders return to
their position
60
STATION 6
Possible cause
voltage supply
open
button is locked
or air valve open
5) Line breaker open
activated
7) Cell unplugged
locked
No.
6.1
Symptom
button has been
pressed
6.2

button has been
pressed and the
the button pad is
blinking
button has been
pressed and the
light is blinking
The station starts
but after a short
while stops again

operating in start mode
conditions
station is not operating under
empty
clogged

the actuators

at 3 Kg/m3 and the air
regulator for the cell at 4
Kg/m3
classroom
An actuator is
moving at excessive
speed
An actuator is

set at minimum


set at maximum

6.3
6.4
6.5
6.6
Remedy
insufficient
air valve
5) Turn line breaker off
6) Turn off switch in fault
box
7) Unplug cell
button
close transfer air valve
1) Press reset

61
6.7
6.8
2) The air station setting

value required
worn
The station always
the same point
activated
2) Detector faulty
Piece to be set
1) Detector faulty
wrongly placed by
one of the station
components
adjusted
activated

at 3 Kg/m3
as circumstances require
2) Replace detector
3) Substitute valve
1) Replace detector
3) Adjust pieces
62
No.
7.1
7.2
Symptom
button has been
pressed
STATION 7
Possible cause
voltage supply
open
button is locked
4) Line breaker open
5) Cell unplugged
locked
transfer air valve is open

button has been
conditions
pressed and the
the button pad is
station is not operating
blinking
For faults associated with the robot consult the robot manual
Remedy
insufficient
4) Shut down line breaker
5) Plug cell in
button
transfer air valve
1) Press reset
63
No.
8.1
Symptom
button has been
pressed
8.2

button has been
pressed and the
the button pad is
blinking
The station starts up
but after a short
while it stops again
8.3
8.4
An actuator is
moving at excessive
speed
STATION 8
Possible cause
voltage supply
open
button is locked
4)Air intake not connected
or air valve open
5) Line breaker is open
6) Cell unplugged
locked

conditions
station is not operating
the actuators
2) The pneumatic
installation in the classroom
does not meet minimum
requirements
set at minimum
Remedy
insufficient
air valve
5) Shut line breaker down
6) Plug cell in
button
transfer air valve
1) Press reset

classroom
64
8.5
An actuator is
moving far too
slowly
8.6
The station always

stops when it
reaches the same
point
Piece to be set
wrongly placed by
one of the station
components
8.7
8.8
The vacuum pads

do not have
sufficient force to
hold the piece

set at maximum
2) The station air setting
value required
3) Cylinder gaskets worn
1) Detector faulty

at 3 Kg/m3
1) Replace detector
2) Substitute valve
1) Detector faulty
adjusted
4) Imbalance between
transfer and station
2) Station air setting does not
reach the minimum value
required
1) Replace detector
3) Adjust pieces
4) Modify the corresponding
co-ordinate in the PLC
program
at 3 Kg/m3
65
No.
9.1
Symptom
button has been
pressed and the
voltage pilot light is
off
9.2
The cell will not

button has been
pressed and the
the unit is blinking
The cell starts up but
after a short while it
stops again
9.3
9.4
9.5
9.6
9.7
An actuator is
moving at excessive
speed
An activator is
moving far too
slowly
The cell always

stops when it
reaches the same
point
The cell frequently
comes to a halt but
not always in the
same place
CELL
Possible cause
1) The cell is unplugged or
voltage supply
open
button is locked
Remedy
1) Plug cell in or supply
voltage to classroom
insufficient
air valve

actuators
2) The pneumatic
installation in the classroom
does not meet minimum
requirements
set at minimum
1) Set the cell air pressure at

4 Kg/m3
classroom

set at maximum
2) The cell air setting does
value required
worn
1) Detector faulty

2) Set the cell air pressure at
4 Kg/m3
1) There are more pallets

than there should be in the
cell (no. stations 2)
1) Remove excess pallets

1) Replace detector
2) Substitute valve
66
6. MAINTENANCE AND INSPECTION

6.1. INTRODUCTION
It is imperative that the procedures for maintenance and inspection outlined on
these pages be scrupulously observed in order to guarantee the best performance from
the cell over a long period of time. As well as the daily inspections, periodic
inspections should also be carried out.
6.2 INSPECTION POINTS

6.2.1 DAILY INSPECTION
Inspection point
Be sure that there are no obstacles in the
station that might distort the system's
performance
Check to see that no components are
loose, out-of-true or wrongly positioned
Make sure sufficient air is reaching the
station/transfer unit
Ascertain that voltage is reaching the
station/transfer unit
Corrective action
Remove
Take appropriate corrective action

See "Locating and Correcting Faults"
See "Locating and Correcting Faults"
6.2.2 PERIODIC INSPECTION

Inspection point
Check that the filter condensate level does
not go beyond the marks
Make sure that the filter pressure does not
drop below a bar
Look at the screws and nuts in case they
are slack or have come loose (6 months)
See that the cylinders are functioning
correctly (6 months)
Lubrication of station 8 shafts (6 months)
Examine the state of the shaft belts on the
robot (6 months)
Check for disk brake-pad wear on the
robot shafts (6 months)
Check for wear on the robot shaft
servomotor brushes (6 months)
Clean cell (6 months)
Corrective action
Bleed: see maintenance procedures 6.3.1
Replace cartridge filter: see maintenance
procedures 6.3.1
Tighten using the appropriate tool
Change the gaskets if needs be: see
maintenance procedures 6.3.1
Lubrication: see maintenance
procedures 6.3.2
Change the belts: see robot manual
Change the pads: see robot manual
Change brushes: see robot manual
Clean: see maintenance procedures 6.3.4
67
Check for wear on the robot's beginning

and end of travel limit switch gear (1 year)
Check the robot bearings (2 years)
Examine the motor reduction gears on each
robot shaft (2 years)
Check the robot to see if there are damaged
cables (2 years)
Change gears: see robot manual

Change bearings: see robot manual
Lubricate gears: see robot manual
Change cables: see robot manual
6.3 MAINTENANCE PROCEDURES

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

The electrical shafts on station 8 require periodic inspection: after every six
months of continuous work or after a month at standstill. This inspection must involve
a check on the unit holding elements, such as screws and nuts, in case they are loose. It
is also necessary to clean the feed shaft with the right kind of grease, moving the
carriage backwards and forwards. The linear guide runners have to be greased as well,
using an appropriate tool. Important Note: The grease used must not contain fluorine.
6.3.3 CLEANING
For the periodic cleaning operations on the FMS200 a clean cloth that leaves
no fibre traces can be used, whilst it is not advisable to use any cleaning product, in
particular those containing alcohol, solvents or chlorinated compounds.
68
7 SAFETY
7.1 GENERAL SAFETY PRECAUTIONS
-
Once the process has begun, care must be taken to avoid adding pieces to, or
removing pieces from, the respective stores or pallets in circulation.
In general, the stations should not be manipulated with whilst the machine is
running.
When proceeding to the disassembly of the mechanism, do not leave any pieces
behind inside the main body.
Under no circumstances must the protection and safety devices described below be
tampered with.
If the stations have to be physically dealt with after a halt, to extract a fallen piece,
for instance, always press the emergency stop mushroom head down until the
intervention is completed. If some damaged element has to be replaced, we must
open either the sectionalising switch on the button pad or the one on the transfer unit,
as circumstances require.
In order to safeguard the cell components, care must be taken to stop foreign bodies
or obstacles from entering the stations .
7.2 PROTECTION AND SAFETY DEVICES

All the stations and the transfer unit are equipped with emergency stop
mushroom heads for stopping the process at any moment in order to prevent accidents.
If the emergency stop mushroom is used, once the incident that caused the stop has
been overcome, make sure, before reactivating the cell or station, that the situation will
not recur, by taking appropriate measures. Furthermore, it is advisable to take away
pieces that are in the middle of a cycle whenever possible. After freeing the emergency
stop mushroom it will be necessary to press the reset button so that the components
return to their starting mode positions.
There is also a pneumatic device at the general air input, which causes a
gradual increase in air pressure when the air is first connected, thus avoiding accidents
produced by the sudden input of air in the circuit.
Station 3 (press) has a protection fairing to prevent accidents occurring with
the press. It descends when the latter is working and goes up when the task is finished.
Stations 7 and 8 (robot and store, respectively) there is a protection fairing that
covers the entire station. We must be sure that all the gates are closed before running
these stations. The gates should never be opened with the station running.
69
8. FAULT SIMULATION SYSTEM

All the stations incorporate a Fault Simulation System fitted to the side of each station.
The system consists of a lockable metal box containing 16 switches which, when operated,
cause a fault in the station.
There is also a connector to use the Fault Diagnosis and Virtual Repair Interactive System
instead, via computer.
70
9. SETS OF PARTS FOR ASSEMBLING

This refers to the sets of parts which are handled by the cell in the assembly process. Six sets
are supplied, each consisting of:
-
1 Body
2 Bearings of different height
2 Shafts of different height
1 Aluminium cover
1 Black plastic cover
1 White plastic cover
4 Screws
71
10. EC SELF-CERTIFICATION
ALECOP S.COOP., hereby declares that model FMS 200 of serial n 10/99 complies with
the standards and essential requirements of directives:
-
D 89/392/EEC (Royal Decree 1435/1992)-8/93.

D 73/23/EEC-D93/68 EEC.
D 89/392/EEC-D93/68 EEC RD 444/1994.
72
11. SUPPORT MATERIAL

1.
2.
3.
4.
5.
6.
7.
8.
9.
FMS-200 Operating Manual.

FMS-200 Practical Activities Manual
Pneumatic Technology Study Manual.
Electro-pneumatic Technology Study Manual.
FX Automaton Programming Manual.
FX-2N Automaton Manual.
485 Communications Card Manual
MEDOC Program Manual.
MEDOC PLUS software.
By way of guidance, a list is given below of the Practical Activities aimed at developing the
skills associated with the various technologies integrated into the Cell, with an explanation of
their training focus..
73
ANNEX A
FAULTS GENERATION
ANNEX A: FAULT GENERATION

Note: The information shown in this Annex refers to the different dysfunctions/ failures that can
be provoked in the Flexible Integrated Assembling System FMS - 200. This part of the
manual should not be given to the students, s o they wont be able to associate the fault
symptom with its cause.
FAULT GENERATION
The Flexible Integrated Assembling System FMS- 200 offers the possibility of generating 16
different dysfunctions for each station. This means that for a complete cell with 8 stations a total
of 128 faults can be generated.
There are two ways of causing this faults/ dysfunctions in each station.
The first way is the traditional method, by means of switches. The only way to accede to these
switches is by opening the li d of the faults box present in each station, with its appropriate key.
Each switch, when activated, will make a dysfunction in some components of the station. Then,
the appropriate red led diode will light up.
There is no limit in the number of faults tha t can be activated at the same time.
After the fault is activated, the student has to analyze the system to find out which the broken
component is. Then he/she will write a report, but the last step of every repairing will not be
done. This would be the substitution of the broken component and the verification of the system
in order to make sure that the dysfunction has been repaired correctly.
This last step, as well as other possibilities, can be done with a connection of a computer to the
system. The computer can be connected by the RS-232C serial line or by the CENTRONICS
parallel. There are two different cables for this purpose. The connection port is located on the
right side of the fault box.
The SIRVAFMS program allows the programming of the faults from the PC. This program
allows the following functions:
-
Personalized work for each student. Every student has a personal password to have
access to the program.
Possibility of committing a dysfunction in the system in order to analyze its effects.
Possibility of committing faults in the system, introducing a code into the program.
These codes can be easily changed by the teacher.
Possibility of making a virtual reparation of the component thats suspicious of being the
cause of the fault.
Registration of the work made by the student in a historical of reparations, in which

comments for each operation can also be included.
In the SIRVAFMS Users manual you can find further information about this program.
STATION 1: BODY SUPPLY
FAULT SYNTHOM
SUSPICIOUS COMPONENT
BROKEN COMPONENT
The station can not be switched on
ON Push-button
OFF Push- button
Wiring
PLC
On Push Button (XO)
The station does no work in

automated mode
Manual Automated switch

Wiring
PLC (Programme)
Manual /Automated switch (X2)
The sensor does no go down
Cylinder of sensor
Solenoid valve Cylinder
Magnetic switch of sensor
Magnetic switch of feeder
Magnetic switch of feeder (X16)
Vertical cylinder of body manipulator

Solenoid valve of vertical cylinder
Vacuum switch detector
Upper magnetic detector of vertical cylinder
Wiring
PLC
Vacuum switch detector (X11)
The vertical cylinder of body

manipulator does no go up

N
FAULT SYNTHOM
The body is always rejected
Magnetic detector of sensing cylinder

Wiring
PLC
The station can no be switched on
ON Push-button
OFF Push- button
Wiring
PLC
Transfer cylinder
Solenoid valve of transfer cylinder
Magnetic detector of transfer cylinder
Wiring
PLC

Solenoid valve of vertical cylinder of body
manipulator
Solenoid valve of vacuum pads
Botton magnetic detector of vertical cylinder
of body manipulator
Wiring
PLC
The Transfer cylinder does no return
The body is left without going down
BROKEN COMPONENT
Magnetic detector of sensing cylinder
OFF Push-button (X1)
Magnetic detector of transfer cylinder.
Botton magnetic detector of vertical cylinder of bosy

manipulator (X10)

N
FAULT SYNTHOM
The horizontal cylinder of the body

manipulator does not go ahead and
leave the body in the initial position
10 The horizontal cylinder does not go

back
11
The vertical Cylinder of the body

manipulator does no go up and the
body crash against the rejector
BROKEN COMPONENT
Horizontal cylinder of the bosy manipulator

Solenoid valve of horizontal cylinder of bosy Front magnetic detector of horizontal cylinder of
body manipulator (X6)
manipulator
Front magnetic detector of horizontal
cylinder of body manipulator
Wiring
PLC
Horizontal cylinder of body manipulator

Solenoid valve of horizontal cylinder of body Rear magnetic detector of horizontal cylinder of
body manipulator
manipulator
Rear magnetic detector of horizontal
cylinder of body manipulator.
Wiring
PLC
Vertical cylinder of transfer manipulator.

manipulator
Upper detector of vertical cylinder of body
manipulator
Wirirng
PLC
Upper detector of vertical cylinder of body

manipulator (X7)

N
FAULT SYNTHOM
BROKEN COMPONENT
The Led of the detector of feeder

cylinder does no light on
Magnetic detector of manipulator

Wiring
The body is no transfered and the

vertical cylider goes down
Transfer Cylinder
Solenoid of transfer cylinder
Wiring
PLC
14
The vacuum is no made at the pady
Vacuum pods solenoid valves

Wiring
PLC
15
The hori zontal cylinder does no go

ahead
Solenoid valve of horizontal cylinder of body

Horizontal cylinder of the body manipulator
Solenoid valve of horizontal cylinder of body manipulator (Y1)
manipulator.
Wiring
PLC
12
13
Detector wiring (X15)
Solenoid valves wiring (Y3-Y7)
Vacuum pods solenoid valves (Y4)

N
16
FAULT SYNTHOM
The vertical cylinder of the body

manipulator does no go up
SUSPICIOUS COMPON ENT

manipulator
Botton detector of vertical cylinder of body
manipulator
Wiring
PLC
BROKEN COMPONENT
Inputs wiring (X7-X10)
STATION 2: BEARING SUPPLY MODULE
FAULT SYNTHOM
BROKEN COMPONENT
ON Push-button
OFF Push- button
Wiring
PLC
On Push Button (XO)
The rotary manipulator does not

move until the lift platform
Rotary actuator
Solenoide valve of rotary actuator
Magnetic detector of supplying cylinder
Magnetic detector of rotary actuator
Wiring
PLC
Magnetic detector of supplying cylinder (X5)
The grippers of rotary manipulator

do not open
Grippers
Solenoid valve of grippers
Magnetic switch of rotary actuator
Wiring
PLC
Magnetic switch of rotary actuator (X11)
Microswitch
Wiring
PLC
Microswitch (X6)
The microswitch does provide any

signal when the bearing is there

N
FAULT SYNTHOM
The grippers of rotary manipulator

do not close
Grippers
Solenoid valve of grippers
Magnetic switch of rotary actuator
Wiring
PLC
ON Push-button
OFF Push- button
Wiring
PLC
BROKEN COMPONENT
Magnetic switch of rotary actuator (X11)
The potentiometer is measuring

wrongly the height of the bearing
Potentiometer
Wiring
PLC
Potentiometer (Analog input)
The potentiometer is measuring

wrongly the height of the bearing
Potentiomete r
Wiring
PLC
Potentiometer (Analog input)

N
FAULT SYNTHOM
The station can not be switched in

to the step mode
10 The grippers of the manipulator

open before they should and crash
against the bearing
Selector step-automatic
Wiring
PLC
Gripper solenoide valve

Bottom magnetic switch of the
manipulator
Wiring
PLC
11
The Led of the detector of lift

cylinder does not light on
Selector step-automatic (X2)
Bottom magnetic switch of the manipulator

(X13)
Solenoide valve of rotary actuator of the

Upper magnetic detector of the manipulator (X1)
manipulator
Upper magnetic detector of the
manipulator
Wirirng
PLC
Magnetic detector of lift cylinder

Wiring
PLC
The manipulator turns before it lifts
12
BROKEN COMPONENT

N
FAULT SYNTHOM
BROKEN COMPONENT
13
The rotary manipulator turns in the

oposite direction
Wiring
PLC
14
The gripper of the supply

manipulator does not open
Gripper
Gripper solenoid valve
Wiring
PLC
Gripper solenoid valve (Y12)
The lift does no go up
Lift cylinder
Lift cylinder solenoid valve
Wiring
PLC.
Solenoid valve of lift cylinder (Y5)
15
Upper detector of lift cylinder.of body

manipulator
Wiring
PLC
16
The manipulator goes down before

it sho uld go.
10
STATION 3: HYDRAULIC PRESS MODULE
N
1
FAULT SYNTHOM
The protection cover does not
go up
The body transfer manipulator

does not turn

go down
Protector cylinder
Solenoid valve of protector cylinder
Upper magnetic detector of press
cylinder
Wiring
PLC
Rotary actuator
Solenoide valve of rotary actuator
Magnetic detector of transfer cylinder
Magnetic detector of rotary actuator
Wiring
PLC
BROKEN COMPONENT
Upper magnetic detector of press cylinder (X16)
Back Magnetic switch of transfer cylinder (X11)

Protection cover cylinder.
Solenoid valve of protection cover
Back Magnetic switch of external
transfer cylinder
Wiring
PLC
11

N
FAULT SYNTHOM
The manipulator of transfer of

body does not turn.
The rotary manipulator does

not stop in the central position
The internal transfer cylinder

does not go ahead
Rotary actuator of body transfer

manipulator
Solenoide valve of rotary actuator of
body transfer manipulator.
Back magnetic switch of internal
transfer cylinder.
Rotary actuator detector
Wiring
PLC
Central magnetic detector of the

rotary actuator.
Wiring
PLC
Cylinder of internal transfer
Solenoid valve of cylinder of internal
transfer
Magnetic detector of cylinder of
internal transfer
Wiring
PLC
BROKEN COMPONENT
Back magnetic switch of internal transfer
cylinder.(X14)
Central magnetic detector of the rotary actuator (X6)
Magnetic detector of cylinder of internal transfer (X12)
12

N
FAULT SYNTHOM
The press does not go up.
The cylinder of external

transfer does not go ahead
Press cylinder
Solenoid valve of press cylinder
Bottom detector of press cylinder
Wiring
PLC
External transfer cylinder

Solenoid valve of extrernal transfer
cylinder
Ahead magnetic detector of external
transfer cylinder
Wiring
PLC
The press and the protection

cover go down at the same
time
BROKEN COMPONENT
Bottom detector of press cylinder (X17)
Ahead magnetic detector of external transfer cylinder

(X15)
Magnetic switch detector of protection

Magnetic switch detector of protection cover cylinder
cover cylinder
(X13)
Wiring
PLC
13

N
FAULT SYNTHOM
ON push-buttom
OFF push-buttom
Wiring
PLC
11 The step/manual mode can not

be activated
Selector step/automatic
Wirirng
PLC
12 The Led of the upper magnetic

detector of the press does not
light on
Upper Magnetic detector of press

Wiring
PLC
13
Wiring
PLC
10
The station does not run
Instead of the internal transfer

cylender, the external one is
working
BROKEN COMPONENT
OFF push-buttom (X1)
Selector step/automatic (X2)
Detector wiring X16
14

N
FAULT SYNTHOM
14

go down
15
The external transfer cylinder

does not go ahead
16
The manipulator of transfer of

the body does not go ahead
BROKEN COMPONENT
Protection cover cylinder

Solenoid valve of protection cover
cylinder
Front magnetic detector of external
transfer cylinder
Wiring
PLC
Solenoid valve of protection cover cylinder (Y6)
External transfer cylinder

Solenoid valve of external transfer
cylinder
Front magnetic detector of external
transfer cylinder
Wiring
PLC
Rotary actuator
Solenoid valve of rotary actuator.
Detector of rotary actuator on the
palet position.
Detector of rotary actuator on the
transfer position.
Wiring
PLC
Solenoid valve of external transfer cylinder (Y6)
15
STATION 4: SELECTION-FITTING OF SHAFT MODULE
FAULT SYNTHOM
1 The module does not run in

automatic mode.
2
Step/ Automatic selector
Wiring
PLC
Vertical cylinder of manipulator

The manipulator of load shaft in
Solenoid valve of vertical
the palet does not go down
cylinder of manipulator
Detector of positioning over the
palet.
Wiring
PLC
Vacuum solenoid valve.
The vacuum pad of the
manipulator does not release the Wiring
shaft
PLC
Detectors in general
The process stopped without any Wiring
specific reason
PLC
Inductive detector.
The inductive detector does not
Wiring
detect correctly
PLC
BROKEN COMPONENT
Step/ Automatic selector (X2)
Detector of positioning over the palet

(X7)
Magnetic detector of indexing plate

(X23)
Inductive detector (X24)
16

N
FAULT SYNTHOM
6 The station can not be switched

on
7 The capacitive detector does not

detect any part
ON Push button
OFF Push-button
Wiring
PLC
Capacitive detector
Wiring
PLC
The manipulator of putting shaft in Touching detector

8 the correct position turns the shaft Wiring
without any reason.
PLC
Rear magnetic detector of

Horizontal Cylinder of
9 The manipulator of incorrect shaft
manipulator
rejection does not work
Wiring
PLC
BROKEN COMPONENT
OFF push-button (X1)
Capacitive detector (X25)
Touching detector (X13)
Rear magnetic detector of Horizontal

Cylinder of manipulator (X16)
17

N
FAULT SYNTHOM
10 The Manipulator for putting shaft

on the palet relieves the shaft
from the top position
BROKEN COMPONENT
Vacuum pads
Vacuum switch solenoid valve
Bottom magnetic detector of the Bottom magnetic detector of the
manipulator (X6)
manipulator
Wiring
PLC
Bottom detector of vertical

11 The manipulator for putting the
cylinder of the manipulator
shaft in the correct position goes Wiring
down with the gripper closed
PLC
Upper Magnetic detector of
12 The Led of the upper magnetic
loading manipulator1
detector of the vertical cylinder of Wiring
loading the palet manipulator
PLC
does not light on
Wiring
13 The incorrect shaft rejection
PLC
manipulator goes down before
going ahead
Bottom detector of vertical cylinder of

the manipulator (X15)
18

N
FAULT SYNTHOM
14 The manipulator of putting the

shaft in the correct position does
not turn
15 The shafts are not delivered
Solenoid valve of shaft

delivering.
Wiring
PLC.
16 The vertical cylinder of incorrect

shaft rejection manipulator does
not go down.
BROKEN COMPONENT
Rotary actuator
Solenoid valve of rotary actuator (Y2)
Solenoid valve of rotary actuator
Wiring
PLC

Front detector of horizontal
cylinder..
Bottom detector of vertical
cylinder.
Wiring
PLC
Solenoid valve of shaft delivering. (Y4)
19
STATION 5: SELECTION-FITTING OF COVER MODULE
FAULT SYNTHOM
1 The module does not run
2 The manipulator of load cover in the

palet does not go down
-
3 The vertical cylinder of manipulator of rejection incorrect cover does not go

up.
4 The linear encoder does not measure the height correctly
-
On push-button
OFF push-button
Wiring
PLC
palet.
Wiring
PLC
Vertical cylinder of manipulator.
cylinder of rejection manipulator.
Wiring
PLC
Linear encoder
Wiring
PLC
BROKEN COMPONENT
ON push-button (X2)

palet (X12)
Linear encoder
20

N
FAULT SYNTHOM
5 The inductive detector does not

detect metal material
- Inductive detector.
- Wiring
- PLC
BROKEN COMPONENT
Inductive detector (X24)
6 The manipulator of loading the cover - Bottom magnetic detector of

on the palet closes the gripper before
vertical cylinder of loading on
going down
the palet manipulator
- Wiring
- PLC
Bottom magnetic detector of

vertical cylinder of loading on the
palet manipulator (X7)
7 The photoelectric detector does not

distinguish the colors correctly
- Photoelectric detector
- Wiring
- PLC
Photoelectric detector (X26)
8 The horizontal cylinder of the

rejection manipulator goes back
before the horizontal cylinder has
gone up.
- Upper magnetic detector of

vertical cylinder
- Wiring
- PLC
Upper magnetic detector of vertical

cylinder (X21)
21

N
FAULT SYNTHOM
9 The horizontal cylinder of the

manipulator of rejection does not go
back and the cover is placed again
on the indexing table
BROKEN COMPONENT
- Rear magnetic detector of

Horizontal Cylinder of
manipulator
- Wiring
- PLC
Rear magnetic detector of

Horizontal Cylinder of manipulator
(X17)
10 The station can not work in the step

mode
- Selector step/ automatic

- Wiring
- PLC
Selector step/ automatic (X4)
11 The load manipulator does not turn

through the plate and leaves the
cover where it has taken it.
- Detector of manipulator
positioned over the plate
- Wiring
- PLC
Detector of manipulator positioned

over the plate
(X22)
12 The Led of the magnetic detector of - Magnetic detector of loading

position over the feeder does not light
manipulator1
on
- Wiring
- PLC
22

N
FAULT SYNTHOM
13 The horizontal cylinder of rejection

manipulator does not go ahead
BROKEN COMPONENT
- Horizontal cylinder of the

rejection manipulator
- Solenoid valve of horizontal
cylinder of rejection manipulator
- Wiring
- PLC
14 The gripper of the manipulator of

- Gripper
putting the cover in the plate does not - Solenoid valve of gripper
turn
- Wiring
- PLC
Solenoid valve of gripper (Y7)
15 The vacuum on the vacuum pads is

not made
- Solenoid valve of vacuum pads Solenoid valve of vacuum pads.

- Wiring
(Y10)
- PLC.
16 The manipulator of loading the plate

closes the gripper before go down
- Bottom detector of loading the

plate manipulator
- Wiring
- PLC
Bottom detector of loading the

plate manipulator (X13)
23
ESTATION 6: SCREW HANDLING- FITTING
FAULT SYNTHOM
BROKEN COMPONENT
1 The module does not run
On push-button
OFF push-button
Wiring
PLC
ON push-button (X0)
2 The insertion manipulator does not go

up
Cylinder of the insertion manipulator

Solenoid valves of the insertion
manipulators cylinder
Magnetic detector of the insertion
Magnetic detector of the grippers
Wiring
PLC
Magnetic detector of the grippers (X11)
Cylinders of the insertion/ transfer

manipulators.
Solenoid valves of the cilindres of
insertion/ transfer manipulators.
Magnetic detectors of the cilindres of
insertion/ transfer manipulators.
Wiring
PLC
Magnetic detector of the vertical cylinder of

insertion manipulator (X6)
3 The insertion manipulator does not
advance and the transfer cylinder does

not return.
24

N
FAULT SYNTHOM

down.

up.
Magnetic detector of the horizontal cylinder of

Insertion/ Transfer cylinders
Solenoid valves of Insertion/ Transfer transfer module (X12)
cylinders
Magnetic detectors of Insertion/
Transfer cylinders
Wiring
PLC
Magnetic detector of the grippers (X10)

Solenoid valve of the insertion
Magnetic detector of the grippers
Wiring
PLC
ON Push-button
OFF Push- button
Wiring
PLC
6 The station can no be switched on.
BROKEN COMPONENT
25

N
FAULT SYNTHOM
BROKEN COMPONENT
7 The station can no be switched on.
ON Push-button
OFF Push- button
Initial conditions
Wiring
PLC
Magnetic detector of the insertion manipulators

horizontal cylinder (X4)
8 The station does no work in automated

mode
Manual/ Automated switch

Wiring
PLC (Programme)
Manual /Automated switch (X2)
9 The transfer cylinder does not go

ahead.
Transfer cylinder
Solenoid valve of the Transfer
cylinder
Magnetic detectors of the Transfer
cylinder
Wiring
PLC
Magnetic detector of the transfer modules

horizontal cylinder (X13)

down.

Wiring
PLC

vertical axe (X7)
26

N
FAULT SYNTHOM

ahead.
12 The Led of the insertion manipulators

magnetic detector does not light on.

down.
BROKEN COMPONENT

Wiring
PLC

hozizontal axe (X5)

Wiring
PLC

horizontal axe (X5)
Cylinder of the insertion manipulator.

mnaipulators cylinder.
manipulators cylinder.
Wiring
PLC
Solenoid valve of the insertion manipulators

(Y3) and grippers (Y4) cylinders.
14 Free fault.
27

N
FAULT SYNTHOM
BROKEN COMPONENT
15 Free Fault
16 The transfer cylinder does not go

ahead.
Transfer cylinder
Solenoid valve of the Transfer
cylinder
Magnetic detectors of the Transfer
cylinder
Wiring
PLC
Inputs wiring (X7- X13)
28
ANNEX B
ELECTRIC DIAGRAMS
ANNEX C
PNEUMATIC DIAGRAMS
ANNEX D
GRAFCET AND
CONTROL PROGRAMS
ANNEX E
MECHANICAL DIAGRAMS
FMS-200
FMS-200
ANNEX F
MANUALS

Fms 200 Manual

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Fms 200 Manual

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TECHNICAL DESCRIPTION

10 REASONS FOR CHOOSING THE FMS-200

2.2. BEARING HANDLING-FITTING LAYOUT..7

2.3. HYDRAULIC BEARING PRESSING LAYOUT...11

2.4. SHAFT HANDLING-FITTING-MEASUREMENT-SELECTION15

2.5. COVER HANDLING-FITTING-SELECTION LAYOUT.21

2.5.2. Integral parts21

2.6. SCREW HANDLING-FITTING..27

2.7. ROBOT SCREWDRIVER..31

2.8. UNLOADING-STORAGE-PALLETIZATION OF COMPLETED ASSEMBLY.33

3. 4-METRE TRANSFER LINE WITH AUTOMATON AND PALLET ASSEMBLY...37

Air requirements ..41

Handling and packaging ..43

PROCEDURE FOR USE 49

LOCATING AND CORRECTING FAULTS 51

MAINTENANCE AND INSPECTION .67

Inspection points .67

Periodic inspection ..67

Maintenance procedures ..68

Electrical shafts ...68

General safety precautions ..69

Protection and safety devices ..69

8. FAULT SIMULATION SYSTEM..70

9. SETS OF PARTS FOR ASSEMBLY.....71

10. EC SELF- CERTIFICATION...72

11. SUPPORT MATERIAL....73

ANNEX A: FAULT GENERATION

ANNEX B: ELECTRIC DIAGRAMS

ANNEX C: PNEUMATIC DIAGRAMS

ANNEX D: GRAFCET AND CONTROL PROGRAMS

ANNEX E: MECHANICAL DIAGRAMS

1.- TECHNICAL AND FUNCTIONAL

Figure 1: Flexible Automated Cell Trainer FMS-200

Installation, Electromechanical Maintenance and Line Transport.

It enables the development of various skills associated with pneumatic, electro-pneumatic,

Figure 2: Turning mechanism

Figure 3: Turning mechanism components

1.2. AUTOMATON PROGRAMMING SOFTWARE

2.1.2. INTEGRAL PARTS

Figure 4: Body-feed positioning

Movement to transfer point:

The cylinder is rectangular, to prevent the pusher from turning.

Rejection of incorrect body:

Placing body on pallet:

Suction is created by a vacuum ejector fitted with a vacuum switch

Figure 6: Vacuum Ejector

2.1.3. TECHNICAL DATA

Position verification module

2.2. BEARING HANDLING-FITTING LAYOUT

Figure 7: Bearing Handling-fitting layout

2.2.2. INTEGRAL PARTS

In this case, there is a bearing proximity sensor in

Transfer to measuring station:

Figure 10: Transfer to measuring station

Figure 12: Bearing insertion

2.2.3. TECHNICAL DATA

Electrical control panel:

2.3.1. STATION FUNCTION

Figure 13: Hydraulic Bearing Pressing Lay-out

2.3.2. INTEGRAL PARTS

Insertion / extraction of assembly:

Pressing the bearing:

Figure 15: Pressing the bearing