Project 1: Assembly, programming and commissioning of a production line including Handling station with electrical drive and stack

magazine and Robot station

Weighting (points out of total) t max 16/100 180 min

All big pictures are also on CD-ROM

Scenario You are responsible for the delivery of a production line purchased by a customer in the world to be used in the partial automation of its production process.

Task Assemble, wire and tube the production line on the profile plate according to the following guidelines and the technical information. Develop a program and commission the system. Your task is complete when: 1. The production line has been mechanically assembled, correctly wired, connected and its correct operation is guaranteed (based on evaluation using the simulation box). 2. Correct execution of the program with PLC activation (based on evaluation with PLC) is guaranteed. 3. The system meets the specifications (in accordance with the 'Agreement on Professional Practice' which has been handed out separately). The system will be sent to the customer as soon as you are finished. You will have no opportunity to make improvements later.

WorldSkills international Mechatronics Competition 2011

Production line layout:

3 4

1. 2. 3. 4. 5. 6. 7.

Handling station (HS) Magazine pickup position Slide Drop down position 1 Slide Drop down position 2 (not used) Robot station (RS) Pallet 1 Place 1 to 6 Pallet 2 Place 1 to 6

Initial position:
HS: RS: See Touch Panel Stack magazine ejecting arm retraced (cylinder extended) Gripper unit in Magazine position Gripper open Gripper up

6 5

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Optical Sensor at Magazine pick up position:

Control panel

Start Lamp Start button Reset Lamp Reset Button Q1 Q2

Stop button

Auto

Man

Assembly and wiring of signal column

WorldSkills international Mechatronics Competition 2011

Back side of the Handling unit

Fixing of the linear axes left and right

WorldSkills international Mechatronics Competition 2011

Multipol I/O module Motor controller Valve terminal Optical Sensor

Motor controller R/L: A1 : move to right side / A2 : move to left side 1, 2 : Motor VCC: 24 V / GND: 0V A3 and I-OUT are not used

Wiring control panel

wiring additional signals to - X7 (pin 5-8 Input; pin 13-16 Output)

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Input of control panel (also on CD-ROM)

Communication Robot station with Handling station:

P1

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The robot station (downstream station) is sending a busy signal via the optical transmitter. This signal can be detected with the receiver at the Handling station (upstream station) in order to achieve a safe material flow. The StationLink receiver on the upstream station. The StationLink Transmitter is mounted on the downstream station.

By switching on or off the StationLink transmitter, the downstream station signals the upstream station whether it is ready to receive a pot or busy.

Pallet 2 A TP 1 D Pallet 1 E TP 3 F TP 2 C malfunction B malfunction/ collision

P5

P6

P2

P3

P7

collision P4

Front

Position P1 is the pickup position in the Robot station!

WorldSkills international Mechatronics Competition 2011

Position P1 is the pickup position in the Robot station! Wiring allocation valve terminal

PIN 1 2
1 2 3 4 5 6 7 8

Core colour White Brown Green Yellow Brown-green White-yellow

Coil 0 1 2 3

Ouput 2 3

Function Move gripper down Open gripper not used but switch for manual use is ON (--)

3 4 5-13 14 15

9 10 11 12 13 14 15

4 0V 0V

Ejecting arm push out pot

Wiring allocation of sensors to Multipol (MPV)

M8 socket/ Pin 0/4 1/4 2/4 3/4 4/4 5/4 6/4 7/4 0-7 / 1 0-7 / 3 0-7 / 3 24V DC 0V 0V

Pin

Core colour

Input

function

1 2 3 4 5 6 7 8 9-12 13 14 15

White Brown Green Yellow Grey Pink Blue Red White-green Brown-green White-yellow

1 2 3 4 5 6

Gripper unit in magazine position Gripper unit in downstream station position Gripper unit in slide position Gripper is down Gripper is up Pot is not black Not used Not used

Wiring to the Control panel

Connector I/O (IN) DI 0 - 3 DI 4 - 5 DI 6 DI 7 Comment: 1 signal indicates Used by Control panel Not used Ejecting cylinder extended Ejecting cylinder retracted Connector I/O (OUT) DO 0 - 3 DO 4 - 5 DO 6 DO 7 Comment: 1 signal set Used by Control panel Not used

WorldSkills international Mechatronics Competition 2011

Evaluation sheet Project 1: Assembly, programming and commissioning of a production line including Handling station with electrical drive and stack magazine and Robot station
Team: Verification of acceptance by experts (names, signatures):

Maximum time: 180 min. /

Description

Maximum points: 16
Evaluation Done Max points

Function to be checked using simulation box and wiring of the I/O Terminal for the station

Preparation: Connect the simulation box to the I/O terminal (Output 0 7: signal 1 or 0); (Input 0 7: signal 1 or 0) Connector I/O Terminal (IN) DI 0 DI 1 DI 2 DI 3 DI 4 DI 5 DI 6 DI 7 Connector I/O Comment 1 signal indicates Pot is in magazine pickup position Gripper unit is in magazine position Gripper unit is in downstream station position / Robot slide Gripper unit is in slide position 1 Gripper is down Gripper is up Pot is not black Downstream station free Comment 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3

Terminal (OUT) 1 signal set DO 0 DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 7 Gripper unit to left hand side (magazin position) Gripper unit to right hand side (drop off position) Gripper down Open gripper Ejecting arm push out pot Signal lamp green Signal lamp yellow Signal lamp red 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3

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SimuBox total

4,8

Description Function to be checked using PLC board

Evaluation Done Max. Points

Preparation: Connect the PLC board with the I/O terminal and the control panel, switch key to the position AUTO, start the PLC, no programming cable between PC and PLC, valve for air opened, Handling linear drive between sensors. Reset the robot station, Start the robot program 20, You will get time do that before the evaluation! RED Signal lamp ON ** Reset lamp ON Switch key to the position MAN (Handling Station) then YELLOW signal lamp ON ** Press Reset button (Handling Station) then system moves to initial position Reset lamp OFF if system is in the initial position Put a minimum of 4 pots into the magazine of the Handling station* Switch key to the position AUTO (Handling Station) then GREEN signal lamp ON ** and Start lamp ON A: Press the START button (Handling station) then Start lamp OFF ***if magazine was previously empty (Yellow signal lamp flashing), now GREEN signal lamp ON ** and Q1 OFF Gripper moves to magazine pickup position if a pot available Start lamp ON Press the START button then Start lamp OFF Gripper up with a pot Partial points If a pot is black YELLOW signal lamp flashing with 1Hz ** Pot placed on slide 1 Done Max. Points 0,2 IF a pot is silver, red or transparent Done 0,2 0,2 0,2 0,3 0,3 0,2 0,2 0,3 0,3

0,3 0,3 0,3 0,3 3,4 Max. Points

0,4

Handling station drops pot on robot slide

0,4

GREEN signal lamp ON**

0,2

Robot put the pot on Pallet 1 place A F

0,4

Partial points

0,8

Partial points

0,8

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Gripper unit moves to Initial Position Start lamp - ON Continue with A:

0,3 0,2 0,3

Evaluation of : Identification that the magazine is empty; coming from A: Q1 ON (Lamp at control panel) Retract ejecting arm (cylinder extended) Start lamp ON YELLOW signal lamp flashing with 2 Hz ** Put a pot into magazine Continue with A: 0,3 0,2 0,3 0,2 0,2

** At any time only one lamp of the signal column is on

0,2

Partial points PLC board total

2,2 7,2

* Red, black, silver or transparent pot will be chosen by the evaluation team ** At any time only one lamp of the signal column is on *** End of Evaluation The Stop button is not used

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Description

Evalua tion

Maximum evaluation

Professional practice

List of Professional Practice will be checked in samples

PP item no. * * * * * * * * * *

Not fulfilled -0,4 -0,4 -0,4 -0,4 -0,4 -0,4 -0,4 -0,4 -0,4 -0,4 4

Professional Practice total

* Each deviation will result in 0,4 points being deducted

Total evaluation Project 1:

Description Evaluation Maximum evaluation Points for operation based on simulation box Points for operation based on PLC board Points for professional practice Total points _____ _____ _____ _____ 4,8 7,2 4 16,0

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