Automation & Material Handling - LabVolt

Student Guide/Portfolio

37177-00 Edition 2

Level one

Automation & Material Handling

Ê>E1fèRÆ9ÄË 3037177000509

SECOND EDITION

First Printing, September 2005

Copyright 2004 Lab-Volt Systems, Inc.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopied, recorded, or otherwise, without prior written permission from Lab-Volt Systems, Inc. Information in this document is subject to change without notice and does not represent a commitment on the part of Lab-Volt Systems, Inc. The multimedia Tech-World software and other materials described in this document are furnished under a license agreement or a nondisclosure agreement. The software may be used or copied only in accordance with the terms of the agreement.

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Table of Contents

i

Introduction ................................................................................................................ 1

Topic 1 – Introduction to Automation and Material Handling........................ 3 Activity 1 – Products: From Start to Finish............................................................. 3 Activity 2 – Career Discovery ................................................................................... 3

Topic 2 – Computers in Manufacturing................................................................. 5 Activity 1 – Computers Make Products? .................................................................. 5 Activity 2 – A Robotics System ................................................................................. 6

Data Sheet: 5200 Series Robot Installation Guide .............................................. 6 Activity 3 – Getting to Know the Robot.................................................................. 20

Data Sheet: Teach Menu Quick Reference......................................................... 20 Rubric .................................................................................................................. 21

Topic 3 – Programming and Automation............................................................ 23 Activity 1 – Robots Always Obey ............................................................................ 23 Activity 2 – Reprogramming ................................................................................... 23 Activity 3 – Go to the Computer ............................................................................. 23 Activity 4 – True Automation ................................................................................. 23

Rubric .................................................................................................................. 24

Topic 4 – Islands of Automation............................................................................ 25 Activity 1 – Automation Islands ............................................................................. 25 Activity 2 – Island Sizing ........................................................................................ 26

Data Sheet: Figuring the Robot’s Work Envelope ............................................. 26 Activity 3 – Other Robot Types............................................................................... 27 Activity 4 – Material Handling............................................................................... 27

Topic 5 – Island Control.......................................................................................... 29 Activity 1 – Overview of Controls ........................................................................... 29 Activity 2 – Control Devices and Methods ............................................................. 29 Activity 3 – Flexible Manufacturing Cells ............................................................. 29

Topic 6 – Interconnecting Automation Islands ................................................. 31 Activity 1 – Conveyor Systems ............................................................................... 31 Activity 2 – Functions of Automated Guided Vehicles .......................................... 31

Table of Contents

ii

Topic 7 – Controlling the Manufacturing Plant ................................................ 33 Activity 1 – Information Gathering for the PLC.................................................... 33

Data Sheet: Sensing Materials, Part A .............................................................. 33 Activity 1 – Information Gathering for the PLC.................................................... 34

Data Sheet: Sensing Distance, Part B................................................................ 34 Activity 2 – Discover PLCs...................................................................................... 35

Rubric .................................................................................................................. 36

Topic 8 – PLC in Command.................................................................................... 37 Activity 1 – PLC Logic............................................................................................. 37 Activity 2 – PLC Programming............................................................................... 38

Data Sheet: Ladsim Worksheet #1..................................................................... 38 Activity 2 – PLC Programming............................................................................... 39





Data Sheet: Ladsim Worksheet #6..................................................................... 43 Activity 3 – PLC Applications................................................................................. 44

Automation and Material Handling Introduction

1

INTRODUCTION

This Student Guide/Portfolio serves as a record of your progress through the multimedia presentation and CELL Guide activities. It includes data sheets and assessment forms. It is structured in the same way as the CELL Guide and the multimedia presentation. Each CELL is divided into topics and each topic consists of a series of activities. Either the multimedia presentation or the CELL Guide will direct you to the Student Guide/Portfolio. You will use the forms available to record your observations, track data, or summarize your experience. Your instructor completes the assessment forms where your performance is observed. Both the data sheets and the assessment forms are labeled according to the topics and activities to which they relate and appear in the corresponding places in your Student Guide/Portfolio. Ask your instructor about adding any additional materials to this guide that you complete during the topics. By keeping a record of your forms and collecting your own work, you create a portfolio that documents your progress through the topics and reviews what you have learned in applying the various technologies.

Automation and Material Handling Introduction

2

Automation and Material Handling Topic 1 - Introduction to Automation and Material Handling

3

TOPIC 1 – INTRODUCTION TO AUTOMATION AND MATERIAL HANDLING

Activity 1 – Products: From Start to Finish There are no data sheets required for this activity.

Activity 2 – Career Discovery There are no data sheets required for this activity.

Automation and Material Handling Topic 1 - Introduction to Automation and Material Handling

4

Automation and Material Handling Topic 2 – Computers in Manufacturing

5

TOPIC 2 – COMPUTERS IN MANUFACTURING

Activity 1 – Computers Make Products? There are no data sheets required for this activity.


6

Activity 2 – A Robotics System Data Sheet: 5200 Series Robot Installation Guide Name Date Introduction Your installation booklet for the 5200 Series robotics system begins on the next page. You will be guided every step of the way. Since it is very likely that the cables and hoses have already been installed by your instructor or a classmate, you will verify that they are correct.

You will draw in connecting lines and label the parts on the drawings provided in your Student Guide/Portfolio. The graphics on your screen will guide you. Then you must check the equipment using your own drawings to verify that the connections have been correctly made. Remember that if you find an incorrect connection, tell your instructor before you do anything else. Finally, you will write the instructions for installing the cables and hoses.

Writing this installation booklet is a practical lesson in technical writing. It is a useful exercise because people in technical fields very often find themselves assigned chores requiring technical writing. You will first see a sample page and will be provided guidance along the way.


7

The Controller and the Emergency Stop Box

(This is a sample page.)

Controller Power Cable Connection

Installation Procedures

CAUTION: Never insert or remove any cable connections while the power cable is plugged in.

1. Make sure the power cable from the controller as shown in the graphic above is

NOT plugged in a wall or strip receptacle.

CAUTION: Make sure the panic button (emergency stop switch) is up (released). If it is down when the controller power cord is plugged in, you will get an error message. If it happens, turn the key in the box clockwise to release the button. You’ll have to press the Clear Error button on the pendant to get started.

2. Plug the cord from the emergency stop box into the controller as shown in the

graphic above.


8

The Teach Pendant


tomation

8 AXIS SERVO ROBOTIC SYSTEM

5200


9

The Linear Slide and the Controller


CNC1 CNC2 Ch2ROBOTDRIVE

EMERGENCYSTOP ROBOT FEEDBACK

LINE INPUT85-132 / 170-254 VAC

200 VA MAX.2A FUSE

Ch1

R1-232


10

The Carousel and the Controller


CNC1 CNC2 Ch1 Ch2ROBOTDRIVE

EMERGENCYSTOP ROBOT FEEDBACK

LINE INPUT85-132 / 170-254 VAC

200 VA MAX.2A FUSE

R2-232


11

The Pneumatic Feeder and the Flow Control Box



12

Additional Installation Procedures


13

The Compressor



14

Connections Between the Pneumatic Feeder and the Controller



15

The Conveyor and the Controller Installation Procedures


16

The Gravity Feeder and the Controller


tomation

8 AXIS SERVO ROBOTIC SYSTEM

5200


17

Your Computer



18

5200 Series Robot



19

Powering Up the Robot

Controller Power Cable Connection



20

Activity 3 – Getting to Know the Robot Data Sheet: Teach Menu Quick Reference This can be used as a quick reference for the Teach Menu found on the teach pendant. It is a summary of the more often used keys to operate the robot.

You can use the arrow key to select the action and press Enter or just press the specific key.

Teach Menu Shortcuts

Key Action Key Action

1 Open Gripper H Close Gripper

2 Rotate Wrist CW I Rotate Wrist CCW

J Raise Gripper (at wrist) 3 Lower Gripper (at wrist)

R Raise Forearm 4 Lower Forearm

5 Lower Upper Arm S Raise Upper Arm

T Rotate Base CW 6 Rotate Base CCW

7 Move Forward (CH 1)1 Z Move Backward (CH 1)2

8 Move Forward (CH 2)3 / Move Backward (CH 2)4

* Save Control

. Save Absolute Point

1 This refers to the device connected to channel 7 of the controller. 2 This refers to the device connected to channel 7 of the controller. 3 This refers to the device connected to channel 8 of the controller. 4 This refers to the device connected to channel 8 of the controller.


21

Rubric A rubric represents an opportunity for you to show your instructor what you have learned in this topic. Notify your instructor when you have completed this topic. He or she will use this rubric checklist to review your work. You will connect or verify the connection of the cables from the controller to the robot, the linear slide, the carousel, the conveyor, the gravity feeder, the pneumatic feeder, and to a computer. This authentic assessment activity will receive a grade. It will also help your instructor determine whether you need additional practice before continuing with this CELL.

Note to instructor: Refer to the Instructor Guide for detailed scenario information.

Assessment Rubric

1 100 50 0 2 100 50 0 3 100 50 0 4 100 50 0 5 100 50 0 6 100 50 0


22

Automation and Material Handling Topic 3 – Programming and Automation

23

TOPIC 3 – PROGRAMMING AND AUTOMATION

Activity 1 – Robots Always Obey There are no data sheets required for this activity. Activity 2 – Reprogramming There are no data sheets required for this activity. Activity 3 – Go to the Computer There are no data sheets required for this activity. Activity 4 – True Automation There are no data sheets required for this activity.

Automation and Material Handling Topic 3 – Programming and Automation

24

Rubric A rubric represents an opportunity for you to show your instructor what you have learned in this topic. Notify your instructor when you have completed this topic. He or she will use this rubric checklist to review your work. You will create a simple pick-and-place program. First you’ll perform a hard home. Then you’ll change speeds in making the program and save it to disk. This authentic assessment activity will receive a grade. It will also help your instructor determine whether you need additional practice before continuing with this CELL.


Assessment Rubric

1 100 50 0 2 100 50 0 3 100 50 0 4 100 50 0

Automation and Material Handling Topic 4 - Islands of Automation

25

TOPIC 4 – ISLANDS OF AUTOMATION

Activity 1 – Automation Islands There are no data sheets required for this activity.

Automation and Material Handling Topic 4 – Islands of Automation

26

Activity 2 – Island Sizing Data Sheet: Figuring the Robot’s Work Envelope Name Date Area = πR2

π = 3.14 R (length of robot’s arm) = 28.5 inches R2 = _______ Area = ________ Work Envelope: Area X 320/360 (8/9) = _________


27

Activity 3 – Other Robot Types There are no data sheets required for this activity. Activity 4 – Material Handling There are no data sheets required for this activity.


28

Automation and Material Handling Topic 5 – Island Control

29

TOPIC 5 – ISLAND CONTROL

Activity 1 – Overview of Controls There are no data sheets required for this activity.

Activity 2 – Control Devices and Methods There are no data sheets required for this activity.

Activity 3 – Flexible Manufacturing Cells There are no data sheets required for this activity.


30

Automation and Material Handling Topic 6 – Interconnecting Automation Islands

31

TOPIC 6 – INTERCONNECTING AUTOMATION ISLANDS

Activity 1 – Conveyor Systems There are no data sheets required for this activity. Activity 2 – Functions of Automated Guided Vehicles There are no data sheets required for this activity.


32

Automation and Material Handling Topic 7 – Controlling the Manufacturing Plant

33

TOPIC 7 – CONTROLLING THE MANUFACTURING PLANT

Activity 1 – Information Gathering for the PLC Data Sheet: Sensing Materials, Part A Name Date

Table 1 – Sensing Material

Material Sensor 6374-A0

Sensor 6375-A0

Sensor 6376-A0

Sensor 6377-A0

Steel

Colored Plastic

Transparent Plastic

Retroreflector

No

No

NOTE: Enter Yes or No to record whether or not a sensor detects the materials listed in the table above.


34

Activity 1 – Information Gathering for the PLC Data Sheet: Sensing Distance, Part B Name Date

Table 2 – Sensing Distance

Material Sensor 6374-A0

Sensor 6375-A0

Sensor 6376-A0

Sensor 6377-A0

Detection Distance

Steel

Colored Plastic

Transparent Plastic

Retroreflector

NOTE: In each box, record the maximum distance that each sensor can detect material specified in the table above. Place an "X" in the boxes for material that was not detected. Use inches as the unit of measurement.


35

Activity 2 – Discover PLCs There are no data sheets required for this activity.


36

Rubric A rubric represents an opportunity for you to show your instructor what you have learned in this topic. Notify your instructor when you have completed this topic. He or she will use this rubric checklist to review your work. You will connect or check the wires between the sensors and the sensor interface (sometimes called input) box. You’ll then perform a series of tests using materials provided. This authentic assessment activity will receive a grade. It will also help your instructor determine whether you need additional practice before continuing with this CELL.


Assessment Rubric

1 100 66 33 0 2 100 50 0 3 100 66 33 0

Automation and Material Handling Topic 8 – PLC in Command

37

TOPIC 8 – PLC IN COMMAND

Activity 1 – PLC Logic There are no data sheets required for this activity.


38

Activity 2 – PLC Programming Data Sheet: Ladsim Worksheet #1 Name Date


39


File Edit Simulate Control Help


40

Activity 2 – PLC Programming Data Sheet: Ladsim Worksheet #3 Name Date 1. There are 12 symbols for input devices, labeled IP0 to IP11, in the DEBUGGING

SIMULATOR window under INPUTS. In the space provided below draw what is shown in the box under each input device number.

2. Click on one of the input device symbols and draw, in the space provided, what is

shown. 3. Since these symbols look similar to the symbol used in the reference for an

electrical switch, which one represents a switch that is OFF? _____ _____ 4. Which one represents a switch that is ON? __________ 5. Is the contact highlighted? __________ 6. Is the output highlighted? __________ 7. Is the input device ON or OFF? __________ 8. Look at the OUTPUTS window in the DEBUGGING SIMULATOR window. Is

OP4, the output device, ON (red) or OFF (black)? ___________

A

B


41

Activity 2 – PLC Programming Data Sheet: Ladsim Worksheet #4 Name Date 1. Is the contact highlighted? __________ 2. Is the output highlighted? _____ _____ 3. Is the input device ON or OFF? __________ 4. Look at the OUTPUTS window in the DEBUGGING SIMULATOR window. Is

the output device ON or OFF? ___________ Open the input device by clicking on the button under IP2. 5. Is the contact highlighted? __________ 6. Is the output highlighted? __________ 7. Is the input device ON or OFF? __________ 8. Look at the OUTPUTS window in the DEBUGGING SIMULATOR window. Is

OP4, the output device, ON or OFF? ___________


42


Truth Table 1

IP2 IP3 OP4


43


Truth Table 2

IP2 IP3 OP4


44

Activity 3 – PLC Applications There are no data sheets required for this activity.

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