Festo CP Factory User manual

Festo Didactic
CP Factory
12/2018
CP Factory®
Manual
Robot feeding for mill

2© Festo Didactic CP Factory ° Robot feeding for mill
Order number:
Status: 02/2018
Layout: 02/2018, Schober, Weiss
File Name: CP-F-RASS-KUKA-GB-A001.doc
© Festo Didactic SE, 73770 Denkendorf, Germany, 2018
Internet: www.festo-didactic.com
E-Mail: [email protected]m
Intended use
This installation was developed and manufactured only for the use in basic and further training in
the fields of automation and communications. The training company and/or the training staff must
ensure that the trainees observe the safety precautions described in the accompanying manuals.
Furthermore this manual describes setup and possible uses of the singular stations. It contains all
information and data required for commissioning, maintenance and operation.
Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any
third parties which may occur when the installation is used beyond a genuine training situation,
except Festo Didactic has caused such injury or harm intentionally or by grossly negligence.
Experimenting on CP Factory / CP Lab systems with hazardous live voltage is not allowed.
This manual, all text and illustrations included, is protected by copyright. Any utilization outside the
limits of the copyright law and other than training purposes are not permissible without our definite
approval. This applies in particular to reproductions, operations, translations, micro filming and the
storing and processing into electronic systems. Distribution of this documentation, as well as
reproduction, use and spread of its contents is prohibited, insofar not permitted explicitly. Offences
are liable to compensation. All rights reserved, especially the right to execute registrations
concerning patents, designs for use and patterns.
Intended use also comprises observing all instructions in the operating manual and carrying out the
inspection and maintenance works.

Content
© Festo Didactic CP Factory ° Robot feeding for mill 3
Content
1 General safety instructions __________________________________________________________________ 6
1.1 Pictographs ___________________________________________________________________________ 7
1.2 Safety terminal sockets _________________________________________________________________ 8
1.3 Information for the electrical connection of the systems ______________________________________ 8
1.4 Handling the system ___________________________________________________________________ 9
1.4.1 Dangers when using the machine _____________________________________________________ 9
1.4.2 Safety precautions in normal operation ________________________________________________ 9
1.4.3 Dangers caused by electrical energy___________________________________________________ 9
1.4.4 Dangers caused by pneumatic energy _________________________________________________ 9
1.4.5 Maintenance and fault clearance______________________________________________________ 9
1.4.6 Organizational measures ____________________________________________________________ 9
1.5 Staff ________________________________________________________________________________ 10
1.5.1 Instructions regarding the staff ______________________________________________________ 10
1.5.2 Training operations________________________________________________________________ 10
1.5.3 Beyond training operations _________________________________________________________ 10
1.6 Commitment of the operator ____________________________________________________________ 10
1.7 Commitment of the trainees ____________________________________________________________ 10
2 Introduction _____________________________________________________________________________ 11
2.1 Warranty and liability__________________________________________________________________ 11
2.2 Important information _________________________________________________________________ 11
2.3 Resources ___________________________________________________________________________ 12
3 Design and function_______________________________________________________________________ 15
3.1 Transport____________________________________________________________________________ 15
3.2 Set up ______________________________________________________________________________ 15
3.2.1 General notes ____________________________________________________________________ 15
3.3 Robot feeding for mill__________________________________________________________________ 16
3.3.1 General__________________________________________________________________________ 16
3.4 Mechanical structure __________________________________________________________________ 21
3.4.1 Supply of the Robot feeding for mill __________________________________________________ 25
3.5 Electrical set up ______________________________________________________________________ 27
3.5.1 Siemens PLC _____________________________________________________________________ 29
3.5.2 Cabling chart _____________________________________________________________________ 31
3.5.3 Emergency stop structure __________________________________________________________ 32
3.5.4 Emergency-stop with central control__________________________________________________ 35
3.6 Commissioning _______________________________________________________________________ 36
3.6.1 Pneumatic commissioning __________________________________________________________ 36
3.6.2 Electrical commissioning ___________________________________________________________ 36
3.7 Commissioning _______________________________________________________________________ 37
3.7.1 Pneumatic commissioning __________________________________________________________ 37
3.7.2 Electrical commissioning ___________________________________________________________ 37
3.8 Adjusting the sensors _________________________________________________________________ 38
3.8.1 Proximity switch (stopper Identsensor) _______________________________________________ 38
3.8.2 Proximity switch (stopper cylinder)___________________________________________________ 40
3.9 Adjusting the one-way flow control valves_________________________________________________ 42

Content
4© Festo Didactic CP Factory ° Robot feeding for mill
3.10 Visual inspection ____________________________________________________________________ 43
3.11 Starting up _________________________________________________________________________ 43
4 Operation _______________________________________________________________________________ 44
4.1 General notes on operation_____________________________________________________________ 44
4.1.1 Handling regulations ______________________________________________________________ 44
4.1.2 Operating regulations______________________________________________________________ 44
4.2 The control units of the robot feeding for mill ______________________________________________ 45
4.2.1 Touch Panel ______________________________________________________________________ 46
4.3 Sequence description of robot feeding for mill _____________________________________________ 47
4.4 Sequence description of the Basic Module ByPass _________________________________________ 49
4.4.1 CP Factory Loading Robot (Mill and Turn)______________________________________________ 54
4.4.2 Switch on robot ___________________________________________________________________ 57
4.5 Operating modes _____________________________________________________________________ 58
4.5.1 Automatic operation _______________________________________________________________ 58
4.5.2 Setup mode ______________________________________________________________________ 58
4.6 Operating the HMi Touchpanel __________________________________________________________ 58
4.6.1 Menu architecture from Panel _______________________________________________________ 59
4.6.2 Menu navigation robot feeding for mill________________________________________________ 60
4.6.3 Display operation modus ___________________________________________________________ 62
4.6.4 Operation mode Home _____________________________________________________________ 63
4.6.5 Operating mode Setup _____________________________________________________________ 69
4.6.6 Operation mode Parameters ________________________________________________________ 76
4.6.7 Operation mode System - settings ___________________________________________________ 80
4.7 Automatic operation __________________________________________________________________ 81
4.7.1 Start automatic ___________________________________________________________________ 81
4.7.2 Stop automatic ___________________________________________________________________ 83
4.8 Writing on the RFID tag manually ________________________________________________________ 84
4.8.1 Pallet carriers ____________________________________________________________________ 84
4.8.2 Boxes ___________________________________________________________________________ 86
4.8.3 Parameter CP Factory feeding robot and mill ___________________________________________ 87
5 Components _____________________________________________________________________________ 88
5.1 Mitsubishi Robot RV-4FL _______________________________________________________________ 88
5.1.1 Drive Unit CR750-D ________________________________________________________________ 89
5.1.2 Teach pendant R32TB______________________________________________________________ 91
5.1.3 Teachpendant R56TB ______________________________________________________________ 92
5.1.4 Set up___________________________________________________________________________ 93
5.1.5 Interface Drive Unit ________________________________________________________________ 96
5.1.6 Parameter ______________________________________________________________________100
5.1.7 Main tasks/Programmes __________________________________________________________101
5.1.8 Return message _________________________________________________________________101
5.1.9 Further information to robot _______________________________________________________101
5.2 Robot positions _____________________________________________________________________102
5.3 Electrical components ________________________________________________________________ 103
5.3.1 2 Quadrant Controller _____________________________________________________________103
5.3.2 Controller Siemens _______________________________________________________________106
5.3.3 Controller Festo CECC _____________________________________________________________107
5.3.4 Turck Interface___________________________________________________________________ 108

Content
© Festo Didactic CP Factory ° Robot feeding for mill 5
5.3.5 Scalance Ethernet Switch __________________________________________________________ 109
5.3.6 RFID with Ethernet _______________________________________________________________112
5.3.7 RFID with CanBus ________________________________________________________________ 116
5.3.8 Mini Terminal____________________________________________________________________ 117
5.3.9 SYS link interface ________________________________________________________________121
5.4 Mechanic components ________________________________________________________________122
5.4.1 Motor of Conveyor _______________________________________________________________ 122
5.4.2 The stopper unit _________________________________________________________________123
5.4.3 Transportation of the basic module _________________________________________________ 125

General safety instructions
6© Festo Didactic CP Factory ° Robot feeding for mill
1General safety instructions
The laboratory resp. the classroom must be equipped according to the rules of EN 50191:
There must be Emergency Stop equipment in the training area and at least one Emergency Stop outside
the training area.
The training area must be protected against any unauthorized switching-on, e.g. by key-operated
switches.
The training area must be protected by fault current protective circuit (RCD).
–RCD circuit breaker with differential current ≤ 30 mA, type B.
The training area must be protected by overcurrent protections -
–fuses or circuit breakers
The training area must be supervised by a person who is responsible for the activities.
–This person must be a skilled electrician or a person instructed in electrical engineering with the
knowledge of all safety requirements and safety precautions on file.
Any damaged device or faulty device may not be used.
–Any faulty or damaged device has to be blocked and removed from the training area.
General requirements regarding a safe operation of the devices:
Do not lay cables over hot surfaces.
–Hot surfaces are marked with a corresponding warning symbol.
The permitted power loads of cables and devices may not be exceeded.
–Do always compare the current values of the device, the cable and the fuse.
–In case of non-compliance, you have to use a separate upstream fuse as an appropriate overcurrent
protection.
Any device with earth connection must always be grounded.
–If there is a ground connection (green-yellow laboratory socket) available, the connection to the
protective ground must always be effected. The protective ground must always be contacted first
(before voltage) and must only be separated last (after voltage separation).
If not specified differently in the technical data, the device does not have an integrated fuse.

General safety instructions
© Festo Didactic CP Factory ° Robot feeding for mill 7
1.1 Pictographs
This document and the described hardware contain information on possible dangers which may occur when
using the system improperly. The following pictographs are used:
Warning
This means that in case of disregarding the rules, serious personal injury or
material damage may occur.
Caution
This means that in case of disregarding the rules, personal injury or material
damage may occur.
Warning
This means that prior to any mounting, repair, maintenance or cleaning operations,
you have to switch off the device and to disconnect the power plug. Please
observe the manual, especially all information on safety. In case of disregarding,
serious personal injury or material damage may occur.
Warning
This means that you could burn yourself when touching hot surfaces
(temperatures up to 85 ° Celsius).
Important
Here you find important information for an appropriate handling of the machine.
Disregarding this symbol may lead to malfunctions at the machine or in its
surrounding area.
i
Information
This means that you obtain tips for the use and especially useful information.

General safety instructions
8© Festo Didactic CP Factory ° Robot feeding for mill
1.2 Safety terminal sockets
If not specified differently in the technical data, the following colour coding applies for the power and signal
supplies with components of the FESTO Didactic learning system automation and technics.
Colour
Meaning
Colour
Meaning
Voltage bigger protective low voltage, e.g.
supply voltage 90 to 400 V AC conductor (grey)
24 V DC
(red)
neutral conductor
(grey/blue)
0 V DC
(blue)
protective earth conductor
(green-yellow)
protective low voltage
signal input/signal output
(black)
The specified protection categories and the safety can only been guaranteed when using Festo Didactic
safety laboratory cables.
Any damaged or faulty safety laboratory cables have to be blocked instantly and to
be removed from the training area.
1.3 Information for the electrical connection of the systems
For the supply of the CP-Factory/ CP-Lab systems, according to the regulations of the EN 60204-1 (VDE
0113-1) part 8.2.8, a supply cable with an additional protective earth conductor is required. Since a leakage
current of > 10mA may flow depending on the expansion, an additional protective earth conductor with
10mm² is required.
See also DIN EN 60204-1.

General safety instructions
© Festo Didactic CP Factory ° Robot feeding for mill 9
1.4 Handling the system
1.4.1 Dangers when using the machine
The system has been constructed in accordance with the state of the art and the recognized safety rules.
Nevertheless, there might occur dangers to life and limb of the user or a third person when used, as well as
negative impact on the system or on other material assets.
You may only use the system:
for the intended use
in excellent condition concerning safety regulations
Any faults which might affect the safety must be eliminated instantly!
1.4.2 Safety precautions in normal operation
Please use the system only if all safety devices are fully functional.
Please inspect the system regarding externally discernible damages and the functionality of the safety
devices at least before starting the operation.
Do not touch the running station.
Before any circuit assembly, disassembly or modifications in a circuit:
Switch off the compressed air supply and the power supply.
Observe the general safety regulations: DIN 58126 and VDE 0100.
1.4.3 Dangers caused by electrical energy
After finishing the maintenance works you have to check the safety devices regarding their function.
Only an electrically or electronically trained person is allowed to execute operations on the electrical supply.
The terminal boxes have to be kept close all of the time. Any access is only allowed if supervised by a
training person.
Please do not operate electrical limit switches manually when searching for an error, but use the tools.
Please do only use low voltage 24 VDC.
1.4.4 Dangers caused by pneumatic energy
Tubes coming off due to compressed air may cause injuries. Take away the pressure instantly.
Caution! When switching on the compressed air, the cylinders may drive in or out automatically.
Do not uncouple the tubes when under pressure. Exception: Debugging. In this case, you have to hold the
tube end tight. Do not exceed the permitted working pressure. See also data sheets.
1.4.5 Maintenance and fault clearance
Carry out all prescribed setting and servicing work in due time (see data sheets).
Protect the compressed air and the electrics against an accidental commissioning.
During all maintenance, servicing or repair works, the machine must be disconnected from the power supply
and the compressed air supply, and it must be protected against an unintentional restart.
Please check that all screw connections which have been loosened during the maintenance, servicing or
repair works are firmly seated.
1.4.6 Organizational measures
All existing safety equipment has to be checked regularly.

General safety instructions
10 © Festo Didactic CP Factory ° Robot feeding for mill
1.5 Staff
1.5.1 Instructions regarding the staff
Regarding the staff, there are basically two starting situations to be considered.
activities during the training operation
activities not connected with the training operations.
1.5.2 Training operations
The trainees are only allowed to work on the machine if supervised by a skilled person or the instructor.
Any activities concerning fault finding and elimination are controlled by the instructing person.
Safety regulations have to be observed here in particular.
1.5.3 Beyond training operations
All activities concerning maintenance, servicing and repair may only be executed by a person with
sufficiently professional qualifications.
1.6 Commitment of the operator
The operators commit themselves to only allowing the work at the CP-Factory/ CP-Lab to a person who:
is familiar with the principle directions of work safety and accident prevention and has been instructed
in the handling of the CP-Factory / CP-Lab,
has read and understood the safety chapter and the warnings in this manual.
The safety-conscious working of the staff should be checked at regular intervals.
1.7 Commitment of the trainees
Before they start work, all persons in charge of works at the system commit themselves to:
read the safety chapter and the warnings in this manual,
observe the basic principles about work safety and accident prevention.

Introduction
© Festo Didactic CP Factory ° Robot feeding for mill 11
2Introduction
2.1 Warranty and liability
Basically, our “General Terms and Conditions“ apply, which have been made available for the user since the
conclusion of the contract at the latest.
Any warranty and liability claims for personal or material damage will be excluded, if they result from one or
more of the following causes:
any non-intended use of the system
any improper mounting, commissioning, operating and servicing of the system
any operating of the system with faulty safety devices or safety and protective devices which have not
been mounted properly or are not functioning
any disregarding of the information in the manual concerning transport, storage, mounting,
commissioning, operation, servicing and setting-up of the system
any unauthorized constructional alterations on the system
insufficient monitoring of installation parts which are subject to wear and tear
any improperly executed repairs
any major emergencies caused by external influence and force majeure.
Festo Didactic herewith rules out any legal responsibility for damages of the trainee, the training company
and/or a third party which might occur when using the system beyond a genuine training situation, unless
the damage has been caused by Festo Didactic intentionally or due to gross negligence.
2.2 Important information
Knowing the basic safety instructions and the safety rules is a basic prerequisite for the safe handling and
the trouble-free operation of the system.
This manual contains the most important information in order to operate the system in a way that meets the
safety demands.
The safety instructions in particular have to be observed by any person working with the system.
Furthermore all rules and instructions concerning accident prevention applying to the deployment location
have to be observed.

Introduction
12 © Festo Didactic CP Factory ° Robot feeding for mill
2.3 Resources
The training equipment of the system consists of several resources. They are used depending on the
process selection.
The following resources are available:
Pallet carrier
These pallet carriers are available for transporting the pallets.
Pallet
These pallets are available for receiving always one workpiece.

Introduction
© Festo Didactic CP Factory ° Robot feeding for mill 13
Box with retainer for 2 pallet carriers –Box Partnumber 20
Box with retainer for 15 raw turning pieces –Box Partnumber 26
Box with retainer for 10 PCB´s –Box Partnumber 27
Box with retainer for 10 front/backcovers or assembled workpieces –Box Partnumber 28

Introduction
14 © Festo Didactic CP Factory ° Robot feeding for mill
External production parts
Workpieces
Description
CP back cover
no 111
CP board
no 120
CP fuse
no 130
CP front cover
no 210 - if there is a CNC milling machine integrated in the system, the front cover can also be produced
there , thus becoming a production part.
Production parts
Workpieces
Description
Workpieces
Description
CP no fuse
no 211
CP part no fuse
no 1211
CP fuse on the left
No. 212
CP part fuse on the left
No. 1212
CP fuse on the right
no 213
CP part fuse on the right
no 1213
CP fuses both
no 214
CP part both fuses
no 1214
CP part customer
no 1210 freely selectable

Design and function
© Festo Didactic CP Factory ° Robot feeding for mill 15
3Design and function
3.1 Transport
On delivery of the stations, special attention must be payed on transporting them only by a suitable
industrial truck.
The weight of a station may amount up to 500 kg.
i
Warning
Before the transport, all supply roads must be cleared to be passable for the
industrial truck. If necessary, you have to install warning signs or barrier tapes.
When opening the transport boxes you have to be very careful because additional
components like computers may also be delivered with the box and have to be
protected against dropping out.
Caution
If the transport box is opened and the possibly additional components are taken
out, you can remove the station and bring it to its place of destination. Please
check the stability of all profile connectors with an Allen key size 4-6. It might
happen that the connectors are loosened during the transport due to inevitable
vibrations. Please pay special attention to any protruding components, sensors or
other small parts may easily be damaged during an improper transport. Do not
grab the station at or even under the pedestals –high risk of being crushed or
jammed!
3.2 Set up
3.2.1 General notes
You have to install the system in a frost-free room with a maximum relative humidity of 70 % and a
maximum ambient temperature of 25 ° Celsius. In countries with a higher humidity or higher temperatures,
you have to install air-conditioning systems for constant ambient conditions. You first have to check any
electrical disturbing sources like welding systems, big motors and contactors regarding their EMC and if
necessary to shield them in order to obtain the values permitted in the guidelines. A stable ground is
essential for a trouble-free operation in order to avoid subsidences. You have to see for an appropriate
distance between the system and the wall. Keep away any dust from the station resulting from construction
works (covering).

Design and function
16 © Festo Didactic CP Factory ° Robot feeding for mill
3.3 Robot feeding for mill
3.3.1 General
The robot feeding for mill consists of a basic module bypass and a loading cell with robot as well as the CNC
machine. The conveyor belts have a width of 80 mm and a length of 1200mm. Carriers with workpieces can
be removed and transferred here for a longer processing. Thus, applications with a longer processing time
can be mounted on the bypass. The workpiece flow is not affected by the bypass line.
The conveyors are for transporting boards on carriers. The carriers are equipped with a read/write ID-
system. This ID-system represents an important item of the CP Factory System. Current data of the
workpiece to be transported is written on the carriers. Thus all information essential for the process is
transported together with the carrier and is therefore available at every station.
On bypass module an aluminum plate is mounted on a base frame. On this plate is a 6-axis robot and the
associated periphery. The robot is responsible for handling all processes within the module. For machining
the workpieces, a CNC machine is mounted on the base frame. The task of the station is to equip the CNC
milling machine with workpieces and to process the workpieces according to the requirements in the CNC
machine.
Different types of robots can be mounted, should there be differences in handling or the interfaces, this is
indicated separately in the operating instructions.

Design and function
© Festo Didactic CP Factory ° Robot feeding for mill 17
Position
Description
1
CNC milling machine
2
Feeding robot for mill
3
Basic module bypass

Design and function
18 © Festo Didactic CP Factory ° Robot feeding for mill
CP Factory robot feeding for mill –front side

Design and function
© Festo Didactic CP Factory ° Robot feeding for mill 19
Position
Description
1
CNC machine
2
Robot
3
Conveyor
4
Working position / workpiece carrier output slide
5
Main switch operation panel
6
Touchpanel
7
E-Board for basic module bypass
8
Multi contact plug
9
Pressure switch (option for energy monitoring) and RFID
10
removable corner pulley /other module available
11
Emergency stop
12
Passage for power supply

Design and function
20 © Festo Didactic CP Factory ° Robot feeding for mill
CP Factory robot feeding for mill –back side
Position
Description
1
E-Board application
2
Drive Unit