SMC Networks FAS-200 User manual

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FAS-200
USERMANUAL

Equipment for training in flexible integrated
assembling systems
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Technical Description

TEN REASONS FOR CHOOSING THE FAS200 SYSTEM
1. The FAS200 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 may include pallet transfer integrate several modules allowing.
4. The process stations or layouts can work independently or integrated in the system in
cell mode.
5. The PLCs 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 most of the modules incorporates a key-protected Fault Generation
System which makes it possible to work on diagnostic and repair capabilities, using the
“Switches” methodology .
7. The FAS200 cell has been designed for assembly of a turning mechanism with a total
of 24 variants.
8. The pallets and transfer incorporate a binary coding system using inductive
detectors, which allow the Control System to identify the position of each pallet at any
time.

9. 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/Electro-
hydraulics, Electrical Actuators, Robotics/Manipulation, Industrial Communications, Control
Systems, Electric Automatisms, Safety Devices, Basic Mechanical Systems, Artificial
Vision Systems and so on.
10. It has been conceived and designed by a knowledgeable team with wide experience in
both the industrial and educational sectors.

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -4-
INDEX
INDEX.........................................................................................................................................................4
1. CONFIGURATION..........................................................................................................................5
2. GENERAL OVERVIEW:................................................................................................................9
FAS-230 LINEAR TRANSFER MODULE: TRANSPORT SYSTEM........................................................13
TROUB-200 FAULT SIMULATION SYSTEM...................................................................................17
FAS-201 BASE FEEDING/VERIFICATION MODULE............................................................................18
FAS-202 BASE REJECTING/TRANSFERING MODULE...............................................................................23
FAS-203 BEARING FEEDING/TRANSFERING MODULE ....................................................................27
FAS-204 BEARING MEASURING/TRANSFERING MODULE ...........................................................31
FAS-205 HYDRAULIC PRESSING MODULE ......................................................................................36
FAS-206 HYDRAULIC PRESS TRANSFERING MODULE .................................................................41
FAS-207 SHAFT CLASSIFICATION MODULE ................................................................................45
FAS-208 SHAFT REJECTING/TRANSFERING MODULE............................................................................51
FAS-209 COVER CLASSIFICATION MODULE...................................................................................56
FAS-210 COVER REJECTING/TRANSFERING MODULE..................................................................63
FAS-211 SCREWS DISPENSING MODULE..........................................................................................67
FAS-212 SCREWS INSERTION MODULE............................................................................................71
FAS-213 ROBOTIZED SCREWING MODULE ..............................................................................................75
FAS-214 TRANSFERING AND VISION INSPECTION MODULE ....................................................................79
FAS-215 AFTER VISUAL INSPECTION REJECTING MODULE.......................................................84
FAS-216 WAREHOUSE MODULE.............................................................................................................87
FAS-220 PALLET TRANSFER MODULE..............................................................................................91
APPENDIX A: FAULT GENERATION
APPENDIX B: ELECTRICAL DIAGRAMS
APPENDIX C: PNEUMATIC DIAGRAMS
APPENDIX D: GRAFCETs / SFCs
APPENDIX E: MECHANICAL DIAGRAMS

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -5-
1. CONFIGURATION
The FAS-200 system is the ideal answer to integral training in industrial
automation. It is fully modular and flexible equipment and in keeping with
industrial reality. The technologies included in its different assembly modules,
as well as the assembly process with several variants, allow the user to develop
the professional skills required by today’s automated industry.
FAS200 MODULES:
FAS200 is comprised of different stations, each performing a part of assembly
process.
Figure 1: System FAS200 with complete configuration.

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -6-
STATION Qty.
FAS-201 Base Feeding/Verification module 1
FAS-202 Base Rejecting/Transfering module 1
FAS-203 Bearing Feeding/Transfering module 1
FAS-204 Bearing Measuring/Transfering module 1
FAS-205 Hydraulic Pressing module 1
FAS-206 Hydraulic Press Transfering module 1
FAS-207 Shaft classification module 1
FAS-208 Shaft Rejecting/Transfering module 1
FAS-209 Cover classification module 1
FAS-210 Cover Rejecting/Transfering module 1
FAS-211 Screws dispensing module 1
FAS-212 Screws insertion module 1
FAS-213 Robotized screwing module 1
FAS-214 Transfering and vision inspection module 1
FAS-215 After visual inspection rejecting module 1
FAS-216 Warehouse module 1
FAS-220 Pallet transfer module 2
FAS-230 Linear transfer for 4 modules 4
FAS-200 Empty module for future projects x

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -7-
FAS200 CONFIGURATION:
The modules that make up the configuration of this system FAS200 are:
Figure 2: Example of system FAS200 with configuration of 8modules.
STATION Qty.
FAS-201 Base Feeding/Verification module 1
FAS-202 Base Rejecting/Transfering module 1
FAS-203 Bearing Feeding/Transfering module 1
FAS-204 Bearing Measuring/Transfering module 1
FAS-209 Cover classification module 1
FAS-210 Cover Rejecting/Transfering module 1
FAS-213 Robotized screwing module 1
FAS-216 Warehouse module 1
FAS-230 Linear transfer for 4 modules 2

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -8-
System FAS200
Number of modules: 8modules
Number of modular conveyors: 2 units of linear transfer (for 4modules)
Control: SIEMENS PLC of CPU 1214C serie.
Field and control network: ETHERNET.
Figure 3: Communication of the system FAS200 with configuration of 8modules.

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -9-
2. GENERAL OVERVIEW:
The flexible assembly system 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.
Figure 4: System FAS200 with different configurations.
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.
-Optical fiber sensors.
-Photoelectric detectors.
-Capacitive detectors.
-Pressure and vacuum switches.
-Linear encoders….

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -10 -
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 5: Turning mechanism Figure 6: Turning mechanism
components
Parts are transported between the different modules by an automated linear
transfer with corresponding stoppers and precision lifters-positioners. Parts are
mounted on pallets.
Figure 7: Linear transfer for 4 modules. Figure 8: Linear transfer for 8 modules.

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -11 -
The process modules function either independently of the transport system, in
in single or couple modes, or integrated into it, in cell mode. The modules are
located in a side of the linear transfer, and may be withdrawn for re-positioning
in a different order (the repositioning of different modules of the system can
mean repositioning of stoppers, lifters-positioners and reprogramming of the
controllers of the system), moved for future extensions or work in
completely independent, in a single mode, or with its complementary module in
a couple mode (requiring reprogramming of the control).
Figure 9: FAS201 module a single mode. Figure 10: FAS201 and FAS202
modules in couple module (without any
linear transfer).
Each station has its own electrical panel, where the wiring
system and PLC are fully visible for study, while new elements
may be fitted to the panel if desired. In addition, students may
design and build their own controls with different PLCs 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.
Figure 11: Electrical
panel of a module.

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -12 -
The front of each station incorporates the start, stop, step-by-
step/continuous cycle and reset pushbuttons. In addition, the control
pushbuttons incorporate a main switch on/off and emergency pushbuttons for
emergency stops.
Figure 12: Control pushbuttons of a module.
The system is modular and may be extended, allowing future incorporation of
other process modules according to user needs.
The modules are mounted on aluminum 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:
Process A: Feed body or base to which the other parts are assembled and
verification of its orientation.
Process B: Pick and Place bearing and measurement of its height.
Process C: Press bearing in hydraulically.
Process D: Pick and Place shaft and verification of its orientation and material.
Process E: Pick and Place cover and verification of its orientation, material and
color.
Process F: Fit screws.
Process G: Robot screw driving.
Process H: Quality control by artificial vision.
Process I: Unloading, storage and palletization of final assembly
In addition to transport processes between modules or between linear
conveyors.

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -13 -
FAS-230 LINEAR TRANSFER MODULE: TRANSPORT SYSTEM
Figure 13: FAS230 Linear Transfer Module.
The transport system is composed by 2meterslong
lines admitting up to four modules each (2`9 meters long
lines admitting up to six modules each for special case)
which links the modules to facilitate the envisaged
assembly process.
Figure 14: Transport system.

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -14 -
Different layouts can be defined for future expansions.The transfer follows a
rectangular path or linear path. The master PLC controls and coordinates the
rest of the PLCs connected to the network and it is located in the “body feeding
and checking” station (FAS201 module).
There is a longitudinal channel in one side of each module and of the linear
transfer to provide the electrical power connections and the air supply
connectionsbetween
the different stations
(and in some
configurations the
communication
connections).
Figure 15: Longitudinal channel for connections.
The modular transfer incorporates a pallet
assembly to transport parts and assemblies
across the handling stations. The pallets and the
transfer stoppers incorporate abinary coding
system using inductive detectors, which allow the
Control System to identify the position of each
pallet at any time.
Figure 16: Binary code on
the pallets.
In front of some modules (which need to interact with the linear transfer
system), there is a mechanical end to stop the pallets, and, depending on the
particular process, a further series of elements for lifting, centering, turning, etc.
All these transport system actuators, stoppers, lifters, positioners and

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -15 -
pallet transfers are operated by a system of solenoid valves connected to each
module.
Figure 17: Stopper and lifter with microswitch and inductive detectors.
Both the pallet retention point and the relative position of the module within the
system FAS200 may be varied, making it simple to modify the distribution of the
component bases of the FAS-200.Although not recommended such
modifications as the system FAS200 is sent mechanically adjusted and
programmed to the specific distribution and any variation of the distribution
would also reprogram the control of the system.
TECHNICAL DATA: Modular transfer:
Dimensions (each transfer (for 4 modules)):
1 section 2000 x 130 mm. Height 970 mm.
Dimensions (each transfer (for 6 modules)):
1 section 2900 x 130 mm. Height 970 mm.
Drive (each transfer (for 4/6 modules)):
1 Motor 24 VDC HIWIN (AM1 M12029A1).
1 Power supply 24 VDC /60 W OMRON (S8VK-G06024).
Composition:
Actuators (each 2 modules):
-1Compact double-acting cylinder Ø32, Stroke: 25mm (CQ2B32-25D-
XSE040). Controlled by 5/2 way monostable solenoid valve.

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -16 -
Actuators (some modules):
-1 Compact double-acting cylinders with guide Ø16, Stroke: 30mm (MGPM16-
30Z), with flow regulators. Controlled by 5/2 way monostable solenoid valve.
-1 Two-directionsrotary table ?max: 90º (MSUB3-90S), with flow regulators.
Controlled by 5/2 way monostable solenoid valve.
Sensors (each 2 modules):
-3Inductive detectors OMRON (E2A-M12KS04-M1-B1).
-1Microswitch OMRON (V-166-1C5).

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -17 -
TROUB-200 FAULT SIMULATION SYSTEM
Most of the modules incorporate a Fault Simulation System TROUB-200 fitted
to the side of each module or in the electrical panel, depending of the
configuration.
Figure 18: TROUB-200 in the Figure 19: TROUB-200 in a side of
electrical panel. module.
The system consists of a lockable box containing 16 switches which, when
operated, cause a fault in the module.
In the Appendix A, there are more details about this Fault Simulation System,
with a series of tables, per module, where the error symptom, suspicious
components and the final faulty component can be found.

FLEXIBLE ASSEMBLY SYSTEM FAS200
User Manual for FAS200 -18 -
FAS-201 BASE FEEDING/VERIFICATION MODULE
Figure 20: FAS201 Base Feeding/Verification Module.
FUNCTION OF THE MODULE:
This first module feeds the body or
base which is the support for the
turning mechanism, verifies its
orientation and moves it to the final
position (loading position) located in
the transfer system of the next
module.
Figure 21: Manipulators of the first module.
This operation begins when the pallet is positioned opposite the second
module, held in a determined location by a stopper on the linear transfer.
Confirmation that the pallet is in the correct position is provided by a