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Riyadh, K.S.A.

Switch Assembly Machine

OPERATING and SERVICE
MANUAL

Published by:

ARCOMA TECHNICAL DIVISION - Riyadh
P.O. Box 54711  Riyadh 11524  Saudi Arabia  Tel. +966-1-4775331  Fax + 966-1-4730201
http://www.arcoma.com  http://www.festo.com

1.2. Sequence of Operation 2 Operation 2. I/O Configurations 4.3.4. Reject Summary 3 Appendix 3. Start-up Procedure 2.1. Auto-Feed Screwdrivers 3. Resetting the Production Data 2.3.2. Running the Machine 2. Overview 1. Disable/Enable Stations 2.3.2.Table of Contents 1 Introduction 1. Project Tree 4. Allocation List .3. Controller Settings 4. Indexing Table 3. System Description 1. Technical Specifications 1.4.1.2. Moving Contact Feeder 4 PLC Section 4.4.5.1.

which can be produced by the machine: one-way switch (two terminals) and two-way switch (3 terminals).2. total products produced and total running time. The assembly parts for the one-way switch are shown on the above picture. -1- . System Description The Automatic Switch Assembly Machine is controlled by a Festo PLC (programmable logic controller). Overview The automated switch assembly machine produces a complete switch assembly from various parts as shown on the picture below. The final product is the right.1. The operator interface also serves as a production data display that shows the speed of production. The operation of the complete system is done via an operator interface mounted on a small panel with Emergency Stop pushbutton. There are two types of switch. There are nine (9) parts needed for the assembly of the complete switch.Operating Manual – 10A Switch Assembly 1 Introduction 1. It also shows the number of reject products as well as good products. 1.

The software runs on the PC as the main operator control interface by communicating with the PLC via RS323 link.3. All necessary process data can be viewed on the screen showing real time values. -2- .Operating Manual – 10A Switch Assembly 1. The dynamic graphic representation of the process helps the operator in monitoring the actual process even if he inside the control room. The operator can also control the process from the PC via the software. Another feature of the software is the ability to store data in the harddisk (database) for further processing and future reference. The ViP-Win Software The Festo Visualization of Industrial Process for Windows (ViP-Win) is a software designed for Human-Machine-Interface (HMI) and Supervisory Control (SCADA). The PLC is still the main controller of the system.

2. If product is present. Station 8 Pressing of 3rd terminal (two-way switch only) -3- . the cylinder extends for about 1 second to press the dummy terminal and then retracts to its initial position. When there is a start signal. starts with the rotation of the index table only when all the stations are in their initial positions. If there is no product present at the pickup point. the vertical axis in the up position and the gripper open. 2. Every cycle. the cylinder extends for about 1 second to press the first and second terminals and then retracts to its initial position. Station 7 Pressing of 1st and 2nd terminals This station consists only of one drive component: ADVU-50-50. gripper opens. vertical axis goes up again and then the horizontal axis returns to its initial position.Operating Manual – 10A Switch Assembly 2 Sequence of Operation Each station has its own sequence of operation independent from other stations. closes the gripper and then moves up. The horizontal axis is extended. Then the vertical axis moves down. There are two modes of operation.2. When there is a signal to start the sequence. the rotary axis rotates while the horizontal axis moves toward the fixture. the station first checks if the product to be picked up is present and also checks the orientation of the product. The sequence of each station starts as soon as the index table stops rotating. This is to ensure that none of the vertical cylinders are extended and no damage may occur to the stations. It will then wait for another start signal.1.3. If the product is not in the correct position.4. 2. the single cycle and the auto-cycle or continuous cycle. the station will not start until another start signal arrives. It will then wait for another start signal. 2. the horizontal axis moves toward the table/fixture. whether it’s single or auto. Station 1 Loading of switch body This station is a pick and place system consisting of the following drive components: SLE-25-100-PPV-A Horizontal Axis DSL-25-50-270-CC Vertical Axis and 180° Rotation HGP-16-A Gripper The initial position of this station is at the pick up point (conveyor). When there is a start signal. The station then waits for another signal to start. the vertical axis moves downward. If the product is in the correct position. Station 3 Pressing of dummy terminal (one-way switch only) This station consists only of one drive component: ADVU-32-50.

Operating Manual – 10A Switch Assembly This station consists only of one drive component: ADVU-50-50. Then the vertical axis moves down. 2. Then the sequence of the auto-feed screwdriver starts. Once a start signal is given. vertical axis goes up again and then the horizontal axis returns to its initial position. the cylinder extends for about 1 second to press the third terminal if the product is a two-way switch and then retracts to its initial position. Station 12 Depth gauge for one way switch This station consists of a vertical axis only (DZF-12-50). The station will wait for another start signal.8. Then the sequence of the auto-feed screwdriver starts. The depth gauge is attached to the cylinder to check the depth of the terminal. When there is a start signal. Station 10 Screwdriver for two way switch This station consists of a clamping cylinder ADVU-25-50 and an autofeed screwdriver. It will then wait for another start signal. the vertical axis in the up position and the gripper open. 2. The auto-feed screwdriver has its own control and sequence of operation.6. As soon as the screwdriver is finished. gripper opens. Please refer to the operating manual of the screwdriver for more details. Once a start signal is given. As soon as the screwdriver is finished. Once a start signal is given. the cylinder extends until the mechanical -4- . the clamp cylinder extends to secure the product in place. 2. the horizontal axis is extended. the clamp cylinder moves up. Station 9 Screwdriver for one way switch This station consists of a clamping cylinder ADVU-25-50 and an autofeed screwdriver. 2. the clamp cylinder extends to secure the product in place. the clamp cylinder moves up. the vertical axis moves downward. The rotary cylinder rotates to invert the product while the horizontal axis moves toward the right. When there is a signal to start the sequence. The station then waits for another signal to start. The auto-feed screwdriver in this station is similar to station 9 except that it is only designed to screw at one point. The station will wait for another start signal. The screwdriver in this station is designed to screw at two points using another cylinder for its horizontal axis.7.5. Station 11 Transfer and rotate This station is a pick and place system consisting of the following drive components: SLT-16-125-PPV-A Horizontal Axis SLT-10-50-270-CC Vertical Axis HGPP-12-A Gripper Sommers Rotary 180° Vertical Rotation In the initial position. closes the gripper and then moves up.

vertical axis moves down. then releases the product and then moves up again. When the start signal is given. the vertical axis moves downward at the same time switch on the vacuum generator. If there is no moving contact. the station sets the reject flag. 2. Station 14 Loading of moving contact This station is also a pick and place system consisting of the following drive components: SLT-16-125-PPV-A Horizontal Axis DZF-12-50P-A Vertical Axis VADMI-140-P Gripper (suction cup) In the initial position. the station checks if there is a moving contact present at the pick-up point. then the vertical axis retracts. The station then waits for another signal to start. Station 15 Checking of moving contact This station consists only of a vertical axis (ADVU).11. above tolerance or below tolerance. the cylinder extends until it reached the end position. Station 13 Depth gauge for two way switch This station works exactly the same way as the previous station. When the vertical axis reaches the bottom position it checks if the vacuum switch is actuated to indicate that the product is already picked-up by the suction cup. The station sets the reject flag when the gauge gives a below or above tolerance. The horizontal axis returns to its initial position.13. There is about 2 seconds delay to allow the measuring gauge to stabilize its reading. 2. The horizontal axis moves towards the table/fixture. If present. 2. An inductive sensor is attached to the cylinder to detect the presence of the moving contact.12. and then the cylinder retracts to its initial position. There is a time delay for about 1 second to stabilize the sensing. 2.Operating Manual – 10A Switch Assembly fix stop is reached. The cylinder then retracts to its initial position and wait for another start signal. Station 20 Pressing of rocker -5- . When there is a signal to start the sequence. the horizontal axis is extended and the vertical axis in the up position.10. The depth gauge will then give a signal either good.9. Station 19 Loading of rocker assembly This station is a pick and place system consisting of the following drive components: SLT-16-125-PPV-A Horizontal Axis SLT-10-50-270-CC Vertical Axis VADMI-140-P Gripper (suction cup) DSNU-10-10-P Pusher 2.

16.14. b) Login Procedure 1. -6- . gripper opens. 2. Switch ON the main air supply and check if the pressure is at least 6 Bar. This station is used when the product being assembled is a two-way switch. Switch ON the main electrical power.15. The station then waits for another signal to start. 1 Operation a) Start Up Procedure Before starting the machine. the horizontal axis is extended. 2. 1. 2. closes the gripper and then moves up. The rotary cylinder rotates the product vertically by 90 while the horizontal axis moves toward the right. Run the machine. Station 21 Electrical testing for one way switch Each station has its own sequence of operation independent from other stations. The login dialog window pops up at the bottom of the screen. Then the vertical axis moves down. When there is a signal to start the sequence. be sure to check visually if there are any foreign objects inside the machine that may obstruct the movement. 2. The cylinder is fitted with a movable finger that presses the rocker into locked position. 2. the vertical axis in the up position and the gripper open. Station 23 Unloading of finished product This station is a pick and place system consisting of the following drive components: SLT-16-125-PPV-A Horizontal Axis SLT-10-50-270-CC Vertical Axis HGPP-12-A Gripper Sommers Rotary 90° Vertical Rotation In the initial position. Click Login button to login as a user. vertical axis goes up again and then the horizontal axis returns to its initial position. the vertical axis moves downward.Operating Manual – 10A Switch Assembly This station consists only of ADVUL cylinder. Station 22 Electrical testing for two way switch This station has a similar function and operation sequence as the previous station. 3.

The default user is always SYSTEM which has 0 access level.Operating Manual – 10A Switch Assembly 3. Figure 1 Login Dialog After successful login. Click Ok. 4. Only those who has a valid user name and password will be able to operate the system. 6. Type your password in the Password textbox. If there is no mouse or keyboard activity within 30 minutes. 5. the command buttons will be enabled and the username and user access level will be displayed at the bottom of the screen. the system will automatically logout the user. Type your user name in the User textbox. -7- .

Operating Manual – 10A Switch Assembly 4. Program overview The IPC Data Server program communicates with up to 48 IPCs using TCP/IP. FPC200 series. APPENDIX APPENDIX A IPC Data Server This program sends and receives data from FST-IPCs with the TCP/IP driver installed. the client program is the ViP-Win software. FPC includes FPC100 series. -8- . The IPCs must have the FST TCP/IP driver installed and working. SF202 and SF3 installation terminals. Additionally it can communicate with Festo FPCs. In this case. FPC400 series controllers and the Festo SB202. It is recommended to run the IPC Data Server first before starting the ViPWin software. Festo IPCs and Festo SF3 installation terminals using the RS-232 command interpreter. The data from the IPCs is then made available to other programs which can utilise DDE. The IPC Data Server must always be started before any client program can access data. Note: IPC includes FEC controllers. It also acts as a DDE server to provide an interface to DDE client programs. Alternatively or additionally the IPC Data Server can communicate via RS-232 with up to 4 Festo FPCs and the SB202/SF202/SF3.

Terminal Press 1st & 2nd Terminals * CMP 8 (V1) .Operating Manual – 10A Switch Assembly 5.Main Program * Program 1 (V2) – Auto Mode * Program 2 (V1) – Display and Keypad Control CMPs (Program Modules) * CMP 1 (V1) .Station 10 Sequence. Moving Contact Loading * CMP 15 (V1) .Station 7 Sequence. Depth Gage 1 way * CMP 13 (V1) . Housing Loading * CMP 3 (V1) .Station 1 Sequence.Station 3 Sequence. Rocker Loading * CMP 20 (V1) .Station 20 Sequence. Dummy Terminal Press * CMP 7 (V1) .Start Station Sequences -9- . Depth Gage 2 way * CMP 14 (V1) . Transfer and Rotate * CMP 12 (V1) . PLC Section Controller Settings Run Mode Autostart: Run/Stop Input: Stop during Download: Error Output: Error Program: Reset Programs: Reset Outputs: Drives Project Drive: Start-up Drive: Kernel Drive: Password Password: Download Download Sources: NO NO NO NO <none> YES YES B B A <none> NO Project Tree Programs * Program 0 (V2) .Station 23 Sequence. Moving Contact Check * CMP 19 (V1) . Unloading * CMP 25 (V1) .Station 12 Sequence.Station 13 Sequence. Screwdriver 1 st & 2nd Terminals * CMP 10 (V1) .Station 21 Sequence.Station 8 Sequence. Rocker Press * CMP 21 (V1) . Testing 1 way * CMP 22 (V1) .Station 11 Sequence.Station 14 Sequence. Screwdriver 3rd Terminal * CMP 11 (V1) .Station 9 Sequence.Station 15 Sequence.Station 19 Sequence.Station 22 Sequence. Testing 2 way * CMP 23 (V1) . Terminal Press 3rd Terminal * CMP 9 (V1) .

6 O2.12. station 11 transfer vertical O2.4. station 11 transfer gripper O2. station 8 3rd terminal press O2.14 O2.1. station 3 dummy terminal press O2.12 O2. station 19 horizontal . spare solenoid valve O2.2 O2.6. station 19 vertical O2.Operating Manual – 10A Switch Assembly * CMP 26 (V1) – Rotate Flags * CMP 30 (V1) – OWS Output using EXT * CMP 31 (V1) – ABG-80 Keyboard using EXT IO Configuration IO Module Switch IW OW Module Description =============================================== HC0X 0 0 0 “CPU module IM10 PLC Safety 1 2 “16 input module IM10 PLC Safety 2 3 “16 input module IM10 PLC Safety 3 4 “16 input module IM10 PLC Safety 4 5 “16 input module IM10 PLC Safety 5 6 “16 input module IM10 PLC Safety 6 7 “16 input module IM10 PLC Safety 7 8 “16 input module IM10 PLC Safety 8 9 “16 input module OM40 PLC Safety 1 2 “16 output module OM40 PLC Safety 2 3 “16 output module OM40 PLC Safety 3 4 “16 output module OM40 PLC Safety 4 5 “16 output module Output Allocation List Operand Symbol Comment O2. spare solenoid valve O2.1 O2. station 11 transfer rotate O2.13 O2.0.11 O2. station 20 rocker press O2.15 O_ADVU3 O_ADVU7 O_ADVU8 O_SLT11_H O_SLT11_V O_HGPP11 O_Rot11 O_ADVU23 O_Pin14 O_ADVU20 O_DSNU19 O_SLT19_V O_SLT19_H O2.4 O2.0 O2. station 14 stopper @ feeder O2.2.10 - . station 23 output chute O2.5 O2.10 O2.10.13.3.8.11.8 O2.5. spare solenoid valve O2. station 7 1st & 2nd terminal press O2.3 O2.14. station 19 rocker load press O2.15.7. station 11 transfer horizontal O2.9 O2.9.7 O2.

12 I2. Screw Feeder 17 (B14-05) O3.14 I2.3 I2. Chain Conveyor B26 Running I2.3.7.0 O3.7 O3. Hopper1 Chain Conveyor (B06) O3.3 O3. Start VFD 1 (Slow) O3. Mixer Disch. Start VFD 2 (Fast) O3. Emergency Stop I2.2.10 I2. Pre-holding bin Full .5.15.1. Pre-Holding Bin Disch Gate I2. Hydrolized Oil Pump O3.15 OFeeder17 OFeeder18 OFeeder19 OFeeder20 OFeeder21 OHop1Dis OHop2Dis OScaleRdy OBatchON OConveyng OVFD1Hi OVFD1Lo OVFD2Hi OVFD2Lo OAcid OCoco O3.3.5 O3.1 O3.7.7 I2.15. Crude Coco Oil Pump Input Allocation List Operand Symbol I2.13.5 I2.9 I2. Start VFD 1 (Fast) O3. Add Mix for Adding I2.14 O3.4.13 O3.12.12 O3.0.6 I2. Start VFD 2 (Slow) O3. Mixing is on-going I2.2.2 O3. VFD 2 Fault Signal I2. Screw Feeder 18 (B14-06) O3. Gate I2.9.2 I2. Hydrolized Oil flow I2.0.12.8 O3. Premix has been added already I2.4 I2. Mixer is discharging (B24) I2. Crude Coco Oil flow I2.9 O3. Hopper2 Chain Conveyor (B16) O3. Mixer Running I2.14.1 I2.11. Screw Feeder 20 (B14-08) O3.4 O3. B06/B16 Conveying Indicator O3. Mixer is being filled (B21) I2.14.0 I2.11.4.10.1.6.10.10 O3.13. Batching On-Going Indicator O3.15 IEmStop IGateB21 IManual IMixerON IGateB24 IChainB26 IAddMix IVFD1Trip IVFD2Trip IFilling IPremix IMixing ImixDisch IAcid ICoco IBinFull Comment I2.6.8.11 O3.5. Screw Feeder 21 (B14-09) O3. Screw Feeder 19 (B14-07) O3.8 I2. Manual/Auto Mode Selector I2. VFD 1 Fault Signal I2.13 I2.11 I2.8.Operating Manual – 10A Switch Assembly Output Allocation List Operand Symbol Comment O3.6 O3. Ready Indicator Lamp O3.11 - .9.

Station 7 – Terminal Press (1 way) Item 1 2 3 Part No. 1 2 3 4 5 6 7 Description / Type Vertical Cylinder w/ Rotate DSL-25-50-90 Gripper Unit HGP-10-A Horizontal Cylinder with Guide SLE-20-125-PPV-A Fiber Optic Sensor SOEG-RT-LLK Fiber Optic Guide SOEZ-LLK Magnetic Switch SMT-8S-PS-K-LED Proximity Sensor SIEN-M5B-PS-K-LED Qty. 1 2 1 C. Station 1 – Loading Station Item Part No.Operating Manual – 10A Switch Assembly PARTS LIST A. Description / Type Short Stroke Cylinder (Vertical) ADVU-50-50-P-A Magnetic Switch SMT-8S-PS-K-LED Pressure Regulator LR-1/8-D-MINI . 1 2 1 . 1 2 4 Description / Type Short Stroke Cylinder (Vertical) ADVU-32-50-P-A Magnetic Switch SMT-8S-PS-K-LED Pressure Regulator LR-1/8-D-MINI Qty. Station 3 – Dummy Terminal Press Item Part No. 1 1 1 2 2 4 2 B.12 - Qty.

Station 10 – Screwdriver (2 way) Item 1 2 4 Part No. Station 8 – Terminal Press (2 way) Item Part No. 1 2 1 E.Operating Manual – 10A Switch Assembly D. Station 9 – Screwdriver (1 way) Item Part No. 1 2 1 F. Description / Type Short Stroke Cylinder (Clamping) ADVU-25-25-P-A Magnetic Switch SMT-8S-PS-K-LED Auto-Feed Screwdriver Unit . 1 2 3 Description / Type Short Stroke Cylinder (Vertical) ADVUL-50-50-P-A Magnetic Switch SMT-8S-PS-K-LED Pressure Regulator LR-1/8-D-MINI Qty. 1 2 1 . 1 2 3 Description / Type Short Stroke Cylinder (Clamping) ADVUL-25-25-P-A Magnetic Switch SMT-8S-PS-K-LED Auto-Feed Screwdriver Unit Qty.13 - Qty.