Bosch Rexroth AG | R900000000 Project 02: mMS4.0, St.

2 - Observation, analysis and documentation 1

Project 02: mMS4.0, St. 2 - Observation, analysis

and documentation
Project definition
Station 2 – Processing with pneumatic press is to be observed and analyzed in the
Automatic and Single Step operating modes regarding its functionality using the
master program. The sensor and actuator components, functional assemblies and
the PLC control sequences are to be recognized and identified and checked in the
documentation. Understanding the interdisciplinary interface forms the basis for
mechatronic knowledge.

mMS4.0, processing station with pneumatic press

Project task
▶ Observe the process
▶ Use the documentation to get information
▶ Set up the process sequence
▶ Understand the function of individual assemblies
2 Project 02: mMS4.0, St. 2 - Observation, analysis and documentation Bosch Rexroth AG | R900000000

Project steps
Informing: How does the mMS 4.0 training system work?
How is the sequence of the system?

Planning: What kind of knowledge is required?

Which aids are available?

Deciding: Selection of the documents.

Executing: Reading, finding and understanding the information.

Checking: Has all the information been found?

Has the functionality of the mMS 4.0 training system been
understood?

Evaluating: Evaluating the work results

Notes
Bosch Rexroth AG | R900000000 Project 02: mMS4.0, St. 2 - Observation, analysis and documentation 3

Safety instructions for the project exercise

To ensure operating efficiency and that the possible dangers of machines and
systems are recognized, the safety regulations have to be observed before and during
order execution.

The training system may only be operated in a technically flawless condition.

The intended use, performance data and application conditions must not be changed.

Safeguards/components must not be rendered inoperative, e. g. by bridging limit

switches, the EMERGENCE STOP function and other control components or by
removing covers.

In case of emergency, in error cases or in case of other irregularities:

▶ Systems are to be switched off (EMERGENCY STOP) and the main switch is
to be secured against restarting, CAUTION
▶ the danger zone is to be cordoned off so that no one can enter the danger
zone accidentally and in an uncontrolled manner,
▶ specialists are to be informed immediately.

Uncontrolled access of external persons to the direct operating range of the system
(also in case of standstill of the system) is prohibited.
4 Project 02: mMS4.0, St. 2 - Observation, analysis and documentation Bosch Rexroth AG | R900000000

Informing
The system for cube assembly consists of three stations:
 Magazine station, workpiece detection
 Processing station with pneumatic press
 High rack storage station

The three stations, magazine, processing with pneumatic press and storage, are set
up next to each other. After that they are interconnected mechanically, pneumatically
and electrically. The cube assembly system allows for the set-up, operation and
observation of a complete automation process.

mMS 4.0 Overall system

In the operating instructions, the safety and the functions of the processing station with
pneumatic press are described.

In the "2015.08440_ST2” electrical circuit diagram, the electrical operating equipment

is shown.

Pneumatic operating diagrams of station 2 Processing.

The data sheets of the operating equipment are to be identified on the “Technical
documentation” CD ROM.

Control and display functions of the control desk.

Bosch Rexroth AG | R900000000 Project 02: mMS4.0, St. 2 - Observation, analysis and documentation 5

Planning
Prerequisites:

▶ Knowledge of components of the electrical engineering and control technology.

▶ Reading the operating instructions.
▶ Commissioning of the mMS 4.0 using the master program (teacher).

Solution:

▶ Exercise: Observe the functional sequences in the automatic operating mode.

▶ Aim: Understanding the functionality of the training system.
▶ Solution steps: Analysis of the start-up conditions.
Analysis of the basic position.
Analysis of the interfaces between assembly modules.
▶ Realization: Creation of a sequence table of station 2.
Explaining the sequence table.

Deciding
Aids: Documentation CD, catalogs

Sequence and dependencies of the steps: see Planning

Team work: 2-3 apprentices together, if possible

Solution: observe, analyze, understand, document

6 Project 02: mMS4.0, St. 2 - Observation, analysis and documentation Bosch Rexroth AG | R900000000

Executing
The following work steps are to be performed:
- Reading the MMS 4.0 operating instructions.
Chapter: Description of the operating functions
- Commissioning of the mMS using the master programs (teacher).
According to the operating instructions, chapter: Set-up, installation and
commissioning
- Switch on the main switch of each station
- Manually fit the magazines of station 1 and the pin magazines of station 2
- Authorization key switch of the machine control desk in position 2
- Push the reset pushbutton
- The control and display functions at the mMS control desk are:
Auto push button is illuminated
Start push button is flashing
- Observe the functional sequences in the automatic operating mode of station 2 (see
the following sequence, since the sequences of station 1 and station 3 are partly
simultaneous)

Station 1 starts with:

 Magazine 1 pushes aluminum cube half on conveyor belt
 Conveyor belt transports cube half past the 1st sensor and stops at the
testing cylinder
 Testing cylinder extends and retracts
 Conveyor belt transports cube half past 2 sensors to the end of the conveyor belt
 Testing unit checks material, position and color of the cube half using sensors
 Light barrier stops the conveyor belt

Station 2 starts with:

 Conveyor belt transports cube half past the first light barrier; the removing cylinder
of the pinning unit extends and stops the cube half
 The slide-in cylinder pushes the cube half in the pinning unit.
The pins are pressed in
 The removing cylinder pushes the cube half back to the conveyor belt
 The conveyor belt transports the cube half past the second light barrier and stops
 The portal lifts the cube half in the press
 The conveyor belt transports the second cube half to the second light barrier
 The portal lifts the cube half in the press and onto the first cube half
 The press presses the two halves together
 The portal lifts the cube from the press to the conveyor belt
 The conveyor belt transports the cube to the end of the belt
Bosch Rexroth AG | R900000000 Project 02: mMS4.0, St. 2 - Observation, analysis and documentation 7

Station 3 starts with:

 The conveyor belt transports the cube past the light barrier to the stop
 The high rack storage accepts the cube and stores it at a free position

Analysis of the start-up conditions:

- Pneumatic pressure switch is active
- System is free from workpieces; magazines are filled
- Emergency off pushbutton is mechanical unlocked
- Control voltage On with emergency stop relay enable
- Referencing of the handling devices

Analysis of the basic positions of station 2:

- Pinning unit
Removing cylinder retracted (limit switch)
Slide-in cylinder retracted (limit switch)
Pressing cylinder up (limit switch)
- Portal
Vertical cylinder up (limit switch)
Horizontal cylinder at front (limit switch)
Suction gripper off
- Press
Slide-in cylinder extended (limit switch)
Pressing cylinder up (limit switch)
- Conveyor belt
Conveyor belt does not run
No light barrier operated

Analysis of the mechanical, electrical interfaces between assembly modules:

- Magazine 1 and 2 with conveyor belt station 1 (limit switch)
- Conveyor belt station 1 with conveyor belt station 2 (light barrier)
- Conveyor belt station 2 with pinning unit (light barrier)
- Conveyor belt station 2 with portal (light barrier)
- Portal with press (limit switch)
- Conveyor belt station 2 with conveyor belt station 3 (light barrier)
- Conveyor belt station 3 with high rack storage (light barrier)

Creation of a sequence table of station 2:

- Compile a table with the sequence of the individual steps of station 2.

Step Component Action

First cube half
1 Conveyor belt On in process direction
2 Light barrier 1 operated

3 Pinning unit extend

Removing cylinder
4 Pinning unit
Removing cylinder retract
Slide-in cylinder extend
5 Pinning unit Position - feed pins
Pin feed cylinder
8 Project 02: mMS4.0, St. 2 - Observation, analysis and documentation Bosch Rexroth AG | R900000000

6 Pinning unit extend

Pressing cylinder
7 Pinning unit retract
Pressing cylinder
8 Pinning unit Position - refill pins
Pin feed cylinder
9 Pinning unit
Slide-in cylinder retract
Removing cylinder extend
10 Pinning unit retract
Removing cylinder
11 Conveyor belt On in process direction

12 Light barrier 2 operated

13 Portal extend
Vertical cylinder
14 Portal switch on
Suction gripper
15 Portal retract
Vertical cylinder
16 Portal move slide back
Horizontal cylinder
17 Portal extend
Vertical cylinder
18 Portal switch off
Suction gripper
19 Portal retract
Vertical cylinder
20 Portal move slide forward
Horizontal cylinder
Second cube half
21 Conveyor belt On in process direction
22 Light barrier 1 operated
23 Light barrier 2 operated
24 Portal extend
Vertical cylinder
25 Portal switch on
Suction gripper
26 Portal retract
Vertical cylinder
27 Portal move slide back
Horizontal cylinder
28 Portal extend
Vertical cylinder
29 Portal switch off
Suction gripper
30 Portal retract
Vertical cylinder
31 Press retract
Slide-in cylinder
32 Press extend
Pressing cylinder
33 Press retract
Pressing cylinder
34 Press extend
Slide-in cylinder
35 Portal extend
Vertical cylinder
36 Portal switch on
Suction gripper
37 Portal retract
Vertical cylinder
38 Portal move slide forward
Horizontal cylinder
39 Portal extend
Vertical cylinder
40 Portal switch off
Suction gripper
41 Portal retract
Vertical cylinder
42 Conveyor belt On in process direction
Bosch Rexroth AG | R900000000 Project 02: mMS4.0, St. 2 - Observation, analysis and documentation 9

Checking
Interim results:
▶ Was the information easy to find?

Result/customer requirement:
▶ Has all the information been understood?
▶ Sequence is explained and corresponds to the Automatic sequence

Evaluating
Own assessment by the apprentice:
 Is the sequence of station 1 described as in Automatic mode?

 Is the sequence of station 2 described as in Automatic mode?

 Is the sequence of station 3 described as in Automatic mode?
10 Project 02: mMS4.0, St. 2 - Observation, analysis and documentation Bosch Rexroth AG | R900000000

Notes