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CIM lab manual
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CIM lab manual
ACTIVITY NO 1
OBJECTIVE: Introduction
To demonstrate and learn the process of controlling individual stations and the system as a whole.
A CIM cell is an automated assembly line that uses a network of computers to control robots, production
machines and quality control devices. The CIM cell can be easily programmed to produce custom parts
and products. Educational CIM cells are used to simulate the production cycle and enable control and
analysis of various aspects of the cycle, from the planning through production.
All CIM systems generally share the following components, which are necessary for most production
processes:
Robotic Arms: CIM systems are fully automated, and robotic arms are critical components in these
automated systems. In CIM, robotic arms perform tasks that would otherwise require human intervention,
thus enabling the system to be fully automated. Examples of tasks performed by robotic arms include the
picking and placing of parts in/from machines, removing of parts from storage, assembling of parts and
handling of parts for quality control. In later activities, you will be introduced to some of the robot types
and robot tasks used in CIM.
Storage: A storage stationis used to store raw materials prior to production, as well as finished products
following the production process. Such stations are fully automatic and controlled by robotic arms.
A typical CIM storage station includes a machine known as an ASRS or Automated Storage and Retrieval
System. The ASRS is a robotic storage device used to store and retrieve parts in a CIM cell. The ASRS is
used as the main source of raw material for the cell, and
can also serve as a warehouse for parts in various
stages of production. Storage cells in the ASRS contain
templates, either empty or containing parts. A CIM cell
may contain any number of ASRSStations.
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Quality Control (QC): This group of equipment includes measuring devices, such
as optical systems, laser scan meters and CMMs (Coordinate Measuring Machines). The purpose of
these devices is to determine whether a product meets the quality control specifications defined prior to
the production process.
QC components include high precision measuring tools that the system uses to determine whether the
product should advance to shipment or be rejected. Following the rejection of a product, the system
must be capable of adjusting itself so that it does not automatically reject subsequent parts.
Closed Loop Conveyor: By nature, CIM components tend to be located in multiple production stations
that are physically distant from one another. This requires a system that moves
parts from one robotic station to another (for example from an ASRS to a CNC
machine). A closed loop conveyer with stop stations controlled by PLC is
typically used for this purpose. Stop and release units (i.e. stop stations) are
located on the conveyor in front of each production station. The stop stations
are controlled by the PLC and enable the robot to pick apart from the conveyor
and place the part on it.
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Technologies:
All stations are controlled by the CIM manager which configures all station simultaneously.CIM
manager maintains sequence of all the stations.CIM manager is used for on-line production and
manufacturing.
Station # 1 ASRS (Automatic Storage and Retrieval System): it picks and place the raw material
or finished goods.
Station #2 CNC lathe & robot Er4u is a 6 axis robot and it picks the parts from the conveyor and
places it in the CNC lathe and CNC mill.
Station # 3 QC robot Er4u: It is also a 6 axis robot and it picks the material places it on QC station
where it is measured by a digital vernier caliper pneumatically operated. It also picks and places the
pallet with raw material from buffer to AGV.
Station # 4 Quality control: At the QC station material is inspected by using a digital camera when
defects are identified by digital image processing.
Transportation and Verification: The material is transported to all the stations by a conveyor
system where it is placed on pallets. The material transportation and identification is controlled by a
PLC.
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ACTIVITY 2
OBJECTIVE: To demonstrate and learn how to boot up the system and SOP software.
1. Manager
Manager PC (First ON, Last OFF)
2. WS1(Station#1)
PC: Storage ASRS-36×2
Controller: USB Type
3. WS2(Station#2)
PC: CNC Milling PC
PC: CNC Lathe & Robot ER4u PC
Controller: USB Type
Controller: CNC Milling
Controller: CNC Lathe
4. WS3(Station#3)
PC: Robot ER4u PC
Controller: USB Type
5. WS4(Station#4)
PC: QC &Camera PC
6. WS5(Station#5)
PC: PLC PC
PLC Unit: PLC Cabinet
Air Compressor:
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CIM lab manual
Click CIM MODE icon and then select real mode or simulations mode then click “save”
Open Robot software on desktop icon click and then click green icon
Open Robot software on desktop icon click and then click green icon
Open CNC Lathe software on desktop icon by clicking and then click icon.
Click run icon & then click “Run Program” → ok → click “Move Turn Home”→ click“ok” →
click“ok”
Open CNC Mill software on desktop icon clicks and then click icon.
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Open Robot software on desktop icon by clicking and then click green icon
Open PLC software on desktop icon Click and then click green icon
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CIM lab manual
TASK 1
Q1:Refer to the actual SCORBOT-ER 4u robot. In the figure on the worksheet, mark the following
parts of the robot:
Robot joints: base, shoulder, elbow, wrist pitch, wrist roll
Gripper
Motors and encoders
Q2: What are the three key elements in the definition of a robot?
Q3: To work on station 1, which system and software you will operate?
Q6: How many types of robot are using in the CIM lab?
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ACTIVITY 3
Objective: SCORBASE Er-4u Software demonstration + pick & Place program training.
Equipment:
♦ Experiment Table
♦ Parts Bin
Technical description:
Number of axes – two axes are required to reach any point in a plane; three axes are required to reach
any point in space. To fully control the orientation of the end of the arm (i.e. the wrist) three more axes
(yaw, pitch, and roll) are required. Some designs (e.g. the SCARA robot) trade limitations in motion
possibilities for cost, speed, and accuracy.
Kinematics – the actual arrangement of rigid members and joints in the robot, which determines the
robot's possible motions. Classes of robot kinematics include articulated, Cartesian, parallel and SCARA.
Speed – how fast the robot can position the end of its arm. This may be defined in terms of the angular or
linear speed of each axis or as a compound speed i.e. the speed of the end of the arm when all axes are
moving.
Acceleration - how quickly an axis can accelerate. Since this is a limiting factor a robot may not be able
to reach its specified maximum speed for movements over a short distance or a complex path requiring
frequent changes of direction.
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Accuracy – how closely a robot can reach a commanded position. When the absolute position of the
robot is measured and compared to the commanded position the error is a measure of accuracy.
Accuracy can be improved with external sensing for example a vision system or Infra-Red. Accuracy can
vary with speed and position within the working envelope and with payload (see compliance).
Repeatability - how well the robot will return to a programmed position. This is not the same as accuracy.
It may be that when told to go to a certain X-Y-Z position that it gets only to within 1 mm of that position.
This would be its accuracy which may be improved by calibration. But if that position is taught into
controller memory and each time it is sent there it returns to within 0.1mm of the taught position then the
repeatability will be within 0.1mm.
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Procedure:
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Conclusion:
Precautions:
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TASK 2
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Q 4: Describe the homing routine. Note the order in which the axes moved, fast or slow motion,
dialog boxes and messages on the screen?
Q 5: Describe the system response to the encounter between the robot arm and the table?
Q 6: What effect does the Close Gripper command have on the gripper?
Q 9: What did you observe? Was it easier to manipulate the robot at a slower or faster speed?
Q10:Modify the program so that the robot returns the object from the Place position to the Pick
position. Save the program as USER4B?
Q 11: In this activity you wrote a program for pick and place task which instructs the robot PICK
the material from RACK 1-1 and PLACE it on RACK 3-1?
Q 12: Describe the differences you observed when using Go Position and Go Linear commands?
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ACTIVITY 4
OBJECTIVE: To demonstrate and learn the process of CNC base spectral light 0200 software and
flexible manufacturing system.
EQUIPMENTS:
SCORBOT-ER 4u Robot
Controller-USB
Teach Pendant.
TECHNICAL DESCRIPTION:
The spectra LIGHT Mill is a CNC tabletop milling machine. Like other mills, it has a spindle, which holds
the cutter. A pneumatically y operated vise, mounted on a cross slide, holds the work piece. Motors move
the cross slide horizontally (X and Y) while other motors move the spindle vertically (Z) and rotate the
cutter.
The Controller is connected between the computer and the mill. The controller houses the electronics
that interpret part programs and send them to the mill in a form the mill can understand.
Computer loaded with the WSLM Control Program; used to create and run CNC programs.
Parts Feeder. This device supplies parts by means of gravity. The feeder includes a micro switch sensor
whose signal indicates to the robot controller that a part is available for pickup.
Procedure:
Conclusions:
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Task 3
Q In this Task you wrote a program for a pick and place Task which includes an output on/off
subroutine each time the robot puts down the block. Describe an industrial application in which
output signals should be sent after a command or operation is executed.
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ACTIVITY 5
Objective: To demonstrate and Learn the process of Automated Storage and Retrieval System (ASRS).
Equipment:
Technical Description:
ASRS 36/36x2 Storage Unit: A floor-mounted automated storage and retrieval system that contains 36
(or72) storage cells arranged in a 6x6 (or 6x6 + 6x6) array. Storage cells in the ASRS contain templates
(either empty or loaded with parts). The unit is used to store these templates containing raw materials
prior to production as well as finished products following the production process and serves as
warehouse for parts in various stages of production.
Templates: Templates are plastic trays which can hold various types of parts. They allow parts to be
transported on the conveyor. A template contains a matrix of holes in which pins are placed to fit the
dimensions of a part. Each arrangement of pins defines a unique template type. Each part may only be
held by its assigned template. The handle, located on top of or in front of the template, facilitates grasping
by a robot’s gripper.
ASRS Robotic Arm: The ASRS robotic arm is fully controlled by the controller and performs various pick
and place tasks to transfer parts between storage cells and conveyor pallets stopped at the ASRS station.
The ASRS robotic arm performs these tasks using a forklift gripper which is connected to the robotic arm.
The robotic arm moves the gripper within the ASRS robots work envelope.
Controller-USB: Controls the ASRS robot using the SCORBASE application that supports the
SCORBASE language (an advanced robotic programming language). The SCORBASE program
accesses the Controller-USB through the PC USB interface.
Teach pendant: A hand-held terminal used for controlling the robot and axes connected to the controller.
The Teach Pendant contains function keys, and its LCD display shows the current status of the controller,
the current user command, and system messages.
Procedure:
1. Open desktop icon Loader of ws1.
2. Click on green icon.
3. Click on home icon and home all axis of robot.
4. In operation mode select STAND ALONE procedure.
5. Open the window of Pick and Place command.
6. Select source Id and Target Id.
7. Press OK.
Conclusions:
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TASK 4
1. Make a program of ASRS on station 1. Pick the material from rack 37 read bar code and place it on
rack 1.
2. Define the following:
Templates
ASRS robotic arm
Teach pendant
3. Write the procedure of ASRS system.
4. Write advantages and disadvantages of ASRS system.
5. Describe the homing routine of ASRS robotic Arm. Note the order in which the axes moved, fast or
slow dialog boxes and message on the screen.
6. In this activity the program flow changed as a result of an input signal. Describe an industrial
application in which an input signal changes the action in the workcell.
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ACTIVITY 6
Objective: To demonstrate and Learn the Process of quality control by using vernier caliper and
digital camera.
Equipment:
Robotic Arm
AGV mobile robot
Vernier caliper
Digital camera
Technical description:
Automated Guided Vehicles can be used in a wide variety of applications to transport many
different types of material including pallets, rolls, racks, carts, and containers. AGVs excel in
applications with the following characteristics:
Repetitive movement of materials over a distance
Regular delivery of stable loads
Medium throughput/volume
When on-time delivery is critical and late deliveries are causing inefficiency
Operations with at least two shifts
Processes where tracking material is important
Vernier Caliper:
The Vernier caliper is an extremely precise measuring instrument; the reading error is 1/20
mm = 0.05 mm.
Close the jaws lightly on the object to be measured.
If you are measuring something with a round cross section, make sure that the axis of the
object is perpendicular to the caliper. This is necessary to ensure that you are measuring the
full diameter and not merely a chord.
Ignore the top scale, which is calibrated in inches.
Use the bottom scale, which is in metric units.
Notice that there is a fixed scale and a sliding scale.
The boldface numbers on the fixed scale are centimeters.
The tick marks on the fixed scale between the boldface numbers are millimeters.
There are ten tick marks on the sliding scale. The left-most tick mark on the sliding scale will
let you read from the fixed scale the number of whole millimeters that the jaws are opened.
(Video presentation)
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ACTIVITY 7
Technical Description:
Evaluates the Production Plan: Fills in details in the production plan on how to produce
the parts submitted in an order.
Gather at a station (e.g. in a storage rack) the parts that are needed in order
Synchronize processes which can be performed concurrently and those which must be
Performed consecutively.
The CIM Manager runs a virtual machine that corresponds to each physical machine in the
CIM. This virtual machine keeps track of the status and parts queue at the physical machine.
The CIM Manager uses this information to decide when to send routing messages to bring parts
to the machine.
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TASK 5
5. Once simulation of the production cycle has begun, can it be paused and restarted only
once?
6. Which viewing option redefines the center of graphic viewing image?
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ACTIVITY 8
Objective: To demonstrate and learn the process of make a new program MRP, New order &
Customer order.
TECHNICAL DESCRIPTION:
About MRP:
Material Requirements Planning (MRP) enables manufacturers to calculate the material requirements
from a list of items they intend to sell. MRP provides a tool for floor control, master production
scheduling and capacity planning. Manufacturing Resource Planning (MRP II) coordinates and integrates
manufacturing resources together with engineering, marketing and financial resources.
About OpenCIM MRP:
The OpenCIM MRP program is used to create and define three types of orders:
Customer Orders: products ordered
Manufacturing Orders: items to be produced
Purchase Orders: items to be purchased from suppliers
In general, OpenCIM MRP allows you to create a list of customers and define the products ordered by
each customer. Once Customer Orders are created, the MRP program automatically creates a
Manufacturing Order and a Purchase Order. You can view and modify or simply accept the
Manufacturing Order, or define a completely new one. When the Manufacturing
Order is submitted, the MRP creates an A-Plan file, or production work order. In addition, the MRP
creates a Purchase Order for items that must be supplied to the CIM. The OpenCIM Report Generator can
be used to display and print the Purchase Order.
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A customer order is a list of the parts (products) ordered by a customer. The Customer Order form shown
below lets you create, view and modify a list of customers and their orders.
Parts must be defined in the Part Definition form before they can be ordered by customers.
The following buttons apply only to the Customer Order table. Any changes you make using these
buttons will not be stored in the database until you click Save.
Option Description:
A manufacturing order specifies the type and quantity of parts to be produced by the CIM cell on a
specific day.
The Manufacturing Order form shown can be generated by the MRP program according to the customer
orders currently in the system. You can view and modify or simply accept the Manufacturing Order, or
define a completely new one.
You can define an order at any time, but you must finish defining all machine processes and subparts used
in the order before you submit the order for production.
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Each row in the Manufacturing Order table represents a total quantity of a particular part which needs to
be manufactured on the specified date, so that all customer orders are filled.
Each row in the Manufacturing Order table represents a total quantity of a particular part which
needs to be manufactured on the specified date, so that all customer orders are filled.
You can switch to the other order forms by clicking the appropriate tab.
The following buttons apply only to the Manufacturing Order table. Any changes you make using these
buttons will not be stored on disk until you click Save.
Options Description
Prints the A-Plan report for the last manufacturing order created.
Creates the selected manufacturing order, its A-Plan and saves it to the database.
Part Name The name of the part you want supplied. This field corresponds to the Part field on the Part
definition screen.
Quantity The number of units you want to receive from the supplier.
Cost The cost per unit, as defined in the Part Definition form.
Due Date The date on which the part must be received from the supplier.
.
Send Date The deadline for sending the Purchase Order to the supplier. Calculated by subtracting from
the Due Date the time required by the Supplier.
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1. In the Customer Order form, click New Customer. The Customer Data box opens.
2. In the Customer Data box, fill in the Name of the customer, and other customer information (e.g.,
address or phone number). Click Save.
The box closes and this customer’s name is added to the Customer List.
3. If you want to make any changes to specific customer information, select the customer from the list,
click Edit Customer and make the desired changes.
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Activity 9
Objective: To demonstrate and learn the turning process of CNC base spectral light 0200 software and
flexible manufacturing system.
Technical Description:
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