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Acrobat Distiller, Job 65

1. Class Date Task 13 5 Team Discussion and Review Q In your own words write a description of the FMS production cycle Worksheets 29 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets 30 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Activities 14 and 15 Worksheets FMS Project and Conclusion Inventory and Safety Checklist Start of Session Item Act 14 Act 15 SCORBOT ER 4u robot and Controller USB TP optional Computer with SCORBASE software spectraLIGHT mill and controller box Pneumatic vise and spacer Computer with WSLM mill control software Parts feeder and sorting bin 3 or more wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 14 2 Final FMS Project Q Describe the ap
2. Figure 1 SCORBASE software SCORBASE is a robotic control software package which has been designed for use with the SCORBOT ER 4 Its menu driven structure and off line capabilities facilitate robotic programming and operation LESE Ll E th F Pig fom pamm TACT PT OED aA A TUE FART 7h Dern lau B epum gud 6 m 0 ae Wae Ee Figure 2 Teacher s Guide 11 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Teach Pendant hand held control pendant for direct operator control of the robot Figure 3 CNC Milling System Components The milling system shown in Figure 4 includes the following components ThespectraLIGHT Mill is a CNC tabletop milling machine Like other mills it has a spindle which holds the cutter A pneumatic 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 TIO LIT IL T E 5 Ir Ye li Computer mm t ed Mic ae M i il 1 ae 11 ER EXE Progam ists Controller Bax Figure 4 The Controller Box is connected between the computer and the mill The controller houses the ele
3. Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off materials returned to proper place Lab station is clean Worksheets 6 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Activity 4 Worksheets Moving the Robot in the FMS Cell Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot Controller USB and teach pendant Parts feeder and sorting bin Computer with SCORBASE software Wax blocks Diskette or personal directory on computer hard disk The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 4 2 Moving the Axes in the Cartesian XYZ Coordinate System Q Describe the difference in the response of the tip of the gripper when the pitch and roll axes are moved in Joint and XYZ modes Worksheets 7 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Task 4 4 Moving to a Location in the FMS Cell Q Describe your observations Was it easier to reach the target when in Joints mode or XYZ mode Task 4 5 Team Discussion and Review Q The accurac
4. The student is properly dressed for operating the FMS cell Task 4 2 Moving the Axes in the Cartesian XYZ Coordinate System Q Describe the difference in the response of the tip of the gripper when the pitch and roll axes are moved in Joint and XYZ modes PITCH IN XYZ MODE THE SHOULDER ELBOW AND PITCH AXES MOVE THIS CAUSES THE PITCH ANGLE TO CHANGE BUT DOES NOT CHANGE THEPOSITION POINT OF THE TCP IN JOINT MODE ONLY THE WRIST PITCH AXIS 4 MOVES UP AND DOWN AND CHANGES THE POSITION OF THE TCP ROLL IN BOTH XYZ AND JOINT MODES THE ROLL Axis 5 ROTATESAND THE TCP REMAINS IN THE SAME POSITION Task 4 4 Moving to a Location in the FMS Cell Q Describe your observations Was it easier to reach the target when in Joints mode or XYZ mode IS OFTEN EASIER TO REACH THE EXACT TARGET WHEN IN XYZ MODE E G IT IS EASIER TO MOVE THE TCP UP AND DOWN BY MEANS OF THE Z AXIS IN XYZ MODE Worksheets Answer Key 0203 7 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 SOME MOVEMENTS ARE MORE EASILY PERFORMED WHEN IN JOINTS MODE SUCH AS TURNING THE ROBOT AROUND ON ITS BASE AXIS Q What error did you receive when you tried to move the robot in XYZ mode Why THE ROBOT COULD NOT MOVE ERROR MESSAGE XYZ NOT ALLOWED IT WAS AT THE EDGE OF ITS WORK ENVELOPE Task 4 5 Team Discussion and Review Q The accuracy of the robot arm is a measure of how close it is able to come to
5. Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 2 5 Running a FMS Milling Program Q Describe or sketch the location of the vise as a result of the codes which have been added to program MILLB THE VISE WILL MOVE NEAR TO THE BACK AND LEFT SIDE OF THE MILL THIS IS THE LOCATION WHERE THE ROBOT CAN LOAD AND UNLOAD A PART TO THE VISE Worksheets Answer Key 3 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Task 2 6 Team Discussion and Review If you were to run program MILLB twice in succession what will happen to the vise when the program starts the second time SINCE THE VISE IS ALREADY AT THE LOAD UNLOAD POSITION IT WILL NOT MOVE LINE N6 TO THE LOAD UNLOAD POSITION THE VISE WILL MOVE LINE N8 TO THE WORKPIECE ORIGIN Q Why does the mill in the FMS require a pneumatic automatically operated vise THIS TYPE OF VISE ALLOWS THE MILL TO BE TENDED BY A ROBOT WITHOUT REQUIRING HUMAN INTERVENTION DURING MACHINING OR MANUFACTURING PROCESSES Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned
6. No unusual noises are heard No unusual vibrations are observed There are no obstacles in the robot s working range 3 Activate the robot homing procedure Check the following items Robot movement is normal No unusual noise is heard when robot arm moves Robot reaches home position in every axis 4 Home the milling machine and initialize a workpiece Check the following items Cross slide and spindle movement is normal No unusual noise is heard when the cross slide and spindle move The machine home and workpiece home are successfully set Teacher s Guide 24 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Robot Positions in the FMS Cell Figures 16 and 17 show the robot positions that are used throughout the tasks in the FMS Activities Book Figure 16 Figure 17 Teacher s Guide 25 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 The following table lists and describes the positions in the FMS cell The shaded positions are absolute non shaded positions are recorded as relative positions Area Position Description of Position Tended 99 robot home facing mill 98 robot facing sorting bin 97 robot facing gravity feeder 2 Position at which robot picks up block from gravity feeder E 12 Intermediate position above position 2 eeder relative to position 2 3 Position at which
7. lise 3 Ux2U x1 5 machinabla wax block Initialize steck to F lt Uiz ae i Low ioff to Roht El as move tno lLloadz unlsad posit ion 1 High tan t Rolee For Input Law fram Habet 2 seconda tpat 1 Leu coff to Robot Claze Uiat pause 2 seconda Claadl start paint taol down move te dat gapa m um AER BRANE FA EM return to lat ine det disgonal 1 return to 2nd 2nd diagonal um tool up i move tn load unload position paure Ka Cun Lown npen idi T high ton to robot wait for input high from robot pause seconds umtput 1 low Cnff tn mobot start new 1 wi BE A Hii Hil i 4 5 27 HiH Hi Hz 1 1 4 7 nT WIA 1 i i 4 5 aa Figure 27 NC program edited Activity 12 Teacher s Guide 0203 30 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 Class Date Pre Test Answer Sheet Pre Test Answer Sheet 1 Flexible Manufacturing System 0203 SCORBOT ER 4 and spectraLIGHT 200 1 To mill the line from point A to point C the cutter will move between which two coordinates 2 2 to 6 4 b 2 2 to 6 2 c 6 4 to 2 4 d 2 4 to 6 4 2 Which tasks can be performed by a milling machine a Operating the robot b Moving the cutter in a straight line
8. 0203 Q How many production cycles were completed What causes production to stop TWO PRODUCTION CYCLES ARE COMPLETED PRODUCTION STOPS BECAUSE THE COUNTER HAS DETERMINED THAT 2 CYCLES HAVE BEEN COMPLETED Task 13 5 Team Discussion and Review Q In your own words write a description of the FMS production cycle ROBOT CHECKS INPUT SIGNAL FOR AVAILABILITY OF PART IN FEEDER PART IS AVAILABLE ROBOT TAKES PART FROM FEEDER AND BRINGS IT TO THE MILL ROBOT WAITS FOR SIGNAL FROM MILL THAT VISE IS AT LOAD UNLOAD POSITION WHEN SIGNAL RECEIVED ROBOT UNLOADS PART TO VISE VISE IS THEN BROUGHT TO POINT OF ORIGIN AND THE PART IS MILLED ROBOT WAITS AT MILL WHILE MILLING OPERATION TAKES PLACE COMPLETED PART IS RETURNED TO LOAD UNLOAD POSITION AND A SIGNAL IS SENT TO THE ROBOT THE ROBOT THEN PICKS UP THE FINISHED PART AND DELIVERS IT TO THE SORTING BIN THE ROBOT THEN MOVES TO A POSITION NEAR THE FEEDER Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets Answer Key 28 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Activities 14 and 15 Worksheets Answer Key FMS Project and Conclusion Inventory and Safety Checkli
9. After the robot has placed the raw material in the milling machine what will it do a Turn on the mill b Turn off the mill c Senda signal to the mill d Receive a signal from the mill Which of the following can be included in a robot program a Input commands b Remarks c Robot arm movement commands d of the above What is a relative position a A position near the robot home b A set of coordinates which defines the robot s location in space Aset of coordinates which defines an offset from another position d A position for another device in the robot s workcell What is the function of a parts feeder a To put parts in the robot s gripper b To sort the parts which the robot will handle c To discard the parts which have failed inspection d To supply parts to the robotic workcell Post Test 3 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 17 18 19 20 21 22 Which is not a method for manipulating the robot arm a Using controller outputs b Using the terminal or computer keyboard c Using a hand held teach pendant d Using robotic software When can the robot open the gripper a When the robot is at its home position b When there is an object in the gripper c When there there is no object in the gripper d of the above After robot positions have been recorded what should you do a Turn off the controller b Delet
10. DELIVERS PARTS TO MILL REMOVES PARTS FROM MILL Q What is the function of the milling machine in the FMS MILL PROCESSES PARTS What are the functions of the computers in the FMS RUN THE SOFTWARE WHICH IS USED FOR PROGRAMMING AND OPERATINGTHE ROBOT AND MILL SERVE AS THE INTERFACE TO THE ROBOT AND MILL CONTROLLERS What are the most important safety rules to remember during operation of the robot 1 WEAR SAFETY GLASSES NO LOOSE CLOTHING OR JEWELRY 2 KNOW HOW TO STOP THE SYSTEM IN AN EMERGENCY 3 DoN T TOUCH OR COME TOO CLOSE TO A MOVING ROBOT 4 DON T CRASH THE ROBOT Q What are the most important safety rules to remember during operation of the mill 1 WEAR SAFETY GLASSES NO LOOSE CLOTHING OR JEWELRY 2 KNOW HOW TO STOP THE SYSTEM IN AN EMERGENCY 3 KEEP SAFETY SHIELD CLOSED WHEN THE MILL IS IN OPERATION 4 KEEP HANDS AND ARMS OUT OF MILL WHILE IT IS CUTTING Worksheets Answer Key 2 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Activity 2 Worksheets Answer Key Preparing the Mill for Automation Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot and Controller USB Computer with SCORBASE software spectraLIGHT mill and controller Pneumatic vise and spacer Computer with WSLM mill control software NC programs MILLA NC and MILLB NC Parts feeder and sorting bin Wax blocks
11. Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets Answer Key 16 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Activity 9 Worksheets Answer Key Optimizing the FMS Robot Program Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot Controller USB and teach pendant Computer with SCORBASE software spectraLIGHT mill and controller Pneumatic vise and spacer Computer with WSLM mill control software NC program EXCHANGE NC Parts feeder and sorting bin Wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 9 3 Editing the Program Q Explain the difference between Remarks comments and Labels in the robot program A REMARK IS A USER COMMENT WHICH HAS NO EFFECT ON PROGRAM EXECUTION IT CAN BE USED TO HELP THE PROGRAMMER DEFINE SEGMENTSOF A PROGRAM PROGRAM CANNOT JUMP TO REMARKS A LABEL IS A SPECIFIC POINT IN THE PROGRAM WHICH CAN BE UTILIZED IN PROGRAM EXECUTION IF JUMP COMMANDS
12. of the above If you attempt to operate the robot without homing it what may happen a The robot will not move properly to a recorded position b The robot will move to the home position by itself c The robot will move to the last recorded position d The controller will shut off After positions have been recorded what should you do a Write a program b Save the positions c Home the robot d Turn off the controller Pre Test 0203 2 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 12 What are the two required stages in programming the robot a Writing the program and recording the robot positions b Operating the robot and recording positions c Writing the program and saving the program d Recording the positions and saving the positions 13 By what means does the robot sends signals to the milling machine a Input commands b Output commands c Encoders d Microswitches 14 The robot can stop precisely when moving at a fast speed a True b False 15 A robot program can be saved and used later a True b False 16 A parts feeder is used to supply a Raw materials to the vise b Air pressure to the vise C Air pressure to the robot gripper d Raw materials to the robot 17 What is the robot doing a Placing a part in the parts feeder b Taking a part from the parts feeder c Placing a part in the vise d Taking a part from the vise Pre Test 3 Flexi
13. Home the robot d Turn off the controller What are the two required stages in programming the robot a Writing the program and recording the robot positions b Operating the robot and recording positions c Writing the program and saving the program d Recording the positions and saving the positions Pre Test Answer Key 3 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 13 By what means does the robot send signals to the milling machine a Input commands b Output commands c Encoders d Microswitches 14 The robot can stop precisely when moving at a fast speed a True b False 15 A robot program can be saved and used later a True b False 16 parts feeder is used to supply a Raw materials to the vise b Air pressure to the vise C Air pressure to the robot gripper d Raw materials to the robot 17 What is the robot doing a Placing a part in the parts feeder b Taking a part from the parts feeder c Placing a part in the vise d Taking a part from the vise 18 When the robot is placing the block of wax into the vise what speed should you use a A fast speed b A slow speed c A medium speed d Any of the above Pre Test Answer Key 4 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 19 Only one movement command is needed to send the robot from the parts feeder to the milling machine vise a True b False 20 When the milling
14. Team Discussion and Review Q In this activity the robot program concludes with commands which send the robot away from the mill Should the robot wait at the mill for the part to be returned to the load unload position Describe an application which explains your answer IF IT IS KNOWN IN ADVANCE THAT THE MILLING OPERATION WILL TAKE SOME TIME THE ROBOT CAN BE SENT TO ANOTHER LOCATION TO PERFORM ANOTHER OPERATION THE MILLING OPERATION IS BRIEF THE ROBOT SHOULD NOT LEAVE ITS MILL TENDING POSITION IN ANY EVENT THE ROBOT SHOULD WAITING AT THE MILL AS SOON AS THE PART IS AVAILABLE FOR PICKUP Worksheets Answer Key 0203 23 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets Answer Key 24 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Activity 12 Worksheets Answer Key Completing the FMS Programs Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot and Controller USB Computer with SCORBASE software spectraLIGHT mill and controller Computer with WSLM mill control software Diskette or p
15. in islands of automation or Flexible Manufacturing Systems FMS Ultimately TEAM exposes students to Computer Integrated Manufacturing CIM systems where they will manufacture a product from concept through design and all the way to production Teacher s Guide 7 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 About SCANS Skills In 1990 the United States Secretary of Labor appointed a group called the Secretary s Commission on Achieving Necessary Skills SCANS to determine the skills people need to succeed in the world of work The Commission was composed of 30 representatives of education business labor and state government and was charged with defining a common core of skills that constitute job readiness in the current economic environment An environment facing fierce economic competition new technologies and rapidly changing skill requirements Specifically the Commission was asked to e Define the skills needed for employment Propose acceptable levels of proficiency e Suggest effective ways to assess proficiency Develop a dissemination strategy for the nation s schools businesses and homes During the course of its work SCANS produced several publications The Commission s first report what Work Requires of Schools resulted from extensive meetings and discussions with a variety of organizations including business industry public employers and unions The report identifies 36
16. End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets 4 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Activity 3 Worksheets Homing and Manipulating the Robotic Axes Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot Controller USB and teach pendant Computer with SCORBASE software Wax block and round plastic block Diskette or personal directory on computer hard disk The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 3 3 Homing the Robot Q Describe the homing of the robot Task 3 4 Operating the Gripper Q Was the gripper able to grasp the wax block on each of its sides Worksheets 5 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Task 3 7 Team Discussion and Review Q Describe the difference between using the SCORBASE software and the teach pendant to control the axes Q What is the best way for the robot gripper to hold a wax block in order to place it into the vise in the milling machine
17. Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 RPP eos TEAM tekLINKs Flexible Manufacturing System Teacher s Guide 6 SCORBOT ER 4u and spectraLIGHT 200 0203 About the TEAM Program intelitek s Technology for Engineering Automation and Manufacturing TEAM is a multi segmented curriculum driven program designed to provide students with a broad base of competencies in modern manufacturing technology Its educational hardware and software are based on actual industrial components and together emulate manufacturing environments TEAM incorporates hands on lab experience with simulation creative design projects problem solving and more A Student Activities Book and Teacher s Guide accompany every TEAM tekLINK The activities include clearly defined objectives subject overview interactive tasks and links to career opportunities and industrial applications Pre and Post tests establish competency and check that objectives and skill levels are achieved Each tekLINK addresses the SCANS Skills and the relevant National Skill Standards established by industry Students work in teams and are exposed to various core technologies on a rotation basis This modular concept allows the program to be tailored to the needs of each student TEAM students will master the technical skills needed for competent use of industrial equipment and manufacturing technology Design projects will then challenge them to combine tekLINKs
18. Safety Checklist Item Start of Session SCORBOT ER 4u robot Controller USB and teach pendant Computer with SCORBASE software spectraLIGHT mill and controller Pneumatic vise and spacer Computer with WSLM mill control software NC program EXCHANGE NC Parts feeder and sorting bin Wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 7 7 Team Discussion and Review Q Whyis it preferable for positions 12 13 23 and 14 to be recorded as relative positions and not absolute positions POSITIONS 2 3 AND 4 MUST BE VERY EXACT THEIR COORDINATES NEED TO BE ADJUSTED RERECORDED IT WILL NOT BE NECESSARY TO RERECORD POSITIONS 12 13 23 AND 14 SINCE THE RELATIVE POSITIONS MAINTAIN THEIR OFFSET FROM THE REFERENCE POSITION Worksheets Answer Key 13 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets Answer Key 14 Flexible Manufactur
19. Table s Coordinate Grid Template If your system was supplied with a coordinate grid and or a template place them on the workcell tables SCORBOT ER 4u Robot Install the robot according to the instructions in the SCORBOT ER 4u and Controller USB user manuals Be sure to position the robot as shown in the figure below When homed the robot should face the mill Teacher s Guide 0203 16 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 act gt I a f i y Figure 7 Suggested cell setups Make sure the robot is securely bolted in place Otherwise the robot could become unbalanced and topple over while in motion Do not yet connect any cables Gravity Feeder with Microswitch 1 Adjust the legs of the gravity feeder so that it slopes at an angle of about 20 25 2 Place several wax blocks supplied with the system in the feeder slide Adjust and set the width of the slide according to the width of these blocks see Figure 8 Figure 8 3 Once the feeder is positioned properly as shown in Figures 7 and 8 duct tape can be used to hold it in place or you can bolt it to the table Do not yet connect any cables or wires Teacher s Guide 17 0203 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 Sorting Bin Make sure a supply of machinable wax blocks 2 x 3 x 1 5 is available Once the bin is positioned p
20. Worksheets 17 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Task 9 4 Timing the Production Cycle Time to Complete Task Segment Cycle 1 Cycle 2 Get workpiece from feeder not timed Deliver workpiece to mill not timed Wait for milling operation not timed Remove workpiece from mill not timed Deliver workpiece to collection bin not timed Return to home position not timed TOTAL TIME Task 9 5 Optimizing the Production Cycle Time to Complete Task Segment Cycle 3 Cycle 4 Optimized Optimized Get workpiece from feeder Deliver workpiece to mill Wait for milling operation Remove workpiece from mill Deliver workpiece to collection bin Return to home position TOTAL TIME Worksheets 18 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Task 9 6 Team Discussion and Review Q Compare the segment and total times of the original cycles and the optimized cycles Describe the results Calculate the reduction in time as a percentage of the original cycle Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All
21. a target position How does speed affect accuracy THE ROBOT IS MOVING TOO FAST IT IS LIKELY TO OVERSHOOT THE TARGET DUE TO THE TIME IT TAKES FOR THE ROBOT TO REACT TO A COMMAND TO STOP MOVEMENT SLOWER MOVEMENTS ALLOW THE ROBOT TO STOP MORE PRECISELY THIS IS COMPARABLE TO THE ABILITY OF A DRIVER OR RIDER TO STOP A CAR OR BICYCLE WHICH IS TRAVELING AT A HIGH OR LOW SPEED Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets Answer Key 8 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Activity 5 Worksheets Answer Key Recording Robot Positions for Parts Handling Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot Controller USB and teach pendant Computer with SCORBASE software Parts feeder and sorting bin Wax blocks Diskette or personal directory on computer hard disk The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 5 4 Displaying and Saving Positions Q Which position 97 98 or 99 is the same as position 100 EITHER 97 OR 98 DEPENDING ON CELL SETUP Task 5 7 Tea
22. in different compartments in the sorting bin Q Which positions in the FMS cell require extreme precision and which positions do not Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets 10 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Activity 6 Worksheets Writing and Running a Robot Program Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot Controller USB and teach pendant Computer with SCORBASE software Parts feeder and sorting bin Wax blocks Diskette or personal directory on computer hard disk The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 6 7 Executing the Robot Program Q What happens when the feeder runs out of wax blocks Task 6 8 Conditional Program Jumps Q Describe the program execution when there are no parts in the feeder Worksheets 11 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Q Describe the program executi
23. machine finishes cutting what will it do a Turn on the robot b Turn off the robot c Send a signal to the robot d Receive a signal from the robot Pre Test Answer Key 3 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Post Test Answer Sheet N N N e N CO o Ee CNN E le Boe y CAEN as ET Eu pe polt CANNE E mos 2 a 22 24 25 je 26 27 ja 29 ENIM a fe ENIM ENIM 35 ENIM EMI ENIM 9 40 ja Post Test Answer Sheet 1 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 1Post Test 1 Which task can be performed by a milling machine a Moving the cutter in a straight line b Operating the robot c Moving the robot in a straight line d All of the above 2 What does it mean to initialize the milling machine a Enter a name for the CNC program b Turn on the system c Define the point of origin of the material to be milled d Delete all programs in the system 3 Each time you operate the milling machine you have to create a new NC program a True b False 4 What are the coordinates of point A a 2 2 b 0 0 c 3 2 d 3 3 5 The robot can stop precisely when moving at a fast speed a True b False Post Test 1 Flexible Manufacturing System 0203 SCORBOT
24. off All materials returned to proper place Lab station is clean Worksheets Answer Key 4 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Activity 3 Worksheets Answer Key Homing and Manipulating the Robotic Axes Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot Controller USB and teach pendant Computer with SCORBASE software Wax block and round plastic block Diskette or personal directory on computer hard disk The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 3 3 Homing the Robot Q Describe the homing of the robot AXES IN THE FOLLOWING ORDER SHOULDER 2 ELBOW Axis 3 PITCH Axis 4 ROLL Axis 5 BASE Axis 1 GRIPPER Axis 6 THE AXES MOVES FAST AT THE START OF THE HOMING THEN MOVE SLOWLY WHEN CHECKING FOR THE MICROSWITCH Task 3 4 Operating the Gripper Q Was the gripper able to grasp the wax block on each of its sides THE GRIPPER JAW CAN OPEN TO 3 IT CAN GRASP THE 1 5 AND THE 2 SIDE OF THE WAX BLOCK IT MIGHT NOT BE ABLE TO GRASP THE WAX BLOCK ACROSS THE 3 SIDE Worksheets Answer Key 5 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Task 3 7 Team Discussion and Review Q Describe the difference between using the SCORBASE software and the teach pendant to control the axes 1 TP AL
25. parts which the robot will handle c To discard the parts which have failed inspection d To supply parts to the robotic workcell Which is not a method for manipulating the robot arm a Using controller outputs b Using the terminal or computer keyboard c Using a hand held teach pendant d Using robotic software Post Test Answer Key 4 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 18 19 20 21 22 23 24 When can the robot open the gripper a When the robot is at its home position b When there is an object in the gripper c When there there is no object in the gripper d All of the above After robot positions have been recorded what should you do a Turn off the controller b Delete the program c Home the robot d Save the positions At what speed should a robot move to a place the workpiece in the CNC mill vise a Ata slow speed b As slow as possible C As fast as possible d Atany speed the operator selects What is a robot program A set of commands which the robotic system will perform b A series of robot movements A set of robot positions d The SCORBASE software Why might the operator need to press the Emergency stop button a The program has a bug in it b A part to be handled is in the wrong position c The robot is in the wrong position d All of the above What are the two required stages in programming the ro
26. robot loads and unloads the block to and from the vise 13 Intermediate position above position 3 se s relative to position 3 23 Intermediate position above position 13 also relative to position 3 4 Place position Position at which robot places the block Sorting into the sorting bin 2 14 Intermediate position above position 4 relative to position 4 Single digit robot positions are pick place positions Double digit robot positions are relative positions above the pick place positions Should you wish to record and check these positions you can test them by running the SCORBASE program which students will write and save as USERS where USER will be replaced by four characters which identify specific student or team For a listing of that program refer to Activity 8 in the Activities Book or to the section Solutions at the end of this Teacher s Guide Important note Teach position 2 first To record position 3 the robot must take a wax block from the feeder position 2 and place it in the mill vise without opening the gripper Teacher s Guide 0203 26 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 NC Programs Required for Activities Figures 18 19 and 20 show the NC programs MILLA NC MILLB NC and EXCHANGE NC which are required for the activities These programs must appear in the WPLM software directory since they will be used but not written by students If t
27. workplace skills that high performance workplaces require and that high performance schools should produce These skills are divided into a Three Part Foundation and Five Competencies The Three Part Foundation includes basic skills which include literacy and computational skills thinking skills described as necessary to put knowledge to work and personal qualities described as making workers dedicated and trustworthy The Five Competencies include the ability to manage resources interpersonal skills needed to work amicably and productively with others the ability to acquire and use information skills needed to master complex systems and skills needed to work with technology It was the finding of the Commission that these skills at the heart of job performance and are essential preparation for all students both those going directly to work and those planning further education The Commission believes the most effective way of learning skills is in context teaching learning objectives within a real environment and that the SCANS foundation and competencies be taught and understood in an integrated fashion that reflects the workplace contexts in which they are applied Source ScansLink The National Scan Skills Concern Get the Facts http 144 162 10 248 nlc misc scans facts htm Teacher s Guide 8 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 SCANS Skills in the TEAM Program The TEAM progra
28. 5 Teacher s Guide 22 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Testing Robot Mill Input Output Communication When the mill and robot controllers are connected the LED for Input 8 on the robot controller is constantly turned on Due to reverse logic in the spectraLIGHT controller I O responses in this FMS differ from typical responses Note the following When spectraLIGHT output Robl blue button emits a LOW signal SCORBOT input 8 turns ON When spectraLIGHT output Robl emits a HIGH signal SCORBOT input 8 turns OFF The same reverse logic holds for the milling system inputs The mill controller input Rob1 red button receives signals from robot controller Output 8 This button is constantly pressed indicating an input on signal although robot controller output 8 is off Again note When SCORBOT outputs 8 emits an OFF signal spectraLIGHT input Robl goes HIGH turns ON button is pressed When SCORBOT output 8 emits ON signal spectraLIGHT input Robl goes LOW turns OFF button is not depressed To check the I O connections between the mill and the robot 1 Make sure none of the inputs or outputs are turned on in the SCORBASE Digital Inputs and Digital Outputs dialog bars except Input 8 Confirm this by checking the LEDs on the robot controller Note that if a part is in the parts feeder input 7 will also be lit In the WPLM toolbar the blue Rob1 input button should be of
29. Define the workpiece s point of origin d Delete all programs in the system 5 What is the robot home position a The last position recorded b A specific position defined by the operator c A specific position defined by the manufacturer d A position defined by the robot Pre Test Answer Key 2 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 10 11 12 You must home the robot each time you turn on the robotic system a True b False In case of emergency what should you do a Turn off the milling machine power switch b Turn off the computer power switch c Pull out the plug from the power supply outlet d Press the milling machine s Emergency Stop button What is a robot program A series of movements b A set of position coordinates c A set of commands which the robot will perform d The robotic control software When can the robot open the gripper a When the robot is at its home position b When there is something in the gripper c When there is nothing in the gripper d All of the above If you attempt to operate the robot without homing it what may happen a The robot will not move properly to a recorded position b The robot will move to the home position by itself c The robot will move to the last recorded position d The controller will shut off After positions have been recorded what should you do a Write a program b Save the positions c
30. ER 4u and spectraLIGHT 200 6 In case of emergency in the milling system what should you do a Turn off the milling machine power switch b Turn off the computer power switch c Press the Esc key on the computer keyboard d Press the milling machine s Emergency Stop button 7 Why should you do a dry run of the NC program before running the program with an actual part in the milling machine a To prevent damage to the milling machine b To guarantee safety c To prevent waste of raw materials d the above 8 Which of the following initializes the milling machine a NC program command b Operator c Robot d CNC mill controller 9 What is the robot home a The factory which produced the robot b A specific position defined by the operator C A fixed reference position d The robot s work environment 10 What is shown in the figure below b A robot arm C A parts feeder d A gripper Post Test 2 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 11 12 13 14 15 16 What does on line programming mean a Program has one main routine b The robot controller is used for recording robot positions Positions are taught in a line d Programmer makes a flow chart of the robot task What is a robot position a A set of coordinates which define the robot s home b A set of coordinates which define the robot s location in space c XYZ d Joints
31. LOWS THE USER TO STAND NEAR THE ROBOT AND CLOSELY OBSERVE ITS MOVEMENTS DURING MANIPULATION WHEN USING SCORBASE USER MUST REMAIN AT PC NOT BE ABLE TO CLOSELY OBSERVE THE ROBOT S MOVEMENTS 2 TP KEYS MUST BE PRESSED IN A SPECIFIC ORDER THE SAME KEY IS OFTEN PRESSED TO SCROLL OR TOGGLE TO DIFFERENT FUNCTIONS IN SCORBASE FUNCTIONS ARE SELECTED IN DIALOG BOXES ORDER OF SELECTION IS FLEXIBLE Q What is the best way for the robot gripper to hold a wax block in order to place it into the vise in the milling machine IN THIS FMS CELL THE ROBOT GRIPPER MUST GRASP THE WAX BLOCK ACROSS ITS NARROWEST 1 5 SIDE Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets Answer Key 6 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Activity 4 Worksheets Answer Key Moving the Robot in the FMS Cell Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot Controller USB and teach pendant Parts feeder and sorting bin Computer with SCORBASE software Wax blocks Diskette or personal directory on computer hard disk The robotic system conforms to the safety guidelines
32. Open Gripper 6 Go to Position 97 fast e 7 Go to Position 12 fast 8 HEPEAT 8 Go Linear to position 2 speed 2 SIF COUNTER CYCLES jump te START PRODUCTION 9 Close Gripper ii Jump ho END PRODUCTION n A im 11 START PRODUCTION 10 Go Linear to position 12 speed 5 iz x 11 Go to Position 23 fast 13 CHECK PART AVAILABILITY 12 14 7 on jump to TAKE PART 13 WAIT FOR MILL READY 15 Jump CHECK PART AVAILABILITY 14 If Input 8 off jump to PLACE PART IN VIS iei 15 Jump to WAIT FOR MILL READY ux dS RM 16 PLACE PART IN 19 Ge to Position 12 fast 17 20 Go Linear tn position 2 speed 18 Go Linear to position 13 speed 5 21 Close Gripper 19 Go Linear to position 3 speed 2 22 Ge Linear position 12 speed 5 20 Open Gripper ZE Goto Position 271 fast 21 Go Linear to position 13 speed 2 en T cp 25 WAIT FOR MILL AEADY 22 Linear to position 23 speed 5 2B input B off jump to PLACE PART IM VISE 23 27 Jump to WAIT FOR MILL READY 24 Turn on output 8 28 PLACE PART IM VISE 25 Wail 100 10 ths of seconds 29 Ge Linear to position 13 speed 5 26 Turn off output 8 30 Ge Linear io position 3 speed 2 eL 31 Open Gripper 28 Go to Position 98 fast 22 Go Linear 10 position 13 speed 2 31 Go Linear tn position Z3 speed 5 34 Turn on output Wait 100 10 the of seconds 3h o 7 ANT MILLING M input off jump ta FINISHED PART 2 dum
33. REFERENCE LABEL COMMAND LINES PROGRAM CAN JUMP TO LABEL Worksheets Answer Key 17 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Task 9 4 Timing the Production Cycle Time to Complete Task Segment Cycle 1 Cycle 2 Get workpiece from feeder not timed Deliver workpiece to mill not timed Wait for milling operation not timed Remove workpiece from mill not timed Deliver workpiece to collection bin not timed Return to home position not timed TOTAL TIME Task 9 5 Optimizing the Production Cycle Time to Complete Task Segment Cycle 3 Cycle 4 Optimized Optimized Get workpiece from feeder Deliver workpiece to mill Wait for milling operation Remove workpiece from mill Deliver workpiece to collection bin Return to home position TOTAL TIME Task 9 6 Team Discussion and Review Q Compare the segment and total times of the original cycles and the optimized cycles Describe the results Calculate the reduction in time as a percentage of the original cycle CYCLE CAN BE OPTIMIZED BY REMOVING COMMANDS TO MOVE TO POSITION 97 98 AND 99 Worksheets Answer Key 18 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No wo
34. a Elbow b Base c Roll d Gripper 34 When initializing the workpiece the cutter is brought to the top front left corner of the workpiece a True b False 35 The robot requires only one movement command to go from the parts feeder to the vise of the milling machine a True b False 36 When the milling machine finishes cutting what will it do a Turn on the robot b Turn off the robot c Senda signal to the robot d Receive a signal from the robot 37 A pneumatic vise opens and closes by means of a Output signal b Air pressure C A piston d of the above 38 What is another term for Cartesian coordinates a XYZ coordinates b Joint coordinates c Robot coordinates d Mill coordinates Post Test 7 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 39 40 What are the NC codes for transmitting output signals a G25 and G26 b M25 and M26 c M25 and G25 d M26 and G26 What is shown in the figure below a A keyboard b A controller A teach pendant d A control panel Post Test 8 0203 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 Post Test Answer Key gt N o gt e ZI a mM 22 EN 25 26 28 29 a0 Post Test Answer Key 1 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 1 Which task ca
35. ask 8 7 Team Discussion and Review Q Describe the similarities and difference between a WAIT command and an IF JUMP command block Give an example of how each can be used in FMS operations Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets 16 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Activity 9 Worksheets Optimizing the FMS Robot Program Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot Controller USB and teach pendant Computer with SCORBASE software spectraLIGHT mill and controller box Pneumatic vise and spacer Computer with WSLM mill control software NC program EXCHANGE NC Parts feeder and sorting bin Wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 9 3 Editing the Program Q Explain the difference between Remarks comments and Labels in the robot program
36. bjects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets 24 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Activity 12 Worksheets Completing the FMS Programs Inventory and Safety Checklist Item Start of Session Controller USB Computer with SCORBASE software spectraLIGHT mill and controller box Computer with WSLM mill control software Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 12 5 Team Discussion and Review Q Whatis the difference between the way the mill and robot are programmed to respond to input signals Worksheets 25 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date How many parts can be milled by executing program USER12 SBP Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mil
37. ble Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 18 When the robot is placing the block of wax into the vise what speed should you use a A fast speed b A slow speed c A medium speed d Any of the above 19 Only one movement command is needed to send the robot from the parts feeder to the milling machine vise a True b False 20 When the milling machine finishes cutting what will it do a Turn on the robot b Turn off the robot c Senda signal to the robot d Receive a signal from the robot Pre Test 4 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Pre Test Answer Key Pre Test Answer Key 1 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 1 To mill the line from point A to point C the cutter will move between which two coordinates 2 2 to 6 4 b 2 2 to 6 2 c 6 4 to 2 4 d 2 4 to 6 4 2 Which tasks can be performed by a milling machine a Operating the robot b Moving the cutter in a straight line c Moving the robot in a straight line d All of the above 3 Why should you do a dry run of the NC program before running the program with an actual workpiece a To prevent damage to the milling machine b To guarantee safety c To prevent waste of raw materials d All the above 4 What does it mean to initialize the milling machine a Enter a name for the NC program b Turn on the system c
38. bot a Writing the program and recording the positions b Operating the robot and recording positions c Writing the program and saving the program d Recording the positions and saving the positions You must write the robot program before you can record positions a True b False Post Test Answer Key 3 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 25 To mill the line from point A to point B the cutter will move between which two coordinates 2 2 to 6 4 b 2 2 to 6 2 c 6 4 to 2 4 d 2 4 to 6 4 26 What is the effect of conditional commands a Quicker to complete program cycle b Operation is more predictable c Robot is responsive to workcell signals d Robot is slower to respond 27 What purpose can a variable serve in robot program a Delete a robot position b Change the program name c Count the number of times a routine has been completed d Notify the operator that the program has changed 28 What is the robot doing a Placing a part in a feeder b Taking a part from a feeder c Placing a part on a conveyor d Taking a part from a conveyor Post Test Answer Key 6 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 29 Where should the robot go immediately after it moves away from this position a To an absolute position b To a relative position c To the home position d To a drop off pos
39. c Moving the robot in a straight line d All of the above 3 Why should you do a dry run of the NC program before running the program with an actual workpiece a To prevent damage to the milling machine b To guarantee safety c To prevent waste of raw materials d All the above 4 What does it mean to initialize the milling machine a Enter a name for the NC program b Turn on the system c Define the workpiece s point of origin d Delete all programs in the system Pre Test 1 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 10 11 What is the robot home position a The last position recorded b A specific position defined by the operator C A specific position defined by the manufacturer d A position defined by the robot You must home the robot each time you turn on the robotic system a True b False In case of emergency what should you do a Turn off the milling machine power switch b Turn off the computer power switch c Pull out the plug from the power supply outlet d Press the milling machine s Emergency Stop button What is a robot program A series of movements b A set of position coordinates A set of commands which the robot will perform d The robotic control software When can the robot open the gripper a When the robot is at its home position b When there is something in the gripper c When there is nothing in the gripper d
40. ctronics that interpret part programs and send them to the mill in a form the mill can understand Computer loaded with WSLM Control Program used to create and run CNC programs Teacher s Guide 12 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 kaiini i UU Figure 5 Additional Devices Parts Feeder The FMS tekLINK has a parts feeders which supplies parts to the cell by means of gravity The feeder is adjusted to the width of the wax blocks It feeder includes a microswitch sensor whose signal indicates to the robot controller that a part is available for pickup Figure 6 Sorting Bin This box is used to collect parts in a sorted manner It has adjustable dividers which divide it into compartments Machinable wax blocks referred to as workpieces serve as the raw material for milling production Teacher s Guide 13 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Materials Required for the Activities The Activities in this book require the following components which are supplied in the FMS tekLINK SCORBOT ER 4u Robot and Controller USB Teach Pendant Computer with SCORBASE software e spectraLIGHT Mill with pneumatic vise and mill controller Computer with WSLM Control Program Gravity parts feeder Sorting bin e Machinable wax blocks 2 x3 x1 5 In addition students will need the foll
41. e the program c Home the robot d Save the positions At what speed should a robot move to a place the workpiece in the CNC mill vise a Ata slow speed b As slow as possible C As fast as possible d Atany speed the operator selects What is a robot program a A set of commands which the robotic system will perform b A series of robot movements A set of robot positions d The SCORBASE software Why might the operator need to press the Emergency stop button a The program has a bug in it b A part to be handled is in the wrong position c The robot is in the wrong position d of the above Post Test 4 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 23 What are the two required stages in programming the robot a Writing the program and recording the positions b Operating the robot and recording positions c Writing the program and saving the program d Recording the positions and saving the positions 24 You must write the robot program before you can record positions a True b False 25 To mill the line from point A to point B the cutter will move between which two coordinates 2 2 to 6 4 b 2 2 to 6 2 c 6 4 to 2 4 d 2 4 to 6 4 26 What is the effect of conditional commands a Quicker to complete program cycle b Operation is more predictable c Robot 15 responsive to workcell signals d Robot is slower to resp
42. er s microswitch sensor to Input 7 on Controller USB one wire to ground one wire to the input terminal The mill is connected to Input 8 and Output 8 Make these connections after the mill has been installed The I O connections will be tested after the software is installed SCORBASE Software Installation and Activation 1 Once you have made all the required hardware connections you can turn on the PC and the controller The green power and motor LEDs will light up Install the SCORBASE software according to the instructions in the SCORBASE user manual and other documentation supplied with the SCORBASE software The SCORBASE application window is shown in Figure 11 ASSN OV EME 22 T aes Figure 11 Teacher s Guide 0203 19 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 Testing Input from the Gravity Feeder From SCORBASE look at the Digital Input dialog bar If it is not already displayed select View Dialog Bars Digital Inputs See Figure 12 Digital Inputs MEMS Figure 12 OnController USB the LED for input 7 should be lit when the part is in the feeder and pressing on the microswitch Inthe SCORBASE software Digital Inputs dialog bar the Input 7 box should also appear lit spectraLIGHT Mill and Mill Controller Install the spectraLIGHT Mill and Controller Box according to the instructions in Section A of the spectraLIGHT 0200 Machining Ce
43. ersonal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 12 5 Team Discussion and Review Q What is the difference between the way the and robot are programmed to respond to input signals THE MILL S NC PROGRAM INCLUDES G25 AND G26 WAIT FOR INPUT CODES THE NC PROGRAM WILL HALT ON THE LINE CONTAINING SUCH A COMMAND UNTIL THE SPECIFIED INPUT CONDITION IS MET ONCE THE CONDITION IS MET PROGRAM EXECUTION CONTINUES AT THE NEXT LINE THE ROBOT S SCORBASE PROGRAM REQUIRES IF JUMP AND LABEL COMMANDS THE SCORBASE PROGRAM WILL LOOP ON THESE PROGRAM LINES UNTIL THE SPECIFIED INPUT CONDITION IS MET ONCE THE CONDITION IS MET PROGRAM EXECUTION JUMPS TO THE LINE CONTAINING THE SPECIFIED LABEL Q How many parts can be milled by executing program USER12 SBP THE PROGRAM SETS THE VARIABLE CYCLES 2 MEANING THAT 2 PARTS WILL BE MILLED PROVIDED THAT AT LEAST TWO PARTS ARE IN THE FEEDER Worksheets Answer Key 25 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off materials returned
44. f not pressed while the red Rob1 output button should be on pressed 2 Inthe SCORBASE Digital Outputs dialog bar click the box for output 8 Look at the red Robl input button and at the LED for output 8 on the robot controller Button off Click on the output 8 box again Button on 3 Inthe WPLM toolbar click on the blue Robl output button Look at the SCORBASE Digital Inputs dialog bar and at the LED for input 8 on the robot controller Button on Click on the blue Rob1 button again Button off Testing the Pneumatic Vise In the WSLM toolbar click on the Acc2 lower output button nr The vise should open d Click on this button again The vise should close Teacher s Guide 0203 23 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 Inspection In addition to a safety check and an inventory check at the start of every working session a routine inspection of the system should also be performed regularly in the following order 1 Before you power on the system check the following items The installation meets all safety standards devices and equipment are positioned properly and securely in place All cables and I O wires are properly and securely connected Cable connector screws are fastened No people are within the robot s working range 2 After you have switched on the PCs and the controllers check the following items The power and motor LEDs light up
45. h parts AS LONG AS THERE ARE PARTS IN THE FEEDER AND INPUT 7 STAYS ON THE ROBOT WILL MOVE TO PICK UP PARTS FROM THE FEEDER AND WILL DELIVER THEM TO THE SORTING BIN Worksheets Answer Key 11 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Task 6 9 Team Discussion and Review Q What are the differences and similarities of off line and on line execution of a robot program OFF LINE SIMULATION SCROLLS THROUGH CHECKS PROGRAM COMMANDS ON LINE ROBOT MOVES IN RESPONSE TO PROGRAM COMMANDS Q What is the purpose of using conditional IF commands in a robot program CONDITIONAL COMMANDS CAN DIRECT PROGRAM EXECUTION TO A SPECIFIC LINE LABEL ACCORDING TO THE STATE OF INPUT SIGNALS WHICH ARE RECEIVED BY THE ROBOT CONTROLLER THIS ENABLES THE ACTIVATION OF DIFFERENT OPERATIONS IN THE WORKCELL MAKES PROGRAMMING FLEXIBLE MAKES PROGRAM RUN ONLY IF CERTAIN CONDITIONS ARE MET Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets Answer Key 12 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Activity 7 Worksheets Answer Key Recording Robot Positions for Mill Tending Inventory and
46. he most important safety rules to remember during operation of the mill Worksheets 2 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Activity 2 Worksheets Preparing the Mill for Automation Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u Robot and Controller USB Computer with SCORBASE software spectraLIGHT mill and controller box Pneumatic vise and spacer Computer with WSLM mill control software NC programs MILLA NC and MILLB NC Parts feeder and sorting bin Wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 2 5 Running a FMS Milling Program Q Describe or sketch the location of the vise as a result of the codes which have been added to program MILLB Worksheets 3 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Task 2 6 Team Discussion and Review If you were to run program MILLB twice in succession what will happen to the vise when the program starts the second time Q Why does the mill in the FMS require a pneumatic automatically operated vise Inventory and Safety Checklist Item
47. he programs do not exist write and save them to the WPLM directory x a ind pol pu mE ard poiat point Aag gp Guide NICE AL EECHI RICE HI ER CHI MY uH i Ewcan lWc derer tnu ER at diagona to Zm gnd diagonal L Engl up M i moye to origin off end of program program Moe e machimahle wax bleck Initialize stock to X H vB Dea tool up B 1 5 move to int le on i serre int int J xZ x1 5 machinahlm wax inialize ttk 3nd point th OD LI n pfe ts ete pauzu nea aD Hei fool up ti Plus pause la En ist imt spindle on qs 1001 Ted polny point tn iet Let diagonal line return En imt 2nd diagonal ies tanl up 0 1 maua to oripis spindis off muum to lna umlaad 9 zeremdzr unload cud rin n is Lon ad end of progran Oat sd 57 wg r 5E Lr ae Initialize stock E H otesl ug 1 TH Eb 5 Yy 8 15 En laoad z unlnad zitinn F2 o peurzr 2 zumcen r load 2 2 Va mvn to ztart point i E potesl paura im a Gi 21 8 Potesl up tus TH Kh 5 Y 4 15 P mera En laad uninad pecition Gad F2 pamu
48. i e 16 SC ORBO TER ROBO s 16 Gravity Feeder with e dedo en aga i a ae 17 Sorting BIN E 18 Controller USB Cable Connections tide eto eet eene rng Ene dels 18 SCORBASE Software Installation and Activation 19 Testing Input from the Gravity Feeder ae a a a i eas 20 spectraLIGHT Mill and Mill Controller eee 20 ui oU DA M 20 Machining Center Cable Connections eese 22 Robot Mill Input Output Connections eene 22 WSLM Control Software Installation and 22 Testing Robot Mill Input Output Communication eee 23 Testing the Pneumatic 23 HOS PO CUO ties puit Neat ecc 24 Robot Positions in the FMS Cell ie sett eset etae roten esa eere 25 NC Programs Required for 21 Solutions SCORBASE Programming Tasks 28 WSLM NC Programming 30 Pre Test Answer Sheet Pre Test Pre Test Answer Key Post Test Answer Sheet Post Test Post Test Answer Key Worksheets Worksheets Answer Key Teacher s Guide 5 Flexible
49. ic position defined by the operator A fixed reference position d The robot s work environment 10 What is shown in the figure below a A vise b A robot arm A parts feeder d A gripper 11 What does on line programming mean a Program has one main routine b The robot controller is used for recording robot positions Positions are taught in a line d Programmer makes a flow chart of the robot task Post Test Answer Key 3 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 12 13 14 15 16 17 What is a robot position set of coordinates which define the robot s home b A set of coordinates which define the robot s location in space c XYZ d Joints After the robot has placed the raw material in the milling machine what will it do a Turn on the mill b Turn off the mill c Send a signal to the mill d Receive a signal from the mill Which of the following can be included in a robot program a Input commands b Remarks c Robot arm movement commands d All of the above What is a relative position a A position near the robot home b A set of coordinates which defines the robot s location in space c set of coordinates which defines an offset from another position d A position for another device in the robot s workcell What is the function of a parts feeder a To put parts in the robot s gripper b To sort the
50. inear to position 13 speed 5 3 Close Gripper 26 Go Linear to position 3 speed 2 10 Go Linear to position 12 speed 5 27 Close Gripper 11 Ge Position 23 fast mi 28 Go Linear to position 13 speed 2 12 G Linear position 13 speed h 13 Ga Linear ta position 3 apeed 2 29 Go Linear to position 23 speed 5 14 Open Gripper 30 15 Go Linear to position 13 speed 2 31 Remark TAKE PART TO BIN 16 Go Linear to position 23 speed 5 32 Go to Position 98 fast 17 WaT 100 10 the of seconds 33 Go to Position 14 fast 18 Go Linear to position 13 speed 5 tas 18 Go Linear to position 3 speed 7 sa EDI to position 4 speed 2 20 Close Gripper betes aha 21 Linear in position 13 speed 7 36 Go Linear to position 14 speed 5 27 Go Linear to position 23 speed 5 af c 23 Go lo Position 98 fast 38 Remark GO HOME 24 Ga ta Position 14 fast 39 Go to Position 98 fast Zh Go Linear position 4 speed 2 26 Open Gripper 2T Ge Linear to position 14 speed 5 zB Ge to Position 98 fast 8 ta Position 12 fast Figure 23 Robot program created in Activity 9 Figure 22 Robot program created in Activity 8 Teacher s Guide 28 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 2 If Input 7 on jump to TAKE PART 2 Set Variable COUNTER 0 3 Jump to CHECK_PART_AVAILABILITY Pp ier als 4 TAKE_PART 5 Golo Position 3H fast 5 Open Gripper
51. ing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Activity 8 Worksheets Answer Key Inventory and Safety Checklist More FMS Robot Programming Item Start of Session SCORBOT ER 4u robot and Controller USB Computer with SCORBASE software spectraLIGHT mill and controller Pneumatic vise and spacer Computer with WSLM mill control software NC program EXCHANGE NC Parts feeder and sorting bin Wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 8 7 Team Discussion and Review Q Describe the similarities and difference between a WAIT command and an IF JUMP command block Give an example of how each can be used in FMS operations WAIT WILL HALT PROGRAM EXECUTION FOR A SPECIFIED AMOUNT OF TIME A WAIT COMMAND CAN BE USED TO ENSURE THAT THE ROBOT PAUSES FOR A MOMENT SAY 2 SECONDS BEFORE MOVING TO ANOTHER POSITION AN IF JUMP COMMAND WILL ALSO CAUSE PROGRAM EXECUTION TO PAUSE BUT ONLY UNTIL A CERTAIN CONDITION IS MET AN IF JUMP COMMAND CAN BE USED TO MAKE SURE THE ROBOT DOES NOT PICK UP A PART FROM THE FEEDER UNLESS THE INPUT IS ON Worksheets Answer Key 15 0203 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 Inventory and Safety Checklist
52. ition 30 Why should you execute a dry run of a robotic program a To avoid damaging materials or equipment b To make sure the robot can perform the operation without damaging materials c To measure the time it takes to perform the operation d All of the above 31 What is the safest way to stop the robot system in an emergency a Turn off the controller b Turn off the computer c Press the red Emergency button d Pull the plug out of the socket 32 Where are robot programs stored a In the robot b In the computer c In the controller d of the above 33 To move the robot gripper from position A to position B which joint must you move refer to the diagrams at right a Elbow b Base c Roll d Gripper 34 When initializing the workpiece the cutter is brought to the top front left corner of the workpiece a True b False Post Test Answer Key 7 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 35 The robot requires only one movement command to go from the parts feeder to the vise of the milling machine a True b False 36 When the milling machine finishes cutting what will it do a Turn on the robot b Turn off the robot c Send a signal to the robot d Receive a signal from the robot 37 A pneumatic vise opens and closes by means of a Output signal b Air pressure C A piston d All of the above 38 What is another term for Cartesia
53. ke Part from Feeder If Input 8 OFF YES Place Part in Vise Turn ON Output 8 Move away START MILL CNC program Open Vise M10 Output Low M26 Vise to Load Unload Position Output High M25 If Input Low YES Output Low M26 Close Vise M11 Pause Milling Return to Load Unload Position Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off materials returned to proper place Lab station is clean Worksheets Answer Key 22 0203 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 Part Loaded Activity 11 Worksheets Answer Key More Robot and Mill Handshaking Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot and Controller USB Computer with SCORBASE software spectraLIGHT mill and controller Pneumatic vise and spacer Computer with WSLM mill control software NC program EXCHANGE NC Parts feeder Wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 11 9
54. l controller turned off All materials returned to proper place Lab station is clean Worksheets 26 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Activity 13 Worksheets Running a FMS Production Cycle Inventory and Safety Checklist Item Start of Session SCORBOT ER 4 robot and Controller USB Computer with SCORBASE software spectraLIGHT mill and controller box Pneumatic vise and spacer Computer with WSLM mill control software Parts feeder and sorting bin 3 or more wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 13 2 Executing a Dry Run of the Production Cycle Q How many production cycles should be completed when a single cycle is executed Explain Worksheets 27 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Task 13 4 Executing an Actual Production Cycle Q How many production cycles were completed What causes production to stop Q How many production cycles were completed What causes production to stop Worksheets 28 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200
55. lion Organizes and Maintains Information Interprets and Communicates Information Uses Computers to Process Information Personal Qualities Responsibility Self Esteem Sociability Sl Management Integrity Honesty Teacher s Guide 0203 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 About the TEAM Activities Book The Activities Book is a lab manual which contains 15 Activities each of which can be completed in one 45 minute lab session Each activity begins with several lists Objectives are the goals students will achieve SCANS Skills are the competencies students will develop Materials are the specific items students will need for each activity The Overview section introduces the students to the subjects which will be explored in each activity The Procedures contain a series of Tasks or operations The first time an operation is to be performed instructions are given in a tutorial manner In subsequent tasks students should be able to perform these operations without guidance Many tasks are best performed when each team member takes on a different role One student may for example handle the hardware while another student manages the software The activities are designed so that students can switch roles and repeat tasks thereby allowing everyone more hands on time Questions and tables for entering results and observations appear throughout the tasks Que
56. m 1 1147 d t amp mm 5297 14 5 3 D 254mm 1 1 Figure 13 Poser Carne Poms ia Ar eed e EI a i sscan foe Cata a mea m T Tg d SHOOT OO a Figure 14 Teacher s Guide 0203 21 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 Machining Center Cable Connections Connect the machining center components to each other according to the instructions in the spectraLIGHT 200 Machining Center User s Guide Robot Mill Input Output Connections Using the interface cable 9 pin connector on one end and exposed wires at the other end connect the robot and mill Connect the 9 pin connector to the TTL I O connector on the rear of the mill Controller Box Connect the exposed wires to the Controller USB I O terminals as follows Pin4 Orange wire to Controller USB input 8 a Pin 7 Purple wire to Controller USB output 8 a Pin 9 Blue wire to ground For more information refer to the documentation supplied with the machining center and vise WSLM Control Software Installation and Activation Install the WSLM mill control software according to the instructions in the spectraLIGHT 200 Machining Center User s Guide The WSLM 200 mill controller software application window is shown in Figure 15 LU 1 Figure 1
57. m Discussion and Review Q What is the purpose of recording and using relative positions RELATIVE POSITIONS ARE USEFUL WHEN PROGRAMMING THE PATH OF THEROBOT FOR PICK AND PLACE TASKS FOR EXAMPLE A RELATIVE POSITION DEFINED AS A VERTICAL OFFSET OF A FEW CENTIMETERS FROM THE PICK POSITION WILL ENABLE THE ROBOT TO APPROACH AND LEAVE THE PICK LOCATION WITHOUT HITTING OTHER EQUIPMENT IN THE SYSTEM IF THE PICK REFERENCE POSITION HAS TO BE ADJUSTED AND RERECORDED IT WILL NOT BE NECESSARY TO READJUST AND RERECORD THE RELATIVE POSITION Worksheets Answer Key 9 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 0203 Q How can relative positions be recorded and used for placing parts in different compartments in the sorting bin ONE ABSOLUTE POSITION SUCH AS POSITION 4 IN THIS ACTIVITY CAN BE RECORDED AS A REFERENCE POSITION POSITIONS FOR THE OTHER COMPARTMENTS IN THE BIN CAN BE RECORDED AS RELATIVE TO POSITION 4 BY OFFSETS ON THE X AND Y AXES THE OFFSET DISTANCE CAN BE MEASURED BY MEANS OF A RULER AND ENTERED IN THE TEACH POSITIONS EXPANDED DIALOG BOX Q Which positions in the FMS cell require extreme precision and which positions do not PICK UP FROM FEEDER AND PLACEMENT IN VISE MUST BE VERY EXACT PLACEMENT IN BIN CAN BE SLIGHTLY LESS PRECISE RELATIVE POSITIONS ABOVE THE ABSOLUTE REFERENCE POSITIONS CAN BE SET AT VARYING OFFSET DISTANCES WITHOUT AFFECTING OPERATION Inventory and Safet
58. m has been designed in recognition of the findings of the Secretary s Commission on Achieving Necessary Skills The TEAM activities enable students to develop and reinforce both technical occupational skills the general SCANS skills which are required by all people in any job or educational environment Tasks enhance problem solving and decision making skills Cooperative learning and team work promote interpersonal and leadership skills Projects emphasize information and communication skills Acquiring these skills will prepare students to successfully meet the social economic and technological challenges of the 21st century Systems Understands Systema Monitors and Corrects Performance Designs Systems Interperaanal Participates as Member of a Team Teaches Others Mew Shilla Serves Cliants Customers Exercises Leadership Magotiates Good Deals Works with Diversity Basie Skulls Reading Writing Arithmetic Mathematics Listening Speaking 5 Competencies Technology Selechs Technology Applies Technology ta Tasks Maintains and Troubleshoots Equipment a Part Foundation Thinking Skills Creating Thinking Decision Making Problem Solving Mental Visualization Knowing How to Learn Reasoning Resources Manages Time Manages Money Manages Materiala F acilites Manages Human Resources Information Acquires and Evaluates Informa
59. materials returned to proper place Lab station is clean Worksheets 19 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Worksheets 20 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Activity 10 Worksheets Robot and Mill Handshaking Inventory and Safety Checklist Item Start of Session Controller B Computer with SCORBASE software spectraLIGHT mill and controller box Pneumatic vise and spacer Computer with WSLM mill control software NC program EXCHANGE NC Experiment I O Table Wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 10 4 Sending Output Signals To and From the Mill Q Were the output and input signals sent and received according to the reverse logic described in the Overview Worksheets 21 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Task 10 7 Team Discussion and Review Q Draw a flow chart which illustrates the commands which synchronize the mill with the robot Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot con
60. n be performed by milling machine a Moving the cutter in a straight line b Operating the robot c Moving the robot in a straight line d of the above 2 What does it mean to initialize the milling machine a Enter a name for the CNC program b Turn on the system c Define the point of origin of the material to be milled d Delete all programs in the system 3 Each time you operate the milling machine you have to create a new NC program a True b False 4 What are the coordinates of point A a 22 b 0 0 c 3 2 d 3 3 5 The robot can stop precisely when moving at a fast speed a True b False 6 In case of emergency in the milling system what should you do a Turn off the milling machine power switch b Turn off the computer power switch c Press the Esc key on the computer keyboard d Press the milling machine s Emergency Stop button Post Test Answer Key 2 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 7 Why should you do a dry run of the NC program before running the program with an actual part in the milling machine a To prevent damage to the milling machine b To guarantee safety c To prevent waste of raw materials d the above 8 Which of the following initializes the milling machine a NC program command b Operator c Robot d CNC mill controller 9 What is the robot home a The factory which produced the robot b A specif
61. n coordinates a XYZ coordinates b Joint coordinates c Robot coordinates d Mill coordinates 39 What are the NC codes for transmitting output signals a G25 and G26 b M25 and M26 c M25 and G25 d M26 and G26 Post Test Answer Key 8 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 40 What is shown in the figure below a A keyboard b A controller c A teach pendant d A control panel Post Test Answer Key 9 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Activity 1 Worksheets Getting Started Task 1 1 Safety Guidelines and Inventory Check Q Does your FMS workcell conform to safety guidelines Q List points in the system which are the most dangerous to touch Task 1 2 Identifying FMS Cell Components Refer to the actual FMS cell In the figure on the worksheet mark the following items Robot Mill vise Parts Feeder Collection Bin Worksheets 1 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Task 1 3 Team Discussion and Review Q What is the function of the robot in the FMS Q What is the function of the milling machine in the FMS What are the functions of the computers in the FMS What are the most important safety rules to remember during operation of the robot What are t
62. nter User s Guide Pneumatic Vise Refer to Figure 13 1 a amp oO N Insert two T bolts into the slot in the right clamp align and fit the T heads into the grooves in the cross slide and attach the right clamp to the cross slide Do not tighten the T bolts Repeat step 1 for the left clamp Do not tighten the T bolts Extract the 3 4 piston about half way It can be pulled out manually Place a 2 x3 wax block into the space between the two clamps Push both clamps together until the wax block securely fits between the two diagonally opposed corners of the clamps Be careful that the piston does not retract Adjust the position of the two clamps so that the left edge of the vise is approximately 3 in from the left edge of the cross slide Tighten all four bolts When the vise is mounted and full open the clearance space between the front right corner of the workpiece and the head of the piston should be in the range 1 2 to 5 8 Plug the power cord from the solenoid valve on the vise into the receptacle end of the accessory port adapter cable Remove the protective cap from the other end of the accessory port adapter cable and then plug it into the receptacle labeled ACC2 on the rear panel of the Controller Box Teacher s Guide 0203 20 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 Connect the air line from the pneumatic vise to the air supply line and regulator 3m
63. on when the feeder has been stocked with parts Task 6 9 Team Discussion and Review Q What are the differences and similarities of off line and on line execution of a robot program Q What is the purpose of using conditional IF commands in a robot program Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets 12 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Activity 7 Worksheets Recording Robot Positions for Mill Tending Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot Controller USB and teach pendant Computer with SCORBASE software spectraLIGHT mill and controller box Pneumatic vise and spacer Computer with WSLM mill control software NC program EXCHANGE NC Parts feeder and sorting bin Wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Worksheets 13 Flexible Manufacturing Sys
64. ond 27 What purpose can a variable serve in robot program a Delete a robot position b Change the program name c Count the number of times a routine has been completed d Notify the operator that the program has changed Post Test 5 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 28 What is the robot doing a Placing a part in a feeder b Taking a part from a feeder c Placing a part on a conveyor d Taking a part from a conveyor 29 Where should the robot go immediately after it moves away from this position a To an absolute position b Toa relative position c To the home position d To a drop off position 30 Why should you execute a dry run of a robotic program a To avoid damaging materials or equipment b To make sure the robot can perform the operation without damaging materials c To measure the time it takes to perform the operation d of the above 31 What is the safest way to stop the robot system in an emergency a Turn off the controller b Turn off the computer Press the red Emergency button d Pull the plug out of the socket 32 Where are robot programs stored In the robot b In the computer c In the controller d of the above Post Test 6 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 33 To move the robot gripper from position A to position B which joint must you move refer to the diagrams at right
65. owing materials for some of the activities which are not supplied with the tekLINK e Clock or timer Diskette or personal directory on computer hard drive The NC programs MILLA NC MILLB NC and EXCHANGE NC must appear in the WSLM software directory since they will be used but not written by students Refer to the section NC Programs Required for the Activities at the end of this Teacher s Guide Teacher s Guide 14 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 tekLINK Requirements To install and operate the FMS tekLINK your facility must provide the following items e Computer for robot a Minimum PC requirements Pentium II 350 MHz 64 MB RAM 100 MB available on the hard disk USB port CD ROM drive or network access for installation Recommended PC requirements Pentium III 600 MHz 128 MB RAM 100 MB available on the hard disk USB port CD ROM drive or network access for installation Operating system Windows 98 ME 2000 XP Computer for mill Hardware Requirements 586 120MHz or higher an available expansion slot 8MB RAM minimum for Windows 95 16MB recommended or 16MB for Windows NT hard drive with at least 5MB of available space 3 5 floppy drive VGA graphics display adapter and monitor Windows compatible mouse Software Requirements Windows 95 98 or Windows NT 3 51 or higher for computers Table s for robot mill and accessories AC power sup
66. p to WAIT FOR MILLING 90 TAKE FINISHED PART 41 Goto Position 13 speed 5 42 Ga Linear io position 3 speed 7 43 Close Gripper At Go Linear tn position 13 speed 2 45 Ga Linear io position 3 speed 5 AE Turn of output B 47 oc AH Ga to Position fast Goto Position 14 fast 50 Go Linear to position speed 7 51 Open Gripper 52 Go Linear io position 14 speed 5 51 Ga tn Positlon 98 inst 54 Ge to Position 12 fast 55 Set Variable COUNTER COUNTERS Jump HEPEAT ET END PRODUCTION Figure 24 Robot program created in Activity 11 Figure 25 Robot program created in Activity 12 Teacher s Guide 29 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 WSLM NC Programming Tasks ROBOT HILL HOMBSHARE line Fe el machinable wax block Initialize stock to T A Z H i Open Uis Hz i Uutpgut 1 Leu gaff ta zi H I teol up 51 GA X65 Y H 15 move load unlnad pos ition H25 Output 1 High Con to Robot rera Hait for Input Low from Robot PEZ use 2 seconda Abb i tput 1 Leu aff toa Kabot 4 Hii i Clase Ud s e GH4 Fz pause 2 seconds iload GA X8 2 YH 2 maus to start point Gl tool down Ph 2 pause 5 ilm milling Gi 731 8 tool up 51 CH T H i15 mawe toa 1d nei poe ition GH4 Fz 2 aeons Cum Load Hz eed of program ES ROOT BILL AGRONI ZATION
67. plication you designed and present a copy of the program s you wrote Worksheets 31 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets 32 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Activity 1 Worksheets Answer Key Getting Started Task 1 1 Safety Guidelines and Inventory Check Q Does your FMS workcell conform to safety guidelines THE ANSWER SHOULD BE YES Q List points in the system which are the most dangerous to touch ROBOT GRIPPER MOVING PARTS JOINTS BELTS GEARS MILL CUTTING TOOL SPINDLE POWER CONNECTORS Task 1 2 Identifying FMS Cell Components Refer to the actual FMS cell In the figure on the worksheet mark the following items Robot Mill vise Parts Feeder Collection Bin CNC Mill Worksheets Answer Key 1 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Task 1 3 Team Discussion and Review Q What is the function of the robot in the FMS HANDLES PARTS MATERIALS
68. ply A power outlet strip with on off switch is recommended Shop compressed air supply for the pneumatic vise Teacher s Guide 15 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Overview Unpacking Tables Installation The system should be installed and checked according to the instructions in the order presented in the following pages Although system configurations can vary the setup defined here will enable students to perform the tasks in the FMS Activities Book User manuals are provided for each of the main components of the system SCORBOT ER 4u Controller USB SCORBASE Teach Pendant for Controller USB and the spectraLIGHT Machining Center Refer to these manuals for complete details on installing configuring and operating the hardware and software Before installing the equipment examine it for signs of shipping damage If any damage is evident contact your freight carrier and begin appropriate claims procedures Make sure you have received all the items listed on the shipment s packing list If anything is missing contact your supplier The tables must be stable and sturdy enough to support the robot mill controllers computers and accessories For personal safety and sufficient access to the tekLINK from all sides a free area of at least meter around the tables is recommended Place the tables within reach of the power supply Place the computers and controllers on the PC
69. ra 2 zacaen r sad nf progran Figure 20 Teacher s Guide 27 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 SCORBASE Programming Tasks 1 CHECK PART AVAILABILITY 2 7 on jump io TAKE PART 3 Jump to PART 4 TAKE Goto Position 97 fast T Go to Position 12 fast Linear to position 2 speed 2 9 Clase Gripper 10 Go Linear to position 12 speed 5 11 Go 15 Position 98 fast 12 ta Position 14 iasi 13 Go Linear to position 4 speed 2 14 Open Gripper 15 Go Linear to posithon 14 speed 5 Figure 21 Robot program created in Activity 6 2 input 7 on jump ta TAKE PART 3 Jump to CHECK PART AVAILABILITw TAKE PART 5 Open Gripper i Go te Position 97 fast T Go to Position 17 fast CHECK PART AVAILABILITY If Input 7 on jump to TAKE PART Jump to CHECK PART AVAILABILITY TAKE PART Open Gripper Go to Position 97 fast Go to Position 12 fast Go Linear to position 2 speed 2 Close Gripper Go Linear to position 12 speed 5 Remark PART TO MILL Go to Position 23 fast Go Linear to position 13 speed 5 Go Linear to position 3 speed 2 Open Gripper Go Linear to position 13 speed 2 Go Linear to position 23 speed 5 Remark WAIT FOR MILLING WaiT 100 10 ths of seconds Remark REMOVE PART FROM MILL Go Linear position 2 speed 2 25 Go L
70. rkpiece in the mill Mill computer turned off Mill controller turned off materials returned to proper place Lab station is clean Worksheets Answer Key 19 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Worksheets Answer Key 20 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Activity 10 Worksheets Answer Key Robot and Mill Handshaking Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot and Controller USB Computer with SCORBASE software spectraLIGHT mill and controller Pneumatic vise and spacer Computer with WSLM mill control software NC program EXCHANGE NC Experiment I O Table Wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 10 4 Sending Output Signals To and From the Mill Q Were the output and input signals sent and received according to the reverse logic described in the Overview THE ANSWER SHOULD BE YES Worksheets Answer Key 21 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Task 10 7 Team Discussion and Review Q Draw a flow chart which illustrates the commands which synchronize the mill with the robot Ue 4 gt al 4 ub Ta
71. roperly duct tape can be used to hold it in place or you can bolt it to the table Controller USB Cable Connections Install the Controller USB according to the installation instructions in the Controller USB user manual Do not yet connect the Controller USB to the AC power supply Numbers in parentheses refer to Figures 9 and 10 DIGITAL INPUTS ey D 0 0 156 0 0 Collector 0 0 0 0 0 0 5 6 7 8 42V Power Supply ANALOG INPUTS OUTPUTS 12 v PULL RELEASE intelitek gt gt Figure 10 Controller USB Back Panel Teacher s Guide 18 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Make sure the PC power switch is turned off Make sure the Controller USB power switch 1 is turned off Refer to the installation manual to properly connect the motors cable and the encoders cable from the robot arm to the controller and the USB cable to the computer Install the Teach Pendant and its mounting fixture according to the instructions in the Controller USB user manual Connect the teach pendant to the Controller USB Set the teach pendant AUTO TEACH switch to AUTO Connect the power cable to the POWER socket 2 on Controller USB and to an AC power source Tighten all connector screws Connect the pair of wires from the feed
72. st Start of Session Item Act 14 Act 15 SCORBOT ER 4u robot and Controller USB TP optional Computer with SCORBASE software spectraLIGHT mill and controller Pneumatic vise and spacer Computer with WSLM 1000 mill control software Parts feeder and sorting bin 3 or more wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 14 2 Final FMS Project Q Describe the application you designed and present a copy of the program s you wrote ANSWERS WILL VARY Worksheets Answer Key 29 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off materials returned to proper place Lab station is clean Worksheets Answer Key 30 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200
73. stions for discussion and review conclude each activity All questions and tables are printed on a set of Worksheets supplied with this book Students should record their answers in the worksheets or as directed by the instructor The Academics section at the end of each activity contains enrichment material such as industrial applications and opportunities or the scientific background upon which the tekLINK technology is based In TEAM tekLINKs which include hardware e g panel robot students will be directed to perform inventory and safety checks at the beginning of every working session and to shut down the system properly at the end of each activity In TEAM tekLINKs which utilize software it is assumed that students are familiar with the PC and are comfortable working in the Windows operating environment However instructions are explicit enough to allow novices to use the tekLINK s specific software Teacher s Guide 10 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 The tekLINK About the FMS tekLINK SCORBOT ER 4u Robot System Components The SCORBOT ER 4u robot system includes the following components SCORBOT ER 4u Robot Arm The SCORBOT ER 4u robot is an instructional robot which provides an inexpensive yet reliable simulation of industrial robots Controller USB The robot s controller is based a RISC 32 bit microcontroller and has a plug and play USB connection to the PC
74. tekLINK FLEXIBLE MANUFACTURING SYSTEM SCORBOT ER 4u and spectraLIGHT 200 4 i Teacher s Guide intelitek Copyright 2002 Intelitek Inc Catalog No 100351 Rev A March 2002 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200 Teacher s Guide Intelitek Inc 444 East Industrial Park Drive Manchester NH 03109 5317 USA Tel 603 625 8600 Fax 603 625 2137 http www intelitek com info intelitek com Table of Contents Introduction About the TEAM Program 7 About SCANS SKINS Eee heic cine EE a acd 8 SCANS Skills the TEAM Program 9 About the TEAM Activities Book 10 The tekLINK About the FMS tekLINK ennt nnne nnn 11 SCORBOT ER 4u Robot System Components eese 11 CNC Milling System 12 Additional Devices esaet a Eon dn Dein EC I SE DU 13 Materials Required for the Activities 14 tekEINK Requiremerits erint einem eec Rename trat ai ios 15 Lei Stal Atl OM P PE 16 OVEIVIEW ssc a DE 16 MAG EIHB 3c noo seuss oet MERE ROS 16 Mr 16 Coordinate Grd Lemiplate ie eit tes e d
75. tem 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Task 7 7 Team Discussion and Review Q Whyis it preferable for positions 12 13 23 and 14 to be recorded as relative positions and not absolute positions Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets 14 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Activity 8 Worksheets More FMS Robot Programming Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u Robot and Controller USB Computer with SCORBASE software spectraLIGHT mill and controller box Pneumatic vise and spacer Computer with WSLM mill control software NC program EXCHANGE NC Parts feeder and sorting bin Wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Worksheets 15 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date T
76. to proper place Lab station is clean Worksheets Answer Key 26 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Activity 13 Worksheets Answer Key Running a FMS Production Cycle Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot and Controller USB Computer with SCORBASE software spectraLIGHT mill and controller Pneumatic vise and spacer Computer with WSLM mill control software Parts feeder and sorting bin 3 or more wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 13 2 Executing a Dry Run of the Production Cycle Q How many production cycles should be completed when a single cycle is executed Explain TWO PARTS SHOULD BE MILLED BUT SINCE THERE ARE NO PARTS IN THE FEEDER NO PRODUCTIONS CYCLES WILL BE COMPLETED Task 13 4 Executing an Actual Production Cycle Q How many production cycles were completed What causes production to stop TWO PARTS SHOULD BE MILLED BUT SINCE THERE IS ONLY ONE PART IN THE FEEDER ONLY ONE PRODUCTION CYCLE WILL BE COMPLETED PRODUCTION STOPS BECAUSE THE FEEDER HAS RUN OUT OF PARTS Worksheets Answer Key 27 Flexible Manufacturing System SCORBOT ER 4u and spectraLIGHT 200
77. troller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off materials returned to proper place Lab station is clean Worksheets 22 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Activity 11 Worksheets More Robot and Mill Handshaking Inventory and Safety Checklist Item Start of Session SCORBOT ER 4 robot and Controller USB Computer with SCORBASE software spectraLIGHT mill and controller box Pneumatic vise and spacer Computer with WSLM mill control software NC program EXCHANGE NC Parts feeder Wax blocks Diskette or personal directory on computer hard disk The milling system conforms to the safety guidelines The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Worksheets 23 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Task 11 9 Team Discussion and Review Q In this activity the robot program concludes with commands which send the robot away from the mill Should the robot wait at the mill for the part to be returned to the load unload position Describe an application which explains your answer Inventory and Safety Checklist Item End of Session Robot at home position No o
78. y Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets Answer Key 10 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Activity 6 Worksheets Answer Key Writing and Running a Robot Program Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot Controller USB and teach pendant Computer with SCORBASE software Parts feeder and sorting bin Wax blocks Diskette or personal directory on computer hard disk The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 6 7 Executing the Robot Program Q What happens when the feeder runs out of wax blocks THE ROBOT WILL CONTINUE MOVING TO THE FEEDER AND GO THROUGH THE MOTIONS OF PICKING UP PARTS EVEN WHEN THERE ARE NO PARTS IN THE FEEDER Task 6 8 Conditional Program Jumps Q Describe the program execution when there are no parts in the feeder SINCE INPUT 7 DOES NOT TURN ON WHEN THERE ARE NO PARTS IN THE FEEDER PROGRAM EXECUTION WILL CONTINUOUS LOOP BETWEEN LINES 1 AND 2 THE ROBOT WILL NOT MOVE Q Describe the program execution when the feeder has been stocked wit
79. y of the robot arm is a measure of how close it is able to come to a target position How does speed affect accuracy Inventory and Safety Checklist Item End of Session Robot at home position No objects in gripper Robot controller turned off Robot computer turned off No workpiece in the mill Mill computer turned off Mill controller turned off All materials returned to proper place Lab station is clean Worksheets 8 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Activity 5 Worksheets Recording Robot Positions for Parts Handling Inventory and Safety Checklist Item Start of Session SCORBOT ER 4u robot Controller USB and teach pendant Computer with SCORBASE software Parts feeder and sorting bin Wax blocks Diskette or personal directory on computer hard disk The robotic system conforms to the safety guidelines The student is properly dressed for operating the FMS cell Task 5 4 Displaying and Saving Positions Q Which position 97 98 or 99 is the same as position 100 Task 5 7 Team Discussion and Review Q What is the purpose of recording and using relative positions Worksheets 9 Flexible Manufacturing System 0203 SCORBOT ER 4u and spectraLIGHT 200 Class Date Q How can relative positions be recorded and used for placing parts

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