A) Short answer/MCQ/True-False/Fill-in-the blank type questions:

1. Three steps to implement CIM are: ______________________________,

__________________________, _______________________

2. Which of the following would provide the highest holding force?

(a) Suction cup in horizontal position, movement in vertical direction

(b) Suction cup in horizontal position, movement in horizontal direction
(c) Suction cup in vertical position, movement in vertical direction.

3. CAPP is a very important component of a successful CIM system.

What does CAPP stand for?

_________________________________________________________

4. Friction grip - the gripper is completely flat, therefore a higher jaw factor
is required for calculating gripping force. What is the typical jaw factor?

(a) 4
(b) 3
(c) 2
(d) 6

5. CMMS is a very important component of a successful CIM system.

What does CMMS stand for?

_________________________________________________________

6. 31114: Bus error - is a system error message. T / F

7. 20010: Em stop state active - is an I/O and Communication error

message. T / F

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8. Draw a Venturi vacuum generator circuit. Include the following
components:
a) 3/2 single solenoid operated valve,
b) Filter,
c) Suction cup,
d) Adjustable vacuum sensor.

9. What is a sensor?
(a) Is DI1-16 in the ABB robot
(b) Is digital input for the ABB robot
(c) Can be a signal for 0 or 1
(d) Measures a physical quantity & converts it into a signal

10. In regards to D1-09 lab, if the e-stop is pressed on the main operator
panel

(a) There is no power to the robot and cannot jog

(b) Have to reset the e-stop, press MCR on, & reset the cell
(c) Have to reset the e-stop, press MCR on, press reset button on
robot controller, & then press motors off
(d) Cannot do anything because e-stop is pressed

11. If the instruction TPWrite says pick answer A below then you should
chose

(a) Do pick this answer and do not move to next question

(b) TPWrite is an instruction step which allows a message to be seen
on the teach pendant
(c) Is always followed by the TPErase instruction
(d) TPWrite allows a message to display to the teach pendant

12. During our time in D1-09 lab, we use the Teach routine for?

(a) To create in the program so that we can see the move instructions
(b) A fully executable set of instructions
(c) Never to be called in the main routine, is only there to teach points
(d) Never to be called in any routine

13. Draw the tool coordinate frame of an ABB robot to show the directions of
X, Y, and Z. of tool0

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14. Calculate the friction grip force if the object to be lifted is 7lbs & the
coefficient of friction is 0.45

15. Friction grip - The gripper has an encompassing grip, therefore a jaw
factor is required for calculating gripping force. What is the typical jaw
factor?

(e) 1.25
(f) 1.5
(g) 1
(h) 3

16. The door Limit Switch at each cell of D1-09 is part of the safety chain,
which affects both Manual and Auto mode T/F

17. If we press the e-stops on the on the robot controller & teach pendant in
D1-09, do we need to press reset button to get the robot active again?
Explain your answer with respect to S4 or S4C controller

18. Does the general stop have any affect if you block it? What happens when
you block the general stop & you are inside the cell? Do you need to press
the reset button & motors on/off button to get the robot active again?

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 19. When will the signals be set? At which point does the signal turn on?
Which signals are on?

MoveJ home, V1000,fine,tool1;

MoveL p1, V1000,fine,tool1;
MoveCDO p2, p3, v300, z30,tool1,do1,1;
MoveLDO p4,v1000,fine,tool1,do2,1

20. When will the signals be set? At which point does the signal turn on?
Which signals are on?

MoveJ p1, V1000,fine,toolZ;

MoveLDO p2, V500,z50,toolZ,do5,1;
MoveLDO p3,V300, fine,toolZ,do7,1;
MoveLDO p4,v1000,fine,toolZ,do8,1;

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B1) ABB robot programming-type question:

Answer the questions below based on the following ABB rapid program.

Main ( )

VAR num Counter1:= 0;

WHILE Counter >10 DO

PICK;
Place;
Counter1:= Counter1 + 10;
END FOR

END PROC

a) The value of the loop variable counte1 is 1 for the first Pick & Place cycle.
T/F

b) What can be the maximum value of the variable Counter1?

Answer __________________

c) What will be the value of counter1 when Pick & Place has been done for 5
times?
Answer __________________

d) How many Pick & Place cycles would be possible in total using the above
loop if the increment value changed to 3? Answer __________________

B2) TPReadNum - Read a numeric value from the teach pendant.

Write a subroutine using TPReadNum instruction together with FOR loop for
sanding 999 car bumpers by your ABB IRB1400 robot. Use :
a) Input as the TPReadNum variable,

b) Sand_part as the sanding subroutine.

c) Y as the FOR loop counter

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B3) ABB robot palletizing program:

The YYY integrator company has hired a robot consultant to write a

program to palletize their parts into a packaging tray. You are the
consultant. The program is to pick up a part PTA from the index
conveyor belt and place it on the packaging tray.
The tray is arranged into 3 columns (30 mm between parts in x
direction), 3 rows (35mm between parts in the Y direction), and
2 layers (25 mm between trays in the Z direction).
The program sets the robot arm to locate and identify the first
position as PTB (See below DWG 002 for the drop parts
sequence).
Use the orientation of the X and Y axes on DWG 002 for your
offset values.
Part gripper: Gripper opens when DO6 is high and DO7 is low,
gripper closes when DO6 is low and DO7 is high
Tray gripper: Gripper opens when DO8 is high and DO9 is low,
gripper closes when DO8 is low and DO9 is high.
a) Do not write your own program. Fill in the missing parts of the
program (See below and next 2 pages).
b) Sketch the robot envelop and create bill of materials including the
missing empty trays on the DWG 002.
c) Sketch the program routine layout.

PROC MAIN ( )
Rows := ______;
Columns := ______;
Layers :=______;
Home;
TPWrite " 3 D Palletizing Program";
WaitTime 1;
Palletize;
WaitTime 1;
Home;

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ENDPROC
PROC ___________ ( )
MoveJ pt_Home, v1000, fine, tool0;
WaitTime 1;
ENDPROC

PROC Palletize ( )
FOR _______ FROM 0 TO _____________ DO
____________;
FOR ________ FROM 0 TO ________________ STEP 1 DO
FOR _________ FROM 0 TO _________________ STEP 1 DO
! sqn_PPNP;
_______________;
MoveJ Offs (__________, (x * 0), (y * 0), (z* 100), v1000, fine, tool0;
ConfL\Off;
MoveL Offs (________, (x*______), (y*_____), (z *_______)), v1000, fine, tool0;
MoveL Offs ( _______, (x*_____ ), (y*______), (z*________)), v80, fine, tool0;
Gripper_Open;
MoveL Offs (_______, (x*______), (y*______), (z*________)), v1000, fine, tool0;
ConfL\On;
ENDFOR
ENDFOR
ENDFOR
ENDPROC

PROC Pickup ( )
_____________;
MoveJ _________,v1000,________,tool0;
MoveL _________,v80,__________,tool0;
_____________;
MoveL __________,v500, _______, tool0;
ENDPROC

PROC Depal (____________)

Home;
MoveJ rotatetool, v1000, z50, tool0;
Gripper_Open_tray;
MoveJ a_pal, v1000, z50, tool0;
MoveJ Offs (pal, 0, 0, z*__________ + 25), v1000, z50, tool0;
MoveL Offs (pal, 0, 0, z*__________), v100, fine, tool0;
__________________________;
MoveJ Offs pal, 0, 0, z*___________+25), v1000, z50, tool0;
MoveJ a_pal, v1000, z50, tool0;
MoveJ a_pald, v1000, z50, tool0;
MoveJ Offs (pald, 0, 0, z*__________+25), v1000, z50, tool0;
MoveL Offs (pald, 0, 0, z*__________), v100, fine, tool0;
__________________________;
MoveJ Offs (pald, 0, 0, z*___________+25), v1000, z50, tool0;
MoveJ a_pald, v1000, z50, tool0;
MoveJ a_pal2, v1000, z50, tool0;
MoveJ rotatetool2, v1000, z50, tool0;
___________;
ENDPROC

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 PROC Gripper_Close ( )
Reset _________;
Set ___________;
_______________________;
ENDPROC

PROC Gripper_Open ( )
Reset ________;
Set _______;
________________________;
ENDPROC

PROC Gripper_Close_tray ( )
Reset _________;
Set ___________;
_______________________;
ENDPROC

PROC Gripper_open_tray ( )
Reset ________;
Set _______;
________________________;
ENDPROC

B4)a ABB robot programming-type question:

Modify the above program (question B3) for the following addition:

The ABB robot can detect a bad part. If the parts are good, the ABB robot
will drop the parts on the packaging tray. If the parts are bad, the robot
should move to drop the parts to a reject box instead of the packaging
tray.
If the parts are bad, a detection system will send a high signal di5
to your program. (di5=1).
Use TPReadFK or TPReadNum to reset the bad bin condition &
have the function to restart program once the register has been
reset
Modify the above program. (Mark and insert the required logic
into the palletizing program. Use the appropriate IF instruction in
this case.
Write the Reject_Part Subroutine separately on this page. (Bottom
of this page). Use the position name Reject.

Reject_Part ( )

ENDPROC

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B4)b The manager has come to you with an engineering change, you are
to reorient the layers 180 degrees for each layer & now the manager
says it can be stacked up to 3 layers. Modify the program and only
write for this subroutine revision.