4MATION

DESIGN REPORT

Industrial Automation Project

Robotics and Industrial Automation – Conestoga College

Justin George
Shubham Dixit
Mayank Kumar Ramchandra
Harsh Shah

Submitted on: February 5th, 2022

Submitted to: Professor Slobodan Damjanovic
4mation DESIGN REPORT

Table of Contents
1. Introduction .................................................................................................................................... 4
2. Contents .......................................................................................................................................... 6
3. Sequence of Operation ................................................................................................................... 7
4. Technical Details ........................................................................................................................... 13
4.1. System Interlocks ....................................................................................................................... 13
4.1.1. Various Interlocks :.............................................................................................................. 13
4.2. Programable Logic Controller (OMRON PLC) ............................................................................. 14
5.2. Lessons Learned ............................................................................ Error! Bookmark not defined.
4.3. Human Machine Interface (OMRON HMI) ................................................................................. 19
4.4. HMI Screens and Navigation Structure ...................................................................................... 21
4.3. I/O Mapping ............................................................................................................................... 21
4.4. Equipment Used......................................................................................................................... 22
4.4.1. Variable Frequency Drive (VFD) .......................................................................................... 22
4.4.2. LinMot Servo ....................................................................................................................... 23
4.4.3. Electro-Pneumatic Regulator .............................................................................................. 25
4.4.3. Ultrasonic Sensor ................................................................................................................ 26
Cool Muscle Servos ....................................................................................................................... 29
4.4.3. Process Flowchart ......................................................................................................... 34
5. Control Panel Layout ..................................................................................................................... 37
6. Project Management .................................................................................................................... 37
5.1. Issues Faced .......................................................................................................................... 38
7. Conclusion ..................................................................................................................................... 39
7.1. Lessons Learned ......................................................................................................................... 41
Appendix A: PLC Hardwired I/O ............................................................................................................ 42
Appendix B: I/O Mapping...................................................................................................................... 44
Appendix C: Minutes of Meeting .......................................................................................................... 48

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Table of Figures
Figure 3.1: Layout of Sequence of Operation .......................................................................................... 8
Figure 3.2: Part Loading Station: Without and with parts placed .......................................................... 9
Figure 3.3: Matting Station: LinMot at Part Pick Position and Initial Position...................................... 10
Figure 3.4: Press Station: Part pressed and Press retracting ................................................................ 11
Figure 3.5: Inspection Station: Ultrasonic sensor providing feedback ................................................. 12
Figure 3.6: Unloading Station: Without Part aand WIth Part Picked by Vacuum Gripper ................... 13
Figure 4.1: HMI Main Screen ................................................................................................................ 21
Figure 4.2: HMI Automatic Mode Screen ............................................................................................. 21
Figure 4.3: HMI Manual Mode Navigation Screen................................................................................ 21
Figure 4.4: HMI Alarm Screen ............................................................................................................... 21
Figure 4.5: HMI Ultrasonic Controls Screen .......................................................................................... 21
Figure 4.6: HMI Manual Matting Controls Screen ................................................................................ 21
Figure 4.7: HMI Manual Press Controls Screen .................................................................................... 21
Figure 4.8: HMI Manual Unloading Controls Screen ............................................................................ 21
Figure 4.9: HMI Navigation Flowchart .................................................................................................. 21
Figure 4.10: Working Principle of Ultrasonic Sensor ............................................................................ 27
Figure 4.11: Working distance of Ultrasonic sensor ............................................................................. 28
Figure 4.12: Part Detection of Ultrasonic sensor .................................................................................. 28
Figure 4.13: Process Flowchart with Cycle Time................................................................................... 35

Table of Tables
Table 2.1: Drawing Index Number .......................................................................................................... 7
Table 4.1: VFD Specifications ................................................................................................................ 22
Table 4.2: VFD Parameter Configurations ............................................................................................ 23
Table 4.3: I/O tags of LinMot to PLC ..................................................................................................... 24
Table 4.4: Specifications of UM18-217 Ultrasonic sensor .................................................................... 28
Table 4.5: Cool Muscle Servo Motor Specifications.............................................................................. 30
Table 4.6: IO tags for Cool Muscle Servos............................................................................................. 33
Table 4.7: Process Cycle time data ....................................................................................................... 35
Table 5.1: Control Panel BIll of Material ............................................................................................... 37

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4mation DESIGN REPORT

1. Introduction
Team 4mation is in the assembly of household pair of keys. The key holder box which is durable and

secure is press locked with the use of two pins diagonally placed and they are sealed tightly to hold

them even in a drop test. With the help of SOLIDWORKS, the design of the product has been made

and the production of the design has been done using 3D printing which is used as a prototype.

Following the Planning phase, 4mation team has started the execution phase of the project where the

part matting, press and inspection after the press is done. The part is sent through machine which can

be operated in two different modes: manual and automatic. In the manual mode, the part is indexed

to each station after being placed on the indexing table and the matting, pressing, ultrasonic

inspection of the part, unloading along with the outcome of the inspection of the part is done in

sequential manner with the help of HMI screen and the written PLC logic. Push buttons on the screen

are used to achieve all the tasks of the program.

The specifications of the process have been detailed to provide an understanding of all the equipment

requirements and the tasks that are required. CX-programming software is used of the OMRON

Programmable Logic Controllers which is integrated with the OMRON CX-Designer software for HMI

design screen designs. The servo motors at each station are configured to the required positions,

speed, and accelerations.

For the execution of the project, main components had to be configured and integrated with the PLC

logic. Initially, the Variable Frequency Drive (VFD) which controls the motor attached to the indexing

table is configured to run such that it runs just once each time the hands are placed on the palm

buttons which are hardwired to run the indexing table. The major processes for the execution of the

project include matting, press assembly, inspection by ultrasonic sensor and unloading at which stage

the product can also be known to be accepted or rejected based on the inspection result.

For Matting, LinMot servo is used which is connected to the PLC with programmable I/Os. They can

be configured to different positions on the LinMot Talk Configuration software. At press, a

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pneumatically powered press is used for which the pressure can be regulated and checked to be okay.

For inspection of the press assembled part, an ultrasonic sensor is taught the two dimensions along

with their tolerance limits to detect for good parts and bad parts. At unloading, the part is then picked

by a vacuum gripper and placed on a In-Out table which moves in if the part is bad and requires rework,

or moves out, towards the operator if the part has is good. The pneumatic pressure in the system is

regulated using a Electro-Pneumatic Regulator on which the minimum and maximum pressure are set.

In this report, an in-depth analysis of the equipment is done. The configurations required and the

programmed parameters that were required of the LinMot and Coll Muscle operation is detailed,

along with the configuration of the VFD, E/P regulator and the ultrasonic sensor for inspection.

Furthermore, control panel layouts along with the mechanical layout of the machine in use is provided.

The pneumatic drawings for each component that are supplied pneumatic solenoids are shown. The

electrical drawings of the components and the PLC connections, along with the VFD, safety relays,

LinMot are given as well.

For the execution phase, the components used, and the software programs used like CX-Programmer,

CX-Designer, Control Room by Myostat, LinMot Talk Configuration were standard throughout the

production floor. Which also means the equipment in use were standard and if replaced, were

replaced with the same parts. Along with that, since the production of the prototype was 3D printed,

it was done based on the single drawing that was earlier provided. Additionally, the working

environment was kept the same throughout the design phase.

The design phase or execution phase was done with the assumptions that the team of 4 human

resources would be enough for the whole completion of the project, the technologies that the

techniques used throughout the project do not change, the team will be able to learn with the

resources provided and be able to utilize their skills and execute the design of the project, the working

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4mation DESIGN REPORT

conditions of the project do not change, and that the electrical, pneumatic and mechanical equipment

provided can be relied upon to complete the task in hand.

2. Contents
4mation team has been in the processing of the key holder casing with the objective of being able to

mate, assemble and provide the required products which fall under the dimensional tolerance limits

in the shortest cycle time possible. The objectives also include the manual and automated operation

of the processes such that human interference is minimal. We are also hoping to be able to provide

the required scalable analysis of the process, along with the lessons learned throughout the different

phases of the project. The team hopes to be able to improve upon its initial work and improve the

process to be able to provide quicker, safer, and intuitive.

The engineering tasks includes from the initial part design, which was 3D printed during the planning

phase, to the configuration of the components of the process, along with setting system interlocks in

the operation and to be able to provide with the detailed drawings of the electrical, pneumatic, and

mechanical components in the form of a report. The tasks also include programming the

Programmable Logic Controllers with the help of the OMRON CX-Programmer, designing the Human

Machine Interface (HMI) on the OMRON CX-Designer; for both manual and automated operations

along with the safety features such as alarms and program interlocks.

Throughout the process, with the automation of the station, the main measurable tasks that are

achieved are process cycle time, process efficiency with the help of inspection through ultrasonic

sensor, and programming, integration, and completion of all the process equipment and machinery

such that they work harmoniously within the scheduled period. With the help of a ultrasonic sensor

placed on the periphery of the rotary indexing table, the dimensional evaluation is done such that the

assembled part can be deemed to be good or bad, based on the if the part falls within the dimensional

tolerance limits set with the sensor.

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Sheet
No. Drawing Title Drawing Number
No.
SW-Views 1.1
1 1 of 3

2 of 3 SW- Details 1.2

3 of 3 SW-Stations 1.3

1 of 3 Station IO 2.1

2 2 of 3 2-Station IO 2.2

3 of 3 3-VFD-Safety 2.3

3.1
3 1 of 1 Pneumatic

4 1 of 1 Control Panel 4.1

Table 2.1: Drawing Index Number

3. Sequence of Operation
In the semi-automatic dial-type machine, parts are loaded onto the base fixture on the circular dial

like rotary indexing table TC. Different processes are performed for assembly and inspection of the 2-

part product at the various workstations located around the periphery of the dial. The dial indexing

machine, which is controlled by a VFD, operates with a synchronous motion, in the clockwise direction,

in which the process cycle time consists of the rotating time plus process time on each station. The

semi-automatic machine used in the project consists of 5 main stations.

The stations include loading the part, matting, pressing the parts together, an inspection of the part,

and then the unloading of the part followed by the evaluation of the press assembled part based on

the ultrasonic inspection as shown in Figure 3.1: Layout of Sequence of Operation.

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3.
Press
Station

2.
Matting
Rotary 4.
Inspection
Station
Indexing Station

Table
1. 5.
Loading Unloading
Station Station

Figure 3.1: Layout of Sequence of Operation

For the station to be operational, the enable switch must be turned on at first. The PLC logic program

must be complied and sent to the PLC, which is discusses in detail in the topic 4.2. Programable Logic

Controller (OMRON PLC). After which it is to be integrated with the HMI (discussed in topic 4.3. Human

Machine Interface (OMRON HMI)). The safety circuit is then reset. One of the two mode od operations

can be selected by the operator. For the automated process, auto mode is selected, shown even by

the green stack light being on, and the start PB is pressed such that cycle is active and is shown on the

HMI screen. These are the initial conditions that need to be met and the starting sequence that must

be followed for the process to be operational.

For the indexing table to be operational, all the cylinders must be in their home position, which

include, vertical cylinder at matting at downward position, the LinMot at initial position and the

horizontal cylinder in retracted position. For the press station, the press must be in retracted position.

For the unloading station, the vacuum gripper must be in retracted position. This can be achieved

during the process as well by pressing the Home PB on the HMI screen. For indexing the table each

time, the operator must be placing his hands on the palm buttons, by which the table is indexed just

once. For the next indexing, the palm buttons must be connected and disconnected again.

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All parts are initially placed on the indexing table which has nests to place the base part and the sliding

mate plate which is used to keep the top part or the cover. This is further explained in detail.

1. Loading station

After the product has been produced and the dimensions of the part meet the nesting and

the mating pate requirements to be placed, the base is placed on the nest and the cover/top

part is placed on the mating plate which is slid on top of the base/nest. After the placement,

the Weiss rotary indexing table is turned with the help of normally closed 2-hand palm buttons

placed on both sides of the frame of the station. Initially mate plate is at extended position

and before the base part is loaded, after which it is retracted to be positioned above the base

part.

Figure 3.2: Part Loading Station: Without and with parts placed

2. Matting station

Matting station consists of a LinMot servo that can be configured to move into the required

positions with the help of the programmable I/Os, X and Y grippers to grip top part, horizontal

cylinder to extend mate plate and a vertical cylinder which holds the base part in position. At

the start, LinMot servo is homed and set to initial position with both the grippers open,

horizontal cylinder in retracted position and vertical cylinder in the downward position.

The part placed on the retracted mating plate is picked up by moving the LinMot to the pick

position and is picked with the help of two double-acting cylinders which powers the X and Y

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grippers. Grippers will grip the part from all four sides and the LinMot servo is moved back to

the initial position. Then the horizontal cylinder is extended to extend the mate plate,

following which the horizontal cylinder retracts. The LinMot moves to the matting position

with the top part and the grippers are opened for the part to be placed on to the base part.

After placing the part, LinMot moves to initial position and the vertical cylinder which has

been holding the part is retracted to its down position. The position status of the mate plate,

vertical cylinder is given by the proximity sensors while the LinMot has programmable status

bits.

Matting procedure only starts if the mate plate is in the retracted position and the LinMot

servo has been homed after it has been initially switched on.

Figure 3.3: Matting Station: LinMot at Part Pick Position and Initial Position

3. Press station

After the part reaches the press station, the press station’s work involves the pressing of parts.

The press station has a double-acting solenoid, which performs pressing and is kept on

retracted position at starting of press. The potential force of a pneumatic press comes from a

pressure regulator. An electrical charge sets the machinery into motion, feeding compressed

air into cylinders connected to the actual press mechanism. When the gas fills the cylinder,

the resultant pressure forces the movement downward of the press mechanism and parts are

pressed together.

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4mation DESIGN REPORT

When this movement is complete, the air pressure helps in retracting the press to its initial

position. The press station has a reed switch for its position and a pressure switch to verify if

the pressure sent to the okay for the operation. Additionally, there is a proximity sensor that

checks if the mate plate is in extend position.

For the press station to be operational, the mate place must be in extended position and the

mating must be complete.

Figure 3.4: Press Station: Part pressed and Press retracting

4. Inspection station

The purpose of the inspection station is to determine whether the product meets the

established design standards. Inspection examines whether the actual dimensions of a

mechanical part are within the tolerance limits taught to the sensor prior to inspection

process. Initially, the ultrasonic sensor is taught the two different positions, using the window

mode. This is further discussed in the topic 4.4.3. Ultrasonic Sensor. When the part is present

at the station it examines it, and a decision is made whether the item falls in between the two

taught positions. The inspection involves a binary decision, in which the item is deemed either

acceptable or unacceptable. An ultrasonic sensor measures dimension of a part. Measured

dimensions are then compared to the tolerance limit and a decision is made.

For the ultrasonic station to be inspecting a part, the mate plate must be extended.

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Figure 3.5: Inspection Station: Ultrasonic sensor providing feedback

5. Unloading station

Parts from the inspection station come to the unloading station where the assembled part is

picked up using a vacuum gripper which is attached to a cool muscle servo motor for the

vacuum gripper to be moving in horizontal X axis, moving the vacuum gripper. The part is then

transferred to a rectangular horizontal In-Out table which moves in Y axis. The table extended

or retracts according to the inspection result from the ultrasonic sensor. Until the part is nor

placed on the In-Out table, it stays in the middle of the sliding area waiting for part. If the

product is within the tolerance limits, the table is extended and if not, the product is retracted,

meaning that it requires rework.

For the process to be stopped, the stop push button can be pressed on the control panel. It will then

stop the automated process until the auto mode and cycle active are started.

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Figure 3.6: Unloading Station: Without Part aand WIth Part Picked by Vacuum Gripper

4. Technical Details
4.1. System Interlocks
System Interlocks is to arrange the control of machines or devices so that their operation is

interdependent to assure their proper coordination. It prevents the functioning of a system or a

process until its prerequisite(s) are met.

4.1.1. Various Interlocks :

a. Homing Procedure: Homing is an automated process that returns the servo motors and

actuators to initial/safe position such that the operation of the indexing table can be deemed

safe. The initial position of devices in cycle is determined by homing routine. In homing routine

system determines state of each component with reed switch and sensors.

In HMI, home screen there is a dedicated home button to send devices in home position.

Another way to send devices to home position is to manually press push buttons on manual

control of each station so that they satisfy the required homing positions for the indexing table

to be rotated without colliding with another actuator gripper. The indexing table will not be

operational until the homing has been complete, and the operator has his hands on the palm

buttons. The following conditions are to be met for homing to be completed:

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4mation DESIGN REPORT

• Matting Station: LinMot is powered on and such that it can be set to home position

(discusses further in 4.4.2. LinMot Servo). Gripper X and Y are in open position such

that it is ready for part pick up. Vertical cylinder is in the retracted downwards

positions, without interfering with the indexing table. The horizontal cylinder is in

retracted position such that it doesn’t collide with the fixtures on the rotary table.

• Press Station: Press is to be in retracted position such that it is not colliding with the

base plate when the indexing table is to be rotated.

• Unloading Station: The vacuum gripper must be in retracted position. The In-Out

Table must be in home position so that the assemble part can be kept.

b. Air Pressure: The press operation cannot start unless adequate air pressure exists. Press

requires certain level of air pressure to press part properly.

c. Part Presence: An operation cannot start until a part is detected in the workstation. At any

station operation will not perform if part is not detected at the station.

d. Permissive Interlock: PLC logic that prevents a sequence of operation proceeding unless the

conditions of the permissive are fulfilled. In our system. Press cycle will not work unless

matting cycle is complete. Cool muscle servo table will not move unless part is passed through

inspection.

e. Faults: If a fault appears in the system, the system will not work unless the fault has been

cleared.

f. Safety Reset: If the safety is compromised, either by pressing the E-stop or when the system

is initially enabled, the safety must be reset for the safety circuitry to be okay.

4.2. Programable Logic Controller (OMRON PLC)

OMRON CX-One SYSMAC CJ1M-CPU11 PLC is used with Toolbus network type via RS-232 serial

communication. It is connected to COM4 port with a baud rate of 115200. CPU 11 has 32k words data

memory, 5k steps user program, 160 I/O points with maximum of 10 I/O units. The PLC has fast

execution time of around 100 ns and is compact in size.

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4mation DESIGN REPORT

There are 2 DC input and 2 DC output modules which are hardwired to the stations and the PLC, along
with an analog output unit. The PLC logic is written to be used in automatic and manual modes. The
hardwired Common Area I/O tags are given in the

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4mation DESIGN REPORT

4. Conclusion
Team 4mation is in the assembly of household pair of keys. With the help of SOLIDWORKS, the design

of the product has been made and the production of the design has been done using 3D printing which

is used as a prototype.

Following the Planning phase, the team started on the execution phase of the project where the part

matting, press and inspection after the press is done. The part is sent through machine which can be

operated in two different modes: manual and automatic. Push buttons on the screen are used to

achieve all the tasks of the program on manual mode while for automated mode, the process is semi-

automated with the operator having to provide palm button disconnects to VFD after each process

completion.

The major processes for the execution of the project include matting, press assembly, inspection by

ultrasonic sensor and unloading at which stage the product can also be known to be accepted or

rejected based on the inspection result.

The specifications of the process had been detailed to provide an understanding of all the equipment

requirements and the tasks that are required. CX-programming software is used of the OMRON

Programmable Logic Controllers which is integrated with the OMRON CX-Designer software for HMI

design screen designs. The servo motors at each station are configured to the required positions,

speed, and accelerations.

For the execution of the project, main components had to be configured and integrated with the PLC

logic for which detailed analysis of the equipment and the configuration are given.

For Matting, LinMot servo is configured with the OMRON PLC. They can be configured to different

positions on the LinMot Talk Configuration software. At press, a pneumatically powered press is used

for which the pressure can be regulated and checked to be okay. For inspection of the press assembled

part, an ultrasonic sensor is taught the two dimensions along with their tolerance limits to detect for

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4mation DESIGN REPORT

good parts and bad parts. At unloading, the part is then picked by a vacuum gripper and placed on a

In-Out table which moves in if the part is bad and requires rework, or moves out, towards the operator

if the part has is good. The pneumatic pressure in the system is regulated using a Electro-Pneumatic

Regulator on which the minimum and maximum pressure are set.

In this report, an in-depth analysis of the equipment is done. The configurations required and the

programmed parameters that were required of the LinMot and Coll Muscle operation is detailed,

along with the configuration of the VFD, E/P regulator and the ultrasonic sensor for inspection.

Furthermore, control panel layouts along with the mechanical layout of the machine in use is provided.

The pneumatic drawings for each component that are supplied pneumatic solenoids are shown. The

electrical drawings of the components and the PLC connections, along with the VFD, safety relays,

LinMot are given as well.

For the execution phase, technologies used include CX-Programmer, CX-Designer, Control Room by

Myostat, LinMot Talk Configuration were standard throughout the production floor. Which also

means the equipment in use were standard and if replaced, were replaced with the same parts. Along

with that, since the production of the prototype was 3D printed, it was done based on the single

drawing that was earlier provided. Additionally, the working environment was kept the same

throughout the design phase.

The execution phase has been done with the assumptions that the team of 4 human resources would

be enough for the whole completion of the project, the technologies that the techniques used

throughout the project do not change, the team will be able to learn with the resources provided and

be able to utilize their skills and execute the design of the project, the working conditions of the project

do not change, and that the electrical, pneumatic and mechanical equipment provided can be relied

upon to complete the task in hand.

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4mation DESIGN REPORT

The measurable data of the process including the process cycle time was found on the automation

process of the which averaged to 42.8 seconds. The dimensions that are taught to the ultrasonic

sensor have also seem to be around tolerance limits of 2 mm.

7.1. Lessons Learned

• Throughout the project the different components and the different ways of integrating them

with the PLC and HMI interfaces were learned and the configuration of the components were

understood with their applications as well.

• The team has been through different stages of bonding and collaboration for the completion

of the project and the understanding the automated processes and the components required

from the start of the project to the end of it is better understood

• The servo motors and the pressure regulator configurations were studied in depth and the

programming of the logic for each was of the components there done sometimes on trail and

error basis, along with the help on manual.

• The system interlocks and their requirements were highlighted with the help of the safety

features and the automated process requirements.

• The stages required for the successful completion of the project was well understood from

the initialization the monitoring and controlling phases, along with the closing phase.

• The importance of collaboration for the completion of the project with the limited resources

provided was understood. The necessary steps required for overcoming the drawback and

issues were delt with.

• The issues with he assigned schedule and the actual schedule had to be addressed so that the

component’s configurations are completed on/ before time.

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Appendix A: PLC Hardwired I/O.

Programming on the CX-Programmer software is done with relay ladder logic with contacts used as

the inputs for the output relays. The ladder logic program is added to the common area I/O tags are

to be monitored in the memory section of the structure tree through which we can access the program

logic For the PLC logic to be run initially, the safety circuit is to be reset by switching it on. The PLC is

to be set at online with the Work Online button on the toolbar. The program logic is written in sections

with the code ending in END instruction. For programming without errors, a section is dedicated for

the END command after all the logic is written. The programmed logic is compiled and then transferred

to the PLC. With the program can be kept in operation when the logic in CX-Programmer is on Monitor

mode.

The program can be modified by right clicking and selecting Online Edit, which needs the changes to

be sent after the selected rung(s) are edited.

The logic is run in the order of the sections. They can be rearranged by dragging them in the order that

is required. The END instruction section is to be placed at the end of the program. Any logic written

after the END instruction will not be executed. The first 4 common area IO tags are used for the

hardwired inputs and outputs. For the tags to be linked to the HMI and the tags required for the PLC

logic, the tags following the 4 hardwired 16 I/O slotted tags are used.

4.3. Human Machine Interface (OMRON HMI)

The OMRON NS5_SQ00B-V2 NS-Series HMI is a 5.7-inch color LCD screen with 320x240 pixels. It is

connected by a RS-232 serial communication port A and port B and an USB Slave with the additional

provision for a memory card. The HMI is designer on CX-Designer software which can be used to

connect with the HMI screen attached on the Control Panel.

The command buttons, Push buttons and status light shave been used to design the HMI screens. The

Screens have been designed with the navigation or screen switch button on the right side of the screen

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and with E-Stop status light on each screen. Ideally the alarm is shown on the bottom of the screen if

there is an alarm raise doing the process.

For the HMI to work with the integration of PLC that is designed, tags have been created such that the

process can respond to the PLC logic. The HMI tags linking to the PLC program is given in the

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Appendix B: I/O Mapping.

To integrate the HMI to the PLC, firstly, the communications setting in the system section of the

project workplace task should be verified. The serial port should be showing the PLC name with the

host name same as the PLC name and using NT Link (1:N) protocol. The type should be SYSMAC-PLC

The NT Link (1:N) unit number must be set to 0 as the PLC will be set to 1. Make sure the PLC has the

mode of protocol. Secondly, the PT option in the toolbar is selected and in PT Transfer setting,

communication route of passing through PLC is unchecked and the Direct Data Transfer to

NS/Computer is selected. In the communication method, USB is selected.

After this, the Transfer [to PT] is selected and click OK when prompted on the request to restart the

NS. The HMI screen will receive the data and show ‘connecting…’. Press on the two ends of the HMI

screen and selected Communication setting. Move to the 2 tab of the screens and select the memory

type to be Host Link in the drop-down list. Select Write option and press Yes till it restarts. It will show

you the HMI screen that has been designed on the CX-Designer.

4.4. HMI Screens and Navigation Structure

4.3. I/O Mapping

The I/O tags used are mainly common area I/O tags and they are given in the

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Appendix B: I/O Mapping.

4.4. Equipment Used

4.4.1. Variable Frequency Drive (VFD)

Electric motors that use alternating current rotate at a rate determined by the number of poles inside

the motor and the power supplied. A motor's frequency (measured in Hertz) is proportional to its

revolutions per minute (RPM). The greater the frequency, the faster the RPM or rotation speed of the

engine. A variable frequency drive (VFD) is a type of motor controller that controls the frequency and

voltage of an electric motor's power supply. The VFD may also control the motor's ramp-up and ramp-

down during start and stop, respectively.

The specifications of the VFD used for the indexing table motor are:

VFD Code: ESV251N01SXB

Series: SMVector Series
Power Rating: 0.33 HP
Installed
Communications not installed
Communications:
120 VAC (double output) or 240
Input Voltage:
VAC
Input Phase: Single phase input only
Input Line Configuration: Unfiltered without disconnect
Table 4.1: VFD Specifications

4.4.1.1. VFD configurations:

VFD contains electronic programming module (EPM). The EPM contains the drives operational

memory. Parameter settings are stored in the EPM and setting changes are made to the “User

settings” in the EPM.

VFD Configuration
Code No. Name Setting Default
P100 Start Control Source 1 0
P101 Standard Reference Source 3 0
P102 Minimum Frequency 0 0
P103 Maximum Frequency 60 60
P104 Acceleration Time 1 2 20
P105 Deceleration Time 1 2 20
P106 S-Ramp Integration Time 0 0

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4mation DESIGN REPORT

P107 Line Voltage Selection 1 1

P108 Motor Overload 100 100
P109 Motor Overload Type 0 0
P110 Start Method 0 0
P111 Stop Method 0 0
P112 Rotation 1 0
P125 Acceleration Time 2 20 20
P126 Deceleration Time 2 20 20
P127 Deceleration Time for Auxiliary Ramp to Stop 20 20
P131 Pre-set Speed #1 30 0
Table 4.2: VFD Parameter Configurations

With the PLC, the VFD has an output of 3.10 bit which turns on the VFD when the pal buttons are

disengaged. A normally open contact of CR2 is connected between the terminals 1 and 11. The

contacts of the 2 hand palm buttons have 2 safety relays attached to it. The first one powers the brake

for the indexing table and the next one controls the indexing table motor power contactor K1.

4.4.2. LinMot Servo

LinMot is a 48VDC Servo Motor which gives linear motion without a transmission mechanism. The

position feedbacks are attained by the non-contact magnetic field sensor. They can be used for higher

acceleration and travel speeds without wearing parts and are more reliable and have higher power

rating when compared to Cool Muscle Servo drives. LinMot is a two-unit operation system.

It consists of a microprocessor, D to A converter, PWM control and an amplifier. The mechanical

components consist of a linear motor slider moving inside a linear motor stator powered by the

brushless DC motor. It is mounted in a vertical position with a hard stop to limit the slider in positive

position.

LinMot Controller X14 IO is connected to the PLC using a 25 on D-shell plug. It consists of 6 inputs and

outputs and 3 analog inputs. LinMot Talk is connected using RS232 serial communication on port

COM3 with the computer. LinMot Talk control panel is where all the configuration of the I/O are done.

LinMot has 7 I/O hardwired connected with the PLC, 5 inputs and 2 outputs.

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4mation DESIGN REPORT

For the process, the parameters are configured with the LinMot inputs that are connected to the PLC

outputs and the LinMot outputs to the PLC inputs, as shown in the Table 4.3: I/O tags of LinMot to PLC

Table 4.4.1: LinMot I/O Configuration. The I/O are linked at X14 I/O definitions where the motion of

the solenoids is initiated and controlled using PLC. Each position is to be set up as Switch on, homing,

Go to Initial Position, Go to Position and Error Acknowledge. The LinMot is to be homed after it is

switched on. Immediately after homing is achieved, it is sent to initial position to avoid overheating

the motor and raising an error. At State Machine Setup, the home, initial position and go to positions

can be configured for their respective positions, speed, acceleration, and deceleration. The speeds,

acceleration and deceleration are set to the default and the positions are changed with the initial

positions slightly lower than the homing position. Go to Position is linked to the Mating position and

the pickup position is linked to the initial position configuration on PLC front.

PLC Output LinMot Input Data Type Description

2.00 X14.4 BOOL LinMot_Power_ON
2.01 X14.2 BOOL LinMot_Initial_Position
2.02 X14.15 BOOL LinMot_Mating_Position
2.03 X14.3 BOOL LinMot_Error_ACK
2.04 X14.16 BOOL LinMot_PickUp_Position
PLC Input LinMot Output Data Type Description
0.03 X14.17 BOOL LinMot_TargetPOS_S
0.04 X14.5 BOOL LinMot_Homed_IND
Table 4.3: I/O tags of LinMot to PLC

Table 4.4.1: LinMot I/O Configuration

The LinMot servo requires that it be homed each that it has been switched on, in which case it is sent

home and as the homing status is active, it is sent to the initial position. The position of LinMot is

configured with the upper limit of 0 mm. Homing is done at 0 mm and initial position that the LinMot

slider is set to after Homing is at -3mm, Initial Position (Part Pick Position on PLC) set to -17 mm and

the Go to Position (Matting Position on PLC) at -23 mm.

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4mation DESIGN REPORT

The programmable outputs of the LinMot are configured to status updates on whether the servo slider

is in a target position, in which case it can be initial or go to position, and the other output status bit

is programmed to show if the servo has been homed.

4.4.3. Electro-Pneumatic Regulator

The Electro pneumatic regulator is transducer that converts 4- 20MA of current to pneumatic air

pressure. The minimum and maximum of the pressure can be set using the regulator or even through

PLC logic. The SMC ITV2000 used at the station uses 4 different connections: brown for the power

supply of 24VDC, white for input signal of 4-20mA, blue for the ground or neutral and black for monitor

output of 24VDC.

The maximum pressure output that can be sent is 1.0 MPa and the minimum can be to 0.1 while the

allowed working range is 0.005 to 0.MPa. The input signal is taken in the current form from 4 – 20 mA

with output signal being sent as analog output. It has a sensitivity of within 0.2% in full span and is

contained in a IP65 enclosure.

When the input signal is sent to the regulator, it is sent through a control circuit which supplies it to

the air supply and exhaust solenoid valves. The supply pressure is sent to the diaphragm and then to

the pilot valve. The pressure sensor monitors and gives feedback on the output pressure that is being

sent out and the error is corrected with the required setpoint pressure required. Proportional gain ca

be set to correct for the required pressure output. The default regulator has a gain setting of 9.

On the E/P regulator, there was 3 buttons one down arrow, one S and one Up arrow buttons. The

minimum pressure setting can be set as F1 which is of a power rating od 0 to 50% and the maximum

pressure f F2 can be set to 10 to 100% power rating. The difference between the maximum and

minimum can be adjustable in the range of 10 to 100% of the power rating.

For configuring the E/P regulator through PLC, the values are moved to the analog output card. The

output1 is used for the regulator on PLC. To enable the use setting of the output, a value of 1 is set to

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4mation DESIGN REPORT

D20000 word tag. The range can be set to 4 to 20 mA by sending a value of 2 to word D20001. While

the conversion of the pressure is done by setting it to max, by moving 2 to work D20002. The

conversion output is begun by turning on the CIO2000 bit. The value that is to be set on the regulator

can be moved using Data memory area word bit 100. The value must be scaled before being changed

through HMI screen. The current input of 4 to 20 mA is 0 to 4000 units without conversion or scaling.

It should be scaled such that the operator can provide the required pressure setting in Psi units.

4.4.3. Ultrasonic Sensor

An ultrasonic sensor is a device that uses ultrasonic sound waves to determine the distance between

two objects. An ultrasonic sensor sends and receives ultrasonic pulses that communicate information

about the vicinity of an item via a transducer. Echo patterns are created when high-frequency sound

waves reflect off limits. In general, on ultrasonic sensors, the less sound the object being measured

absorbs, the greater the possible sensing range

The sensor sends out a sonic pulse, which is reflected by the object surface. The time it takes for the

pulse to travel from the sensor to the object and back is measured, evaluated, and translated into

distance in the following way.

Distance = Speed of sound X total sonic sound to flight/2

4.4.3.1. Ultrasonic sensor for quality control

An ultrasonic sensor is a device that uses ultrasonic sound waves to determine the distance between

two objects. An ultrasonic sensor sends and receives ultrasonic pulses that communicates information

about the vicinity of an item via a transducer. Echo patterns are created when high-frequency sound

waves reflect off limits. In general, on ultrasonic sensors, the less sound the object being measured

absorbs, the greater the possible sensing range.

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4mation DESIGN REPORT

The sensor sends out a sonic pulse, which is reflected by the object surface. The time it takes for the

pulse to travel from the sensor to the object and back is measured, evaluated, and translated into

distance such that

Distance = Speed of Sound x Total Sonic Sound to Flight (T2) /2

Figure 4.10: Working Principle of Ultrasonic Sensor

Ultrasonic sensor used for the process is SICK UM18-217.

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4mation DESIGN REPORT

Figure 4.11: Working distance of Ultrasonic sensor

Specification of SICK UM18-217:

Operating range 20 ... 150 mm

Limiting range 250 mm
Ultrasonic frequency (typical) 380 kHz
Hysteresis 2 mm
Resolution ≥ 0.069 mm
Accuracy ± 1%
Supply voltage DC 10 ... 30 V
Power consumption (without load) ≤ 1.35 W
Connection type Male connector, M12, 5-pin
Response time 32 ms
Table 4.4: Specifications of UM18-217 Ultrasonic sensor

After completing press cycle, Part will arrive at Inspection station, Inspection is carried out by

ultrasonic sensor. Ultrasonic sensors measure the dimensions of part and gives and binary output

whether part is in acceptable tolerance limit or not.

Figure 4.12: Part Detection of Ultrasonic sensor

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4mation DESIGN REPORT

4.4.3.2. Configuration
There are different methods available to teach Ultrasonic sensor, here the sensor is configured by

Teach-in the switching window (window mode).

Window mode steps:

When the object is within the window, the switching output is set. When the switching output is
operational, the orange LED flashes

• Place the object for point (1)

• Wait for around 3 seconds when until both LEDs simultaneously.
• When the
• Place the part for point (2).
• Apply "L+" to "MF" for around 1 second when both LEDs alternately flash.

Cool Muscle Servos

Cool Muscle Servos use brushless multi-pole synchronous motor. For the positioning, a magnetic

encoder is used with 50000 PPR (Pulses per revolution). It is a 24VDC closed loop, sinusoidal, vector

driver. The controller can be used for configuring the torque, speed, acceleration, and position using

2-axis coordinates. The servo uses daisy chain network connection for it’s analog and digital I/O.

The servos connect with the interface using RS-232 serial communication with a baud rate of 38400,

with 8 data bits and one stop bit. For the configuration, Control Room software by Myostat is used.

For establishing communication, the control panel is switched off initially. Under Connection tab,

choose COM3 in the COM port, the same used for the LinMot Servo connection. The control panel is

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4mation DESIGN REPORT

powered on after which the motor information (motor type and firmware version) can be seen in the

Motor tab.

For positioning, linear encoder is used which gives position and speed feedback based on the

command given by the user. The position and speed command is sent through the controller to the

servo amplifier and the difference in setpoint to the process variable is given int eh feedback of the

encoder.

4.4.2.1. Motor Specifications

The specifications for the servo motor models CM1-C-17A30 and CM1-X-17S30 are given as follows:

Table 4.5: Cool Muscle Servo Motor Specifications

4.4.2.2. Configuration

Cool Muscle configuration is done using the Cool Muscle Language (CML) command sequence which

uses ACII characters, ending in “,” or “CR”. CML is not letter case sensitive. Motor addresses start

from 1 (M.M) to 15. The nomenclature of the register identifier elements is K for parameters, P for

positions, S for speed, A for acceleration, T for timer, M for torque and V for variables.

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4mation DESIGN REPORT

4.4.2.3. Parameter

The K Parameters that need to be changed for the horizontal movement of the vacuum gripper are:

K42.1 = 100 //Speed for the origin search

K43.1 = 100 //Acceleration for origin search
K45.1 = 102 //Direction
K46.1 = 1 //Start origin search
K48.1 = 1 //Distance

The K parameters for the In-Out Table to move into the horizontal good part or bad part are:

K26.1=1111 // Set Input Logic

K42.1 = 100 //Speed for the origin search
K43.1 = 100 //Acceleration for origin search
K45.1 = 102 //Direction
K46.1 = 1 //Start origin search
K48.1 = 1 //Distance
K49.1=15 // Set the Speed for Manual Feed
K58.1=500 // Set Software Limit CW
K59.1=-500 // Set Software Limit CCW

4.4.2.4. Cool Muscle Servo Code

Code and Parameters for Vacuum Gripper

K42.1=100
K43.1=100
K46.1=3
K48.1=0

//3 positions for the left, center and right of the vacuum gripper
P1.1=200
p2.1=2000
p3.1=3850

//Speed for the 3 different positions

S1.1=100
s2.1=200
S3.1=300

//Acceleration setting
A1.1=100
A2.1=200

B1.1
|.1 //searching origin
|1.1 //Position 0 move
|2.1 //Current position to 0
S1.1, A1.1, P1.1 //Position testing
END

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4mation DESIGN REPORT

//timer
T1.1=1500

I3.1, C2.1, C1.1

B1.1 // For Good Part Position

S1.1, A1.1, P1.1

B2.1 //For Center Position

S2.1, A2.1, P2.1

B3.1 //For Reject Part Position

S3.1, A3.1, P3.1
END

Code and Parameters for Vacuum Gripper

K26.1=1111
K49.1=15
K58.1=500
K59.1=-500

//Positions, Speed and accelerations for the 3 positions

P1.1=100
P2.1=1500
P3.1=3000
S1.1=100
S2.1=200
S3.1=100
A1.1=100
A2.1=100
A3.1=100
T1.1=1000

I3.1, C2.1, C1.1

B1.1 //Good Part Position Bank

S1.1, A1.1, P1.1

B2.1 //Home position Bank

S2.1, A2.1, P2.1

B3.1 //Reject Part Position bank

S3.1, A3.1, P3.1
END

B1.1 // Start of The Content of Bank 1

C2.1 //Calling Bank 2
C3.1 //Calling Bank 3

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4mation DESIGN REPORT

4.4.2.5. PLC Integration

The servos are connected to the PLC function with fixed scanning rate, programmable I/s ad using

arithmetic and logic functions. The hardwired programmable I/O tags of the Cool Muscle Servo

are linked to the inputs and outputs on PLC as shown in the Table 4.6: IO tags for Cool Muscle

Servos.

PLC Output Cool Muscle Servo: Vacuum Gripper

Tag Rack Location Data Type Usage Description
2.10 Slot 3 BOOL Out CMS_Vac_Grip_Left
2.11 Slot 3 BOOL Out CMS_Vac_Grip_Right
PLC Output Cool Muscle Servo: Unload
2.13 Slot 3 BOOL Out CMS_Unload_Home_POS
2.14 Slot 3 BOOL Out CMS_Unload_Good_Part_POS
2.15 Slot 3 BOOL Out CMS_Good_Part_POS
Table 4.6: IO tags for Cool Muscle Servos

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4mation DESIGN REPORT

4.4.3. Process Flowchart

Palm Buttons engaged after Press is retracted

STEP 0
Press Start PB
(Auto Mode) STEP 6
Part at Inspection

Green Light ON
If the ultrasonic sensor has been taught

STEP 1
Initial State
STEP 7
Part Loaded
Inspection
Complete

Palm Buttons engaged to rotate table

Palm Buttons engaged after inspection is complete

STEP 2
Part Picked by
LinMot STEP 8
Part at Unloading

Horizontal extends mate plate

Is pressure is OK
STEP 3
Matting Complete
by Placing Top part STEP 9
on base part Part Picked by
Vacuum Gripper

Palm Buttons Engaged after LinMot in Initial Position

Inspection feedback has been given
STEP 4
Part at Press
Station STEP 10
Press Extended Part Placed on In-
Out Table

Is the pressure is OK

If part is inspected to be good If part is inspected to be bad

STEP 5
Press Complete
STEP 11 STEP 11
Part Good to be Part sent back for
shipped rework

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4mation DESIGN REPORT

4.4.3.1. Process Cycle Time

PRESS OPERATION
Cycle Time = 5 seconds

ULTRASONIC IS THE PART

PART MATTING
INSPECTION DIMESIONS IN
Cycle Time = 12 seconds TOLERANCE LIMITS
Cycle Time = 4 seconds

YES NO

PART LOADING PART UNLOADING PART

Cycle Time = 3 seconds Cycle Time = 10 seconds REWORK

Process Cycle Time = 42.8 seconds

Figure 4.13: Process Flowchart with Cycle Time

The cycle tiem at inidvifual station was calculated as the PLC programming was modified to make it
achieve more cycle time. The timers for each positions of the LinMot was modifiesd to reduce delays
and still provide for a smooth and effective automated process.

The calculated cycle time is an average of the different times that were taken during testing of the
automation process.

The data providing for the average cycle tile is given in the Table 4.7: Process Cycle time data

No. Cycle Time in seconds

1 45.36
2 41.67
3 42.63
4 42.75
5 43.93
Table 4.7: Process Cycle time data

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4mation DESIGN REPORT

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4mation DESIGN REPORT

5. Control Panel Layout

The Bill of Material list fo the control Panel is provided in

ITEM PART DESCRIPTIO Widt Heig Dept Din Rail QT

NO. NUMBER N h ht h Mount? Y.
3 Din Rail3 180 30 3 no 2
4 Din Rail 1 450 30 3 no 1
Omron PLC
5 Omron PLC 65 90 31 yes 1
CJ11
Linmot Power
6 S01-48/150 157 114.6 57.6 no 1
Supply
7 32 AMP Fuse 17.8 78.7 61 yes 5
SMVector Lenze AC Tech 111.7
9 99.06 190.5 no 1
Blue VFD 6
20 Terminal
10 Terminal Block 184 56 42 yes 1
Block
Sprecher+sch
11 Contactors yes 1
uh 45 60 80.5
98.80 114.3 22.35
12 MSR126.1T Safety Relay yes 2
6 2
S8JX- Omron Power
13 50 97 174 yes 1
G15024CD Supply PLC
10 Terminal
14 Terminal Block 51.5 16.64 17.8 yes 1
Block

77 Terminal
16 Terminal Block 450 35 42 yes 1
Block
Linmot
8 0150-1736 31 206 106 yes 1
Controller
15 WireDuct no 1
716.2 563.8
16 Base Plate 5 no 1
8 8
Phoenix
17 2961105 6.2 80 94 yes 1
Contact
18 700-TBR24X Safety Relay 6.2 76 93 yes 4
10 Din Rail2 130 30 3 no 2
Table 5.1: Control Panel BIll of Material

6. Project Management
The minutes meeting proving the different tasks assigned and the deadline of each task along with

the status on the completion of each task is provided in the Appendix C: Minutes of Meeting.

The Gantt-Chart is provided in the end of the document along with the critical path which is

highlighted in yellow o the tasks and with red color in the graphical representation. The Cool Muscle

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4mation DESIGN REPORT

configuration if extended any further can be critical for the completion of the project in the given

schedule.

5.1. Issues Faced

• The LinMot configuration took additional time than the assigned and that caused the

timeline to be adjusted farther by a week.

• The Cool Muscle configuration has not gone as planned as the servo motors have not

responded as per the program and additional information were need on the K parameters,

which delayed the configuration further.

• The delays in completion of Milestone 1 and Milestone 2 have caused delays in the

completion o the manual and automated station processes.

• Delays in the completion od individual tasks has pushed the deadlines for each tasks further.

The above issues were resolved with the collaboration with other teams and inputs from Project

Manager, along with the help of the teammates to provide assistance in the completion tasks.

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4mation DESIGN REPORT

7. Conclusion
Team 4mation is in the assembly of household pair of keys. With the help of SOLIDWORKS, the design

of the product has been made and the production of the design has been done using 3D printing which

is used as a prototype.

Following the Planning phase, the team started on the execution phase of the project where the part

matting, press and inspection after the press is done. The part is sent through machine which can be

operated in two different modes: manual and automatic. Push buttons on the screen are used to

achieve all the tasks of the program on manual mode while for automated mode, the process is semi-

automated with the operator having to provide palm button disconnects to VFD after each process

completion.

The major processes for the execution of the project include matting, press assembly, inspection by

ultrasonic sensor and unloading at which stage the product can also be known to be accepted or

rejected based on the inspection result.

The specifications of the process had been detailed to provide an understanding of all the equipment

requirements and the tasks that are required. CX-programming software is used of the OMRON

Programmable Logic Controllers which is integrated with the OMRON CX-Designer software for HMI

design screen designs. The servo motors at each station are configured to the required positions,

speed, and accelerations.

For the execution of the project, main components had to be configured and integrated with the PLC

logic for which detailed analysis of the equipment and the configuration are given.

For Matting, LinMot servo is configured with the OMRON PLC. They can be configured to different

positions on the LinMot Talk Configuration software. At press, a pneumatically powered press is used

for which the pressure can be regulated and checked to be okay. For inspection of the press assembled

part, an ultrasonic sensor is taught the two dimensions along with their tolerance limits to detect for

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4mation DESIGN REPORT

good parts and bad parts. At unloading, the part is then picked by a vacuum gripper and placed on a

In-Out table which moves in if the part is bad and requires rework, or moves out, towards the operator

if the part has is good. The pneumatic pressure in the system is regulated using a Electro-Pneumatic

Regulator on which the minimum and maximum pressure are set.

In this report, an in-depth analysis of the equipment is done. The configurations required and the

programmed parameters that were required of the LinMot and Coll Muscle operation is detailed,

along with the configuration of the VFD, E/P regulator and the ultrasonic sensor for inspection.

Furthermore, control panel layouts along with the mechanical layout of the machine in use is provided.

The pneumatic drawings for each component that are supplied pneumatic solenoids are shown. The

electrical drawings of the components and the PLC connections, along with the VFD, safety relays,

LinMot are given as well.

For the execution phase, technologies used include CX-Programmer, CX-Designer, Control Room by

Myostat, LinMot Talk Configuration were standard throughout the production floor. Which also

means the equipment in use were standard and if replaced, were replaced with the same parts. Along

with that, since the production of the prototype was 3D printed, it was done based on the single

drawing that was earlier provided. Additionally, the working environment was kept the same

throughout the design phase.

The execution phase has been done with the assumptions that the team of 4 human resources would

be enough for the whole completion of the project, the technologies that the techniques used

throughout the project do not change, the team will be able to learn with the resources provided and

be able to utilize their skills and execute the design of the project, the working conditions of the project

do not change, and that the electrical, pneumatic and mechanical equipment provided can be relied

upon to complete the task in hand.

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4mation DESIGN REPORT

The measurable data of the process including the process cycle time was found on the automation

process of the which averaged to 42.8 seconds. The dimensions that are taught to the ultrasonic

sensor have also seem to be around tolerance limits of 2 mm.

7.1. Lessons Learned

• Throughout the project the different components and the different ways of integrating them

with the PLC and HMI interfaces were learned and the configuration of the components were

understood with their applications as well.

• The team has been through different stages of bonding and collaboration for the completion

of the project and the understanding the automated processes and the components required

from the start of the project to the end of it is better understood

• The servo motors and the pressure regulator configurations were studied in depth and the

programming of the logic for each was of the components there done sometimes on trail and

error basis, along with the help on manual.

• The system interlocks and their requirements were highlighted with the help of the safety

features and the automated process requirements.

• The stages required for the successful completion of the project was well understood from

the initialization the monitoring and controlling phases, along with the closing phase.

• The importance of collaboration for the completion of the project with the limited resources

provided was understood. The necessary steps required for overcoming the drawback and

issues were delt with.

• The issues with he assigned schedule and the actual schedule had to be addressed so that the

component’s configurations are completed on/ before time.

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Appendix A: PLC Hardwired I/O

PLC I/O
Address Rack Location Data Type Usage Comment
MAIN RACK SLOT 1
0.0 Slot 1 BOOL In E-Stop_safety_Circuit_OK
0.1 Slot 1 BOOL In Start_PB
0.2 Slot 1 BOOL In Stop_PB
0.3 Slot 1 BOOL In LinMot_TargetPOS_S
0.4 Slot 1 BOOL In LinMot_Homed_IND
0.5 Slot 1 BOOL In SPARE TERMINAL
0.6 Slot 1 BOOL In Linear_motor_downward_Sensor
0.7 Slot 1 BOOL In SPARE TERMINAL
0.8 Slot 1 BOOL In Turn_Table_PS
0.9 Slot 1 BOOL In Inspection_MatePlate4_extend_PS
0.10 Slot 1 BOOL In Mating_MatePlate4_Extend_PS
0.11 Slot 1 BOOL In Mating_MatePlate4_Retract_PS
0.12 Slot 1 BOOL In Press_MatePlate3_Extend_PS
0.13 Slot 1 BOOL In Palm_Buttons
0.14 Slot 1 BOOL In SPARE TERMINAL
0.15 Slot 1 BOOL In SPARE TERMINAL
MAIN RACK SLOT 2
1.00 Slot 2 BOOL In Vac_Grip_Retract_RS
1.01 Slot 2 BOOL In Vac_Grip_Extend_RS
1.02 Slot 2 BOOL In SPARE TERMINAL
1.03 Slot 2 BOOL In Press_Cyl_Extend_RS
1.04 Slot 2 BOOL In SPARE TERMINAL
1.05 Slot 2 BOOL In Vertical_Cyl_Up_RS
1.06 Slot 2 BOOL In Vertical_Cyl_Down_RS
1.07 Slot 2 BOOL In Press_Cyl_Retract_RS
1.08 Slot 2 BOOL In SPARE TERMINAL
1.09 Slot 2 BOOL In Vac_Grip_Right_RS
1.10 Slot 2 BOOL In Vac_Grip_Left_RS
1.11 Slot 2 BOOL In Ultrasonic Inspection
1.12 Slot 2 BOOL In SPARE TERMINAL
1.13 Slot 2 BOOL In SPARE TERMINAL
1.14 Slot 2 BOOL In SPARE TERMINAL
1.15 Slot 2 BOOL In SPARE TERMINAL
MAIN RACK SLOT 3
2.00 Slot 3 BOOL Out LinMot_Power_ON
2.01 Slot 3 BOOL Out LinMot_Initial_Position
2.02 Slot 3 BOOL Out LinMot_Mating_Position
2.03 Slot 3 BOOL Out LinMot_Error_ACK
2.04 Slot 3 BOOL Out LinMot_PickUp_Position

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4mation DESIGN REPORT

2.05 Slot 3 BOOL Out Safety_Reset

2.06 Slot 3 BOOL Out Red_LT
2.07 Slot 3 BOOL Out Green_LT
2.08 Slot 3 BOOL Out Amber_LT
2.09 Slot 3 BOOL Out Vacuum_Gripper_Power
2.10 Slot 3 BOOL Out CMS_Vac_Grip_Left
2.11 Slot 3 BOOL Out CMS_Vac_Grip_Right
2.12 Slot 3 BOOL Out SPARE TERMINAL
2.13 Slot 3 BOOL Out CMS_Unload_Home_POS
2.14 Slot 3 BOOL Out CMS_Unload_Good_Part_POS
2.15 Slot 3 BOOL Out CMS_Good_Part_POS
MAIN RACK SLOT 4
3.00 Slot 4 BOOL Out Vertical_Cyl_Down
3.01 Slot 4 BOOL Out Vertical_Cyl_Up
3.02 Slot 4 BOOL Out Horizontal_Cyl_Retract
3.03 Slot 4 BOOL Out Horizontal_Cyl_Extend
3.04 Slot 4 BOOL Out Gripper_X_Cyl_Open
3.05 Slot 4 BOOL Out Gripper_X_Cyl_Close
3.06 Slot 4 BOOL Out Gripper_Y_Cyl_Open
3.07 Slot 4 BOOL Out Gripper_Y_Cyl_Close
3.08 Slot 4 BOOL Out Press_Cyl_Extend
3.09 Slot 4 BOOL Out Press_Cyl_Retract
3.10 Slot 4 BOOL Out VFD
3.11 Slot 4 BOOL Out Vac_Grip_Extend
3.12 Slot 4 BOOL Out Vac_Grip_Retract
3.13 Slot 4 BOOL Out Ultrasonic_Teach
3.14 Slot 4 BOOL Out Ultrasonic_Reset
3.15 Slot 4 BOOL Out Ultrasonic_Power
2001 Analog Input Word -

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Appendix B: I/O Mapping

PLC I/Os
Rack Data
Address Location Type Interface Usage Comment
MAIN RACK SLOT 1
0.0 Slot 1 BOOL PLC and HMI In E-Top_safety_Circuit_OK
0.1 Slot 1 BOOL PLC In Start_PB
0.2 Slot 1 BOOL PLC In Stop_PB
0.3 Slot 1 BOOL PLC In LinMot_TargetPOS_S
0.4 Slot 1 BOOL PLC In LinMot_Homed_IND
0.5 Slot 1 BOOL PLC In SPARE TERMINAL
0.6 Slot 1 BOOL PLC In Linear_motor_downward_Sensor
0.7 Slot 1 BOOL PLC In SPARE TERMINAL
0.8 Slot 1 BOOL PLC In Turn_Table_PS
0.9 Slot 1 BOOL PLC In Inspection_MatePlate4_extend_PS
0.10 Slot 1 BOOL PLC and HMI In Mating_MatePlate4_Extend_PS
0.11 Slot 1 BOOL PLC and HMI In Mating_MatePlate4_Retract_PS
0.12 Slot 1 BOOL PLC and HMI In Press_MatePlate3_Extend_PS
0.13 Slot 1 BOOL PLC In Palm_Buttons
0.14 Slot 1 BOOL PLC In SPARE TERMINAL
0.15 Slot 1 BOOL PLC In SPARE TERMINAL
MAIN RACK SLOT 2
1.00 Slot 2 BOOL PLC and HMI In Vac_Grip_Retract_RS
1.01 Slot 2 BOOL PLC and HMI In Vac_Grip_Extend_RS
1.02 Slot 2 BOOL PLC In SPARE TERMINAL
1.03 Slot 2 BOOL PLC and HMI In Press_Cyl_Extend_RS
1.04 Slot 2 BOOL PLC In SPARE TERMINAL
1.05 Slot 2 BOOL PLC and HMI In Vertical_Cyl_Up_RS
1.06 Slot 2 BOOL PLC and HMI In Vertical_Cyl_Down_RS
1.07 Slot 2 BOOL PLC and HMI In Press_Cyl_Retract_RS
1.08 Slot 2 BOOL PLC In SPARE TERMINAL
1.09 Slot 2 BOOL PLC and HMI In Vac_Grip_Right_RS
1.10 Slot 2 BOOL PLC and HMI In Vac_Grip_Left_RS
1.11 Slot 2 BOOL PLC In Ultrasonic Inspection
1.12 Slot 2 BOOL PLC In SPARE TERMINAL
1.13 Slot 2 BOOL PLC In SPARE TERMINAL
1.14 Slot 2 BOOL PLC In SPARE TERMINAL
1.15 Slot 2 BOOL PLC In SPARE TERMINAL
MAIN RACK SLOT 3
2.00 Slot 3 BOOL PLC Out LinMot_Power_ON
2.01 Slot 3 BOOL PLC Out LinMot_Initial_Position
2.02 Slot 3 BOOL PLC Out LinMot_Mating_Position
2.03 Slot 3 BOOL PLC Out LinMot_Error_ACK
2.04 Slot 3 BOOL PLC Out LinMot_PickUp_Position
2.05 Slot 3 BOOL PLC Out Safety_Reset

44
4mation DESIGN REPORT

2.06 Slot 3 BOOL PLC Out Red_LT

2.07 Slot 3 BOOL PLC Out Green_LT
2.08 Slot 3 BOOL PLC Out Amber_LT
2.09 Slot 3 BOOL PLC Out Vacuum_Gripper_Power
2.1 Slot 3 BOOL PLC Out CMS_Vac_Grip_Left
2.11 Slot 3 BOOL PLC Out CMS_Vac_Grip_Right
2.12 Slot 3 BOOL PLC Out SPARE TERMINAL
2.13 Slot 3 BOOL PLC Out CMS_Unload_Home_POS
2.14 Slot 3 BOOL PLC Out CMS_Unload_Good_Part_POS
2.15 Slot 3 BOOL PLC Out CMS_Good_Part_POS
MAIN RACK SLOT 4
3.00 Slot 4 BOOL PLC Out Vertical_Cyl_Down
3.01 Slot 4 BOOL PLC Out Vertical_Cyl_Up
3.02 Slot 4 BOOL PLC Out Horizontal_Cyl_Retract
3.03 Slot 4 BOOL PLC Out Horizontal_Cyl_Extend
3.04 Slot 4 BOOL PLC Out Gripper_X_Cyl_Open
3.05 Slot 4 BOOL PLC Out Gripper_X_Cyl_Close
3.06 Slot 4 BOOL PLC Out Gripper_Y_Cyl_Open
3.07 Slot 4 BOOL PLC Out Gripper_Y_Cyl_Close
3.08 Slot 4 BOOL PLC Out Press_Cyl_Extend
3.09 Slot 4 BOOL PLC Out Press_Cyl_Retract
3.10 Slot 4 BOOL PLC Out VFD
3.11 Slot 4 BOOL PLC Out Vac_Grip_Extend
3.12 Slot 4 BOOL PLC Out Vac_Grip_Retract
3.13 Slot 4 BOOL PLC Out Ultrasonic_Teach
3.14 Slot 4 BOOL PLC Out Ultrasonic_Reset
3.15 Slot 4 BOOL PLC Out Ultrasonic_Power

4.00 BOOL HMI Work HMI_Good_Part_LT

4.01 BOOL HMI Work HMI_Bad_Part_LT
4.02 BOOL - Work BLANK
4.03 BOOL - Work BLANK
4.04 BOOL PLC Work LinMot Pick POS Completed
4.05 BOOL PLC Work LinMot Mating POS Completed
4.06 BOOL PLC Work Press Extend Completed
4.07 BOOL PLC Work Horizontal Extend Activated
4.08 BOOL PLC Work Horizontal Retract Activated
4.09 BOOL Work BLANK
4.10 BOOL Work BLANK
4.11 BOOL PLC Work LinMot Initial POS Activiated
4.12 BOOL PLC Work LinMot Pickup POS Activiated
4.13 BOOL PLC Work LinMot Matting POS Activiated
4.14 BOOL Work BLANK
4.15 BOOL PLC Work Press Extend Activated
5.00 BOOL HMI Work Home PB
5.01 BOOL HMI Work Safety Reset PB

45
4mation DESIGN REPORT

5.02 BOOL HMI Work LinMot Power ON PB

5.03 BOOL - Work BLANK
5.04 BOOL HMI Work LinMot Home POS PB
5.05 BOOL HMI Work LinMot Pick ON PB
5.06 BOOL HMI Work LinMot Mate ON PB
5.07 BOOL HMI Work LinMot Gripper X Open PB
5.08 BOOL HMI Work LinMot Gripper X Close PB
5.09 BOOL HMI Work LinMot Gripper Y Open PB
5.10 BOOL HMI Work LinMot Gripper Y Close PB
5.11 BOOL HMI Work Vertical Cyl Up PB
5.12 BOOL HMI Work Vertical Cyl Down PB
5.13 BOOL HMI Work Horizontal Cyl Ext PB
5.14 BOOL HMI Work Horizontal Cyl Ret PB
5.15 BOOL PLC and HMI Work Home Complete
6.00 BOOL PLC Work Safety Circuit Active
6.01 BOOL PLC and HMI Work Cycle Active
6.02 BOOL PLC Work Estop Active
6.03 BOOL PLC and HMI Work Ultrasonic Teach Complete LT
6.04 BOOL PLC and HMI Work Homing Status Active
6.05 BOOL PLC and HMI Work LinMot Home
6.06 BOOL PLC and HMI Work LinMot Initial POS LT
6.07 BOOL PLC and HMI Work LinMot Pick POS LT
6.08 BOOL PLC and HMI Work LinMot Mate POS LT
6.09 BOOL PLC and HMI Work LinMot Gripper X Open LT
6.10 BOOL PLC and HMI Work LinMot Gripper X Close LT
6.11 BOOL PLC and HMI Work LinMot Gripper Y Open LT
6.12 BOOL PLC and HMI Work LinMot Gripper Y Close LT
6.13 BOOL PLC and HMI Work Horizontal Ret LT
6.14 BOOL PLC and HMI Work Horizontal Ext LT
6.15 BOOL PLC and HMI Work Vertical Up LT
7.00 BOOL HMI Work Manual Mode PB
7.01 BOOL HMI Work Press Extend PB
7.02 BOOL HMI Work Press Retract PB
7.03 BOOL HMI Work Auto Mode PB
7.04 BOOL HMI Work Fault Reset PB
7.05 BOOL HMI Work CMS Gripper Power PB
7.06 BOOL HMI Work CMS In-Out Table Home PB
7.07 BOOL HMI Work CMS Gripper Left PB
7.08 BOOL HMI Work CMS Gripper Right PB
7.09 BOOL HMI Work CMS Gripper Ret PB
7.10 BOOL HMI Work CMS Gripper Ext PB
7.11 BOOL HMI Work LinMot Error ACK PB
7.12 BOOL HMI Work Ultrasonic Reset PB
7.13 BOOL HMI Work Ultrasonic Power PB
7.14 BOOL HMI Work Ultrasonic Teach PB
7.15 BOOL HMI Work Work_PB

46
4mation DESIGN REPORT

8.00 BOOL PLC Work Part at Mating

8.01 BOOL PLC Work Part at Press
8.02 BOOL PLC Work Part at Inspection
8.03 BOOL PLC Work Part at Unloading
8.04 BOOL PLC Work Mating Complete
8.05 BOOL PLC Work Press Complete
8.06 BOOL PLC Work Inspection Complete
8.07 BOOL PLC Work Unloading Complete
8.08 BOOL HMI Work Matting Gripper Closed
8.09 BOOL HMI Work CMS In-Out Table Home LT
8.10 BOOL HMI Work CMS Gripper Left LT
8.11 BOOL HMI Work CMS Gripper Right LT
8.12 BOOL HMI Work CMS Gripper Ext LT
8.13 BOOL HMI Work CMS Gripper Ret LT
8.14 BOOL HMI Work CMS Gripper Power LT
8.15 BOOL HMI Work VFD Indexed LT
9.00 BOOL HMI Work Estop Fault
9.01 BOOL HMI Work Safety Circuit Fault
9.02 BOOL HMI Work Fault Acknowledge
9.03 BOOL HMI Work Horizontal Cylinder Fault
9.04 BOOL HMI Work LinMot Target POS Fault
9.05 BOOL HMI Work P+A93:F157ress Retract Fault

47
4mation DESIGN REPORT

Appendix C: Minutes of Meeting

MINUTES OF MEETING

Team
4mation Project: Industrial Automation Project
Name:

13/1/202 Minutes Issued

Date: Place: Online Justin George
2 By:
Meeting Present: Justin George Shubham Dixit Mayyankumar Harsh Shah
Members Absent:

AGENDA Team formation and Initiation

Status or
No. Action Item Assigned To Finish Time
Comment
Justin George,
Mayyankumar Completed on
1 Team Name Discussion 13/1/2022
, Shubham Time
and Harsh
Justin George, Completed on
2 Designing Team Logo 14/1/2022
Shubham Time
Justin George,
Mayyankumar Completed on
3 Product Discussion 13/1/2022
, Shubham Time
and Harsh
Creating team Logo on Completed on
4 Shubham Dixit 14/1/2022
SolidWorks Time
Justin George,
Mayyankumar Completed on
5 Report Writing 15/1/2022
, Shubham Time
and Harsh

21/1/202 Minutes Issued

Date: Place: Online Justin George
2 By:
Meeting Present: Justin George Shubham Dixit Mayyankumar Harsh Shah
Members Absent:

AGENDA Project Planning Initiation

48
4mation DESIGN REPORT

Status or
No. Action Item Assigned To Finish Time
Comment
Justin, Completed on
1 Product Market Research 24/1/2022
Mayyankumar Time
Justin, Completed on
2 Cost analysis on product 26/1/2022
Shubham Time
Completed on
3 PLC logic planning Justin 25/1/2022
Time
Completed on
4 HMI design initation Mayyankumar 24/1/2022
Time
Shubham and
5 Safety analysis 23/1/2022
Harsh
Shubham and Completed on
6 Risk analysis 15/1/2022
Harsh Time

27/1/202 Minutes Issued

Date: Place: Online Justin George
2 By:
Meeting Present: Justin George Shubham Dixit Mayyankumar Harsh Shah
Members Absent:

AGENDA Project Planning Report and Milestone 1

Status or
No. Action Item Assigned To Finish Time
Comment
Troubleshootin
PLC logic for Manual
1 Justin 27/1/2022 g with HMI and
Operation
PLC pending
Changes ro
Justin George,
make the
2 HMI Screens and design Shubham and 27/1/2022
design more
Mayyank
user-friendly
Preliminary product Shubham and Completed on
3 23/1/2022
design Harsh Time
Completed on
4 Safety analysis Harsh 28/1/2022
Time
Justin George,
Mayyankumar Completed on
5 Report Writing 15/1/2022
, Shubham Time
and Harsh

Minutes Issued
Date: 3/2/2022 Place: Online Justin George
By:
Present: Justin George Shubham Dixit Harsh
Meeting
Mayyankuma
Members Absent:
r

AGENDA Planning Report Tasks

49
4mation DESIGN REPORT

Status or
No. Action Item Assigned To Finish Time
Comment
Justin George, Completed on
1 Product Market Research 24/1/2022
Mayyankumar Time
Justin George, Completed on
2 Cost analysis on product 14/1/2022
Shubham Time
Shubham and Completed on
3 Prelimnary product design 23/1/2022
Harsh Time
Creating team Logo on Completed on
4 Shubham Dixit 14/1/2022
SolidWorks Time
Justin George,
Mayyankumar Completed on
5 Report Writing 15/1/2022
, Shubham Time
and Harsh

10/2/202 Minutes Issued

Date: Place: Online Justin George
2 By:
Meeting Present: Justin George Shubham Dixit Mayyankumar Harsh Shah
Members Absent:

AGENDA PLC Automation

Status or
No. Action Item Assigned To Finish Time
Comment
Completed on
1 Press station automation Justin George 17/2/2022
time
HMI screen update based Completed on
2 Mayankkumar 15/2/2022
on Milestone1 time
Machine Layout Harsh Shah, Completed on
3 17/2/2022
understanding shubham Dixit time

17/2/202 Minutes Issued

Date: Place: Online Justin George
2 By:
Meeting Present: Justin George Shubham Dixit Mayyankumar Harsh Shah
Members Absent:

AGENDA Process Automation with Inspectiona and Unloading station

Status or
No. Action Item Assigned To Finish Time
Comment
Completed on
1 Electrical Wiring learning Shubham Dixit 23/2/2022
time
Collaborated
Machine Layout
2 Harsh Shah 23/2/2023 with Justin to
Understanding
finish
pneumatic wiring and Completed on
3 Mayankkumar 21/2/2022
drawing understanding time

50
4mation DESIGN REPORT

LinMOt Configurationa dn
Completed on
4 Ultrasonic analog inputs Justin George 22/2/2022
time
study

24/2/202 Minutes Issued

Date: Place: Online Justin George
2 By:
Meeting Present: Justin George Shubham Dixit Mayyankumar Harsh Shah
Members Absent:

AGENDA Milestone 1 and Peer Evaluation Part A

Status or
No. Action Item Assigned To Finish Time
Comment
Manual Controls HMI
Design Update and Completed with
1 Justin George 2/3/2022
manual mode PLC delay by a day
progrmming
Faults and homing routine Completed on
2 Shubham Dixit 1/3/2022
configuartion on PLC time
PeerEvaluation Completed with
3 Harsh Shah 27/2/2022
completion task delay by a day
PeerEvaluation Completed on
4 Mayankkumar 28/2/2022
completion task time

Minutes Issued
Date: 3/3/2022 Place: Online Justin George
By:
Present: Justin George Shubham Dixit Harsh Shah
Meeting
Mayyankuma
Members Absent:
r

AGENDA Process Automation and Electrical wiring

Status or
No. Action Item Assigned To Finish Time
Comment
Indexing table and cycle Completed on
1 Justin George 9/3/2022
active integration time
Faults forcylinder and Delayed by a
2 Mayankkumar 10/3/2022
safety compromise day
Cool Muscle Langauage Completed on
3 Mayankkumar 8/3/2022
Learning time
Completed on
4 PLC programming updates Shubham Dixit 9/3/2022
time

10/3/202 Minutes Issued

Date: Place: Online Justin George
2 By:
Meeting Present: Justin George Shubham Dixit Mayyankumar Harsh Shah
Members Absent:

AGENDA Solidworks Machine designing and Process Automation

51
4mation DESIGN REPORT

Status or
No. Action Item Assigned To Finish Time
Comment
Completed on
1 Solidworks design layout Harsh Shah 16/3/2022
time
Learning AutoCAD Completed on
2 Shubham Dixit 17/3/2022
electrical time
LinMot Configuration and Completed with
3 Justin George 17/3/2022
PLC programming a days' delay
HMI automatic mode completed on
4 Mayankkumar 17/3/2022
deisgn time

17/3/202 Minutes Issued

Date: Place: Online Justin George
2 By:
Meeting Present: Harsh Shah Shubham Dixit Mayyankumar
Members Absent: Justin George

AGENDA Design Report and Cool Muscle Configuration

Status or
No. Action Item Assigned To Finish Time
Comment
Completed
1 Cool Muscle Configuartion Justin George 23/3/2022
coding
Sequence of operation
Completed on
2 and photos of the Mayankkumar 22/3/2022
time
machine
collaborated to
PLC programming for
3 Shubham Dixit 23/3/2022 complete by
process automation
finish time
Dimensions for machine Completed on
4 Harsh Shah 24/3/2022
layout time

24/3/202 Minutes Issued

Date: Place: Online Justin George
2 By:
Meeting Present: Justin George Shubham Dixit Mayyankumar Harsh Shah
Members Absent:

AGENDA Design Report and Milestone 2

Status or
No. Action Item Assigned To Finish Time
Comment
Mechanical Machine Completed On
1 Harsh Shah 30/3/2022
Layout time
Pneumatic Schematics for Completed On
2 Shubham Dixit 29/32022
Report time
Delay in
PLC Interlocks and HMI
3 Justin George 30/3/2022 ultrasonic
Design Update
design
Delayed by a
4 EP pressure regulator Mayankkumar 28/3/2022
day

52
4mation DESIGN REPORT

31/3/202 Minutes Issued

Date: Place: Online Justin George
2 By:

Meeting Present: Justin George Shubham Dixit Mayyankumar Harsh Shah

Members
Absent:

AGENDA Design Report and Milestone 2

Status or
No. Action Item Assigned To Finish Time
Comment
Mechanical Machine Completed On
1 Harsh Shah 30/3/2022
Layout time
Pneumatic Schematics for Completed On
2 Shubham Dixit 29/32022
Report time
Delay in
PLC Interlocks and HMI
3 Justin George 30/3/2022 ultrasonic
Design Update
design
Delayed by a
4 EP pressure regulator Mayankkumar 28/3/2022
day

53
 8 7 6 5 4 3 2 1

F F

E E

D D

C C

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP

Conestoga College
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

SECTION C-C NAME SIGNATURE DATE TITLE:

SCALE 1 : 12
4Mation
DRAWN

CHK'D

APPV'D

MFG

A Q.A MATERIAL: DWG NO.

1.1-Views A3 A
WEIGHT: SCALE:1:20 SHEET 1 OF 3

8 7 6
SOLIDWORKS Educational Product. For Instructional Use Only. 5 4 3 2 1
 8 7 6 5 4 3 2 1
7
PART DESCRIPTION QTY
F 8
NUMBER
1
2
BASE PLATE
TOP PLATE
5
5
F
3 LINMOT 1
9 4 COOL MUSCLE SERVO 2
5 PNUEMATIC GRIPPER 1
c 6 X-Y GRIPPER 2
7 STACK LIGHT 1
8 HMI 1
9 ESTOP 1
10 PRESS 1
c A ULTRASONIC SENSOR 1
B PROXIMITY SENSOR 3
10 i B i ACTUATOR FOR PRESS
ii ACTUATOR FOR LINMOT
E A iii ACTUATOR FOR HORIZONTAL
EXT/RET
E
ii

iii

D D
3

C C
2

SECTION c-c 5 1
B SCALE 1 : 6
B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP

Conestoga College
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D
4Mation
APPV'D

MFG
MATERIAL: DWG NO.

A A
Q.A

1.2-Details A3

WEIGHT: SCALE:1:20 SHEET 2 OF 3

8 7 6
SOLIDWORKS Educational Product. For Instructional Use Only. 5 4 3 2 1
 8 7 6 5 4 3 2 1

F F
c c

Press Station Inspection Station

E E

D D

C C
Matting Station

Loading Station
Unloading Station
B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP

SECTION c-c
Conestoga College
SURFACE FINISH: EDGES
TOLERANCES:
SCALE 1 : 4 LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

4Mation
DRAWN

CHK'D

APPV'D

MFG
MATERIAL: DWG NO.

A A
Q.A

1.3-Stations A3

WEIGHT: SCALE:1:20 SHEET 3 OF 3

8 7 6
SOLIDWORKS Educational Product. For Instructional Use Only. 5 4 3 2 1
 V A C U U M G R IP P E R
UP A ND DO W N P R E S S S T A T IO N

5-3 w a y s o l eno i d va l v e
V a c u u m G r ip p e r
5-3 w a y s o l eno i d va l v e

4 2 4 2

5 1 3 5 1 3
V E N TU RI

4 2

5 1 3

VE R TIC A L
C YL IN D E R H O R IZ O N T A L G R IP P E R -X G R IP P E R - Y
C YL IN D E R
R E E D S W IT C H

5-3 w a y s o l eno i d va l v e 5-3 w a y s o l eno i d va l v e

5-3 w a y s o l eno i d va l v e 5-3 w a y s o l eno i d va l v e
4 2 4 2 4 2
4 2

5 3 5 1 3 5 1 3
1 5 1 3

PRESSUR E
S hut- o ff V a l v e GA U GE
1
M a i n A i r S up p l y F R L o c ko ut R e g ul a to r

SO F T ST A R T V A L VE