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To sort boxes in different trays using the Pneumatic Sorting Device.

1. Perform the basic safety procedures listed in Appendix F of this manual.

2. Make sure the system is configured for Ethernet communication as described in the Ethernet configuration procedure given in Job Sheet 2.

3. Make sure the DeviceNet network is configured according to the procedure described in Job Sheet 3.

4. Use Table 5-1 and Figure 5-1 to identify the components that will be added to the setup used in this Job Sheet.

Table 5-1. New components used for Job Sheet 5.

Name Model Description/Function

Pneumatic Sorting Device 5913 Sorts the boxes in different trays.

Sorting Trays (from the Accessories) 5951 Used to collect boxes sorted by the Pneumatic Sorting Device.

Sorting Process

Job Sheet 5

OBJECTIVE

PROCEDURE

Job Sheet 5 – Sorting Process

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Figure 5-1. New components used for Job Sheet 5.

a Refer to the Equipment Utilization Chart in Appendix A of the manual to obtain the complete list of equipment required to complete this Job Sheet.

System setup

5. Install the Inductive Proximity Switch halfway across the Flat Belt Conveyor as shown in Figure 5-2.

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Figure 5-2. Installation of the Inductive Proximity Switch.

6. Install a sorting tray at the end of the Flat Belt Conveyor as shown in Figure 5-3.

Figure 5-3. Installation of the sorting tray at the end of the Flat Belt Conveyor.

7. Install the Background Suppression Photoelectric Switch at the end of the sorting tray as shown in Figure 5-4.

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Figure 5-4 Installation of the Background Suppression Photoelectric Switch.

8. Install two sorting trays, two Inductive Proximity Switches, and the Pneumatic Sorting Device on the Flat Belt Conveyor as shown in Figure 5-5. Make sure the two Inductive Proximity Switches are positioned at the end of each sorting tray.

Install the Background Suppression Photoelectric Switch at the end of the Tray

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Figure 5-5. Installation of the sorting apparatus.

9. Make the pneumatic connections according to the diagram presented in Figure 5-6.

Tray 3

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Figure 5-6. Sorting process pneumatic connection diagram.

Make sure to adjust the pressure in the circuit downstream from the valve of the

Conditioning Unit to 138 kPa (or 20 psi).

a Some of the pneumatic cylinders installed on the Pneumatic Sorting Device are equipped with needle valves allowing control of the air flow. Use these valves to adjust the speed at which the pneumatic cylinders extend and retract.

A video showing how to adjust the needle valves on the Pneumatic

Sorting Device is available on the Flexible Manufacturing System

Resource Kit (student) CD-ROM.

Pneumatic Sorting Device 5913

V4

Directional Control Valve Station 5914

Lateral Cylinder Stopper Push Rod

Pneumatic Box Feeder 5911

V3 V1 V2

Safety Valve 6494

Conditioning Unit 6411-A

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10. Connect the equipment as shown in the wiring diagram presented in Figure 5-7.

Figure 5-7(a). Sorting process wiring diagram (Compact Logix L32E).

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Figure 5-7(b). Sorting process wiring diagram (Compact Logix L43).

a Make sure the AC Drive "Start Source" parameter (P036) is set to 5 (Comm Port).

11. Once completed, the setup should look as shown in Figure 5-8.

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Figure 5-8. Sorting process setup.

a Before running the program, always check that the sensors are accurately positioned to detect the targets. An LED on the sensor lights up when a target is within sensing distance.

Running the program

a Make sure RSLinx and RSNetWorx for DeviceNet are running on your computer before trying to download the program to the PLC.

12. Before downloading the program to the PLC, restore the RSNetWorx configuration made in Job Sheet 3. To do so, start RSNetWorx for DeviceNet (if not already started).

13. From the File menu, select Open and open the file named Networx_1st_Config (Refer to Job Sheet 3 for details).

14. Opening the Networx_1st_Config file restores the DeviceNet configuration made in Job Sheet 3.

15. Open the RSLogix 5000 project file named intro_manu_stu5.acd and download the program to the PLC. Refer to the Running the programs procedure given in Job Sheet 2 for details on downloading programs.

16. Make sure the setup is working properly. You should be able to:

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Start the process by pressing the green push button;

terminate a paused process by pressing the red push button;

observe that the boxes are directed to Tray 1 by the Pneumatic Sorting

Device. If tray 1 is full, the boxes are directed to tray 2. If both tray 1 and

tray 2 are full, the boxes are directed to tray 3.

Reset the system using the red push button on the Indicator

Light/Push-Button Station;

A video of the setup presented in this Job Sheet is available on the

Flexible Manufacturing System Resource Kit (student) CD-ROM.

17. Ask the instructor to check and approve your work.

Troubleshooting exercise

a Prior to this exercise, the instructor must insert a fault into the circuit of the Flexible Manufacturing System.

18. Try to use the setup and determine whether everything is working properly.

19. If the system is not working properly, describe the symptom(s).

20. Use your troubleshooting skills to identify the malfunctioning module(s) and isolate the problem(s).

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21. Explain in detail your approach to isolating the problem.

22. Ask the instructor to check and approve the Troubleshooting Exercise.

Programming exercise

a Make sure there is no fault from the troubleshooting exercise left on the setup.

In this Job Sheet, boxes are successively dropped on the Flat Belt Conveyor. When the boxes reach the end of the Flat Belt Conveyor they are sorted in three trays.

Modify the program so that the yellow light turns on if the Inductive Proximity Switch installed halfway across the conveyer does not detect any box for more than five seconds.

23. Once this exercise is complete, ask the instructor to check and approve your work.

Name: ______________________________ Date: ____________________

Instructor's approval: ______________________________________________