Proposal Of EDU VR1 CIM-120 TB - mtsdidactic.com … · a Page 4 of 38 COPYRIGHT This document is the sole property of the MTS Didactic Group of Companies. Recipients of the document

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EDU VR1 CIM-120 TB MTS Didactic Associate Companies

SAR Blended Training Concept

COPYRIGHT This document is the sole property of the MTS Didactic Group of Companies. Recipients of the document

shall not copy, divulge, or distribute it within their organization or to external third parties without the written permission from the MTS Didactic Group of Companies.

Proposal Of

EDU VR1 CIM-120 TB (Computer Integrated Manufacturing System)

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COPYRIGHT This document is the sole property of the MTS Didactic Group of Companies. Recipients of the document

shall not copy, divulge, or distribute it within their organization or to external third parties without the written permission from the MTS Didactic Group of Companies.

1. Automatic Storage & Retrieval Station 2. FMS station

2.1 Educational CNC Lathe 2.2 Educational CNC Mill 2.3 Robot feeding Unit

(1 set of 6-axis articulated robot) 3. Vision Inspection Station 4. Material Handling Station 5. Assembly station 6. Central Control Station 7. OPTIONAL - CAD/CAM software for programming &

designing (HYPERMILL) x 1 unit with Emulator

NOTE: Station Configuration for reference only. Actual offered station & configuration might be different after final discussion upon technical practicability & requirement

1. EDU VR1 CIM-120 TB Station

NOTE: Illustration for visual reference only. Actual offered system might be different

from illustration shown

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COPYRIGHT This document is the sole property of the MTS Didactic Group of Companies. Recipients of the document shall not copy, divulge, or distribute it within their organization or to external third

parties without the written permission from the MTS Didactic Group of Companies.

2. EDU VR1 CIM-120 TB Layout

NOTE: Illustration for visual reference only. Actual offered system might be different from illustration shown

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This document is the sole property of the MTS Didactic Group of Companies. Recipients of the document shall not copy, divulge, or distribute it within their organization or to external third parties without the

written permission from the MTS Didactic Group of Companies.

EDU VR1 CIM-120TB MTS Didactic Associate Companies


3.1 What is CIM? The CIM system is a manufacturing model for the unmanned factory of the future. It is used for teaching and training of manufacturing engineering students in areas related to automation, material handling, system integration, CNC machining and robotics. The system is designed for flexible manufacturing and allows a wide range of machine tools, automation devices and software to be integrated. It has an open system concept whereby manufacturing software such as CAD/CAM, databases, MRP, ERP are easily integrated. 3.2 How does CIM works? Manufacturing today is a web of global activities, integrated via computer and communication networks. It is multi-facetted, incorporating both technology and management. Computer Integrated Manufacturing (CIM) is the discipline in which these areas are organized into a structured and cohesive whole. Implementation of CIM can result in significant improvements in productivity and product quality and a stronger presence in the global marketplace. To achieve these benefits, there is a need to educate and motivate practicing engineers, managers and information technologists regarding CIM methodology, planning and implementation. 3.3 Fundamental of Manufacturing 3.3.1 Factory Operations For a company to be engaged in making product, there are certain basic functions that must be carried out in order to transform raw materials into the desired products (finished goods). The functions are:

- Processing - Assembly - Material Handling and Storage - Inspection and Test - Control

All these functions that carried out in a typical manufacturing company is termed Factory Operations. These operations usually come in direct contact with the product during the manufacturing process and are taking place within the production shop floor. 3.3.2 Information Processing Operations A large amount of data, records, and knowledge are required to be injected / generated into / from or flow through the entire manufacturing process in order to produce the product successfully. A manufacturing company must properly organize themselves to coordinate all these information or knowledge in order to accomplish the above-mentioned five functions. We described the system of managing the data, information, and knowledge as an information-processing system. Unlike the activities carries out in factory operations,

3. CIM Background

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these information-processing activities usually do not come in contact with the actual product and are taking places outside the production shop floor. The information-processing system can generally be described as comprises 4 functions. They are:

- Business Function - Product Design Function - Manufacturing Planning Function - Manufacturing Control Function

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1. FMS station 1.1 EDU VR1 Mill-TB - Floor typed educational CNC milling machine with built-in troubleshooting board to carry out basic machining process, such as drilling, pocketing and also learn machine Mechanical Specifications Controller : Siemens 808D Spindle Axis : Vertical Work Table : 280 x 150mm Strokes : 200 x 150 x 180mm T-Slots : 3 x 8 x 55mm Resolution : 0.001mm X, Y, Z motors : Servo Motors Spindle Speed : 200 - 2800 rpm Spindle Motor Power : 400 w Rapid Feed : 2000 mm/min Transmission : Ball Screw Automatic Tool changer: None Tool Change Time : No or Ca. 10s Overall Dimensions (L×W×H) : 1450 × 1100 × 1670mm Machine weight : 530 kg Power Supply : 50Hz, 380V, 16A, Three-Phase Accuracy : 0.04 mm Repeatability : 0.02 mm Spindle mounting : BT 30 Distance between table : 30-210 mm

4. EDU VR1 CIM-120 TB Station Description

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1.2 EDU VR1 Lathe-TB - Floor typed educational CNC turning machine with built-in troubleshooting board to carry out basic machining process Mechanical Specifications Controller : Siemens 808D Swing over bed : 280 mm Swing over carriage : 150 mm Distance between centers: 140 mm Stroke of Z axis : 230 mm Stroke of X axis : 130 mm Taper of spindle bore : No. 4 Taper of tailstock bore : No. 3 Pulse : 0.001 mm Accuracy : 0.02 mm Spindle motor power : 1.5 KW (2 HP) Spindle speed : 100 – 2000 rpm Turret : 6 tools Coolant : Yes Rapid feed : 3000 mm / min Coolant : Yes Cutting tools : 12 x 12 Overall size : Approx. 1750 x 1750 x 1200 mm (WxLxH) Machine weight : 800 kg Power supply : Siemens 808D; Three phase, 380V 4kW, AC50Hz, ,

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2. Vision Inspection Station Inspection is an important part of any manufacturing process being used for: The proposed sub-system shall equip the trainees with practical machine vision technology for industrial inspection applications. The trainees shall be taught in the following areas: - Core components of vision system and how to configure the physical system and running of machine vision system - Image acquisition and digitization - Image processing and analysis Vision System Camera

- Processing resolution 752 × 480 - Real color - 32 Number of simultaneous measurements - 32 Number of registered scenes - Communications (Ethernet TCP no-protocol, Ethernet - FINS/TCP no-protocol, EtherNet/IP, or PLC Link) - 1/2-inch color CMOS Image elements - Measurement trigger : External trigger (single or continuous) - Communications : (Ethernet TCP no-protocol, Ethernet FINS/TCP no-protocol, EtherNet/IP, or

PLC Link) - Auxiliary function : Math (arithmetic, calculation functions, trigonometric functions, and logic

functions) - Power supply voltage : 21.6 to 26.4 VDC (including ripple) - Current consumption : 2.4 A max.

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3. Material Handling Station The purpose of this handling system is to provide a means of transportation of pallets between various processing stations. The handling system must, at least, equip with 4 locating units and 4 buffer units. The purpose of the locating unit is to allow the pick-and-place arm, from each sub-system, to interact with the pallet. The buffer unit is to stand-by a fresh work-piece for immediate processing by the working-station (example CNC milling) once they have finished with the existing work-piece. Both of the units must be able to be re-located to another position with ease (module type of design). Besides this, the material handling system must also be configured such that the stand-by pallet shall not block the flow of other pallets. The pallet is conveyed around various stations through a conveying media and the proposed handling system must be capable of handling different pallets-sizes according to specification list. Component storage systems can be designed to suit customer application ranging from simple magazine loading to a completely automated palletized storage and retrieval systems. Raw material and finished products can be automatically retrieved and stored managed by a host computer. All parts and assemblies are transported by the ASRS on standard carrier pallets allowing material to be supplied to the manufacturing system at the same time for batch orders involving different products.

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3.1 Endless Conveyor Belt Unit Conveying Media : Plastic Plain Chain (or equivalent) Conveyor vertical support : To be at least 8 supports done by 80x80mm profile with footing pad Diameter

approx. 260mm. Power Source : Gear Motor comes with inverter Conveying Speed : Approx. 15m/min Conveyor Frame : Aluminium Profile and Aluminium Plate with Treated Surface Pallet Conveying Media and Pallet Material : Reinforced PPE/PA for conveying media (Reference only) Safety : Emergency stop button available at 4 corners 3.2 Stopper/Locator Unit Quantity : 4 units for stopper and 4 units for locator Power Source : Air cylinder Material : Aluminum Plate & harden steel Position detector : Photo sensor 3.3 Pallet Conveying Media and Pallet Quantity : 10 conveying pallets Dimensions : Approx. 150 x 100 x 30mm (conveying media) Material : Aluminium or Engineering plastic (Reference only) Equipped with RF tag mount on top of the conveying media 4. Assembly station - The proposed system must be capable of interfacing with the software. Only the inspected with ‘Pass result’ to perform the assembly process

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5. Automatic Storage and Retrieval (ASRS) Station The purpose is to provide for a system, which is the combination of equipment, and controls that handles, store, and retrieves materials with precision, accuracy, and speed under a defined degree of automation. The sub-system comprises storage modules and a storage/retrieval (S/R) unit. Storage of materials inside a storage compartment is via a pallet. A Pick-and-place robot arm shall be included into this sub-system to facilitate the transfer of pallet from the S/R unit to the conveyor and vice versa. 6.1 Storage Rack System Mechanical structure : Floor-mounted storage unit with 4 footings pads & castor wheels Storage Spaces : 30 storage compartments (Stainless Steel with aluminium) Storage Dimension : Approx. 1650L x525W x 1720H mm Dimensions (Storage) : Approx. 100L x 75W x 100H mm Maximum Weight : Less than 1.5 kg per storage space Structure : Aluminium profiles. 6.2 Storage and Retrieval Cartesian Robot Robot Travel (X/Y/Z) : 1050 x 300 x 550mm with cable carrier Acceleration & Deceleration: Adjustable Home : Hard-home position on each axis Feedback : Encoder on each axis Sensor : Photoelectric sensor Structure : Auminium Profiles Drive Mechanism : Precision Ball screw with LM guide End effector Standard : Pneumatic gripper with precision guide Payload capacity : 1.5 kg (3.3 lbs.) Repeatability : ±0.2 mm (0.008”) at TCP (tip of gripper) Home : Hard-home position on each axis Feedback : Encoder on each axis Safety features : Emergency switches; can be connected to safety mats, warning lights, etc.

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6. Central Control Station Master Control Unit PLC : CJ2M-CPU13 PLC, CPU Unit User memory : 20k step Power Supply : CJ1W-PA205R Power Supply Ethernet Unit : CJ1W-ETN21 64 POINTS Input Unit : CJ1W-ID261 64 POINTS Output Unit : CJ1W-0D261 Relay Output Unit 16 pts : CJ1W-OC211 Input Unit 16pts 24VDC : CJ1W-ID211 RFID Control 3 in 1 RFID: Antenna, Amplifier & Controller V680S-HMD64-ETN (4 sets) RF Tag (1-kbyte Memory) V680-D1KP54T (10 sets)

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7. OPTIONAL - CAD/CAM software for programming & designing (HYPERMILL) with Emulator 7.1 Hypermill CAD/CAM software

CAD & CAM in one single interface for efficient and continuous processes. Both simple and complex geometries can be programmed efficiently. Workpieces can be completely

machined in a single setup. The advantages of this is to provide continuous and more efficient processes, reduced processing times and higher reliability.

Easy, time-saving programming with automated functions such as transformation and mirroring Intelligent functions such as job linking or production mode reduce auxiliary processing times Fully automated collision checking and avoidance for the highest process reliability Functions for HSC machining and High-Performance Machining Safe and proven Post Processor with configurations relevant to the machine.

Software is inclusive of: CAD system for repairing and designing of surfaces and solids. CAM System covers from 2D and 3-Axis. Internal simulation verification. Tool Database. Automation Macro. Unified Post Processor for the specified machine. DVD Installer.

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Software Manuals. Dongle which serves as a hard lock key.

Software Details: (A) CAD Data Exchange Capability: 2D-DXF / 2D-DWG (Paper Space and Drawing Space), IGES 5.2, VDA-FS 2.0, STEP ( AP203, AP214 ), STL ( ASCII/Binary ), ASCII ( Points ), VRML ( Export ). Sketching Feature: Lines, Circles, Arcs, Rectangle, Polygon, Polyline, Fillet, Chamfer, Offset on plane, Text, Hatches. Point Snapping Feature: Position, Delta, polar, on curve, on surface, Intersection of curves, Intersection of curve and surface, Projection to curves and surfaces. Curve definition: Control Points, Approximation, Continuity, Spline, Helix, Offset, Offset on Surface, Connect, Conic, Fitting, 2D to 3D conversion, Leitlinie, On spine, Isoparametric, Boundaries, Section, Project, Hermite-Spline, Flexibility, Helix, Intersect, Orientation, Split, Tangent Extension, Through Points, Union. Surface Modelling Mix of canonical and Nurbs-based surface definition for compact data structures Surface definition: Lofted Surfaces, Explode Solids, Linear Sweep, Normal, Offset Surface and Plane. Primitive Definition: Revolved, Ruled, Intersection Surface, Proportional, Stretch, Helical, Draft Surface from non-planar parting plane. Surface Modification: Invert Surface, Trim Limits, Untrim. Surface Fillet: Constant-variable-parabolic- Radius Surface Fillet, Chamfer. Solid Modelling Construction of Solid Shapes, solid chamfer, solid fillet, draft angle, solid shell, Boolean features (Solid Union, difference and Intersect), pattern, mirror, solid sweeping, solid rotation, hole construction and solid breaking feature.

(B) CAM 2D and Drilling CAM Contour Milling Pocket Milling Face Milling 2D Chamfer Milling on 3D model 2D Contour Milling on 3D model Automatic Rest Machining Adaptive Pocket Machining Thread Milling Center Drill Simple Drilling

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Drilling with chip break/pecking Tapping Boring Gun Drilling Optimized deep hole drilling with the consideration of stock model update/cross hole detection. Collision checking of 3D Model against tool, tool holder and spindle in 2D 3-Axis CAM Arbitrary Stock Roughing Stock Model Update Spanning Several Jobs Step Height machining (Bottom to Top machining) Profile Roughing and Finishing Free Path Milling ISO-Machining Z-Level Finishing XY Optimized Machining Automatic Pencil Milling Automatic Rest Machining Slope Machining Multiple Stock Allowance 3D cutter compensation

(C) Supportive Features Metric/Inch Support Part Analysis Feature Technology with Pocket Recognition Macro Technology Transformations of tool paths (Patterning, mirroring) Job list, compound job Associative job copy Job linking Parametric Job definition Toolpath / Toolholder Collision Check Holder collision check Tapered Tools Visualisation of Single Toolpath Support of Multiple Tool References Free Defined Tool Geometry (simulation and material removal) Free NC Text Automatic backup NC Events Report Designer and generation

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(D) Hardware/Workstation and Network/Server Specifications (PC NOT INCLUDED)

For Workstation Processor: 3rd gen Intel® Core™ i7 processor Operating System : Windows® 7 Professional 64bit RAM: Minimum 8GB Ram Hard Drive: 2TB 7200RPM SATA Hard Drive Video Card: Nvidia® with 2GB VRAM Some supported Video Card models: GeForce™ 8 8600 series GeForce™ 8 8800 series GeForce™ 9 9600 series GeForce™ 9 9800 series GeForce™ 100 series GeForce™ 200 series Quadro FX™ 3400 Quadro FX™ 3450 Quadro FX™ 3500 Quadro FX™ 1700 Quadro FX™ 180

7.2 EDU CNC Studio Emulator The Emulator should consist of a touch screen CPU system with a CNC machine emulator on monitor screen, which will emulate the function on the CNC controller. Meanwhile there will be another LCD monitor emulating the machine view & motion corresponding to the CNC controller at touch screen CPU system. The emulator must include all the following functionality: - An ideal Machine Emulator with hardware panel and built in software.

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- Create and customizing your own specified CNC controller for any basic to multi axis CNC machine tools is possible for further expansion. - Convert machine controller screen graphics & NC Code directly into touch on screen for machines motion. Ready to use on Mills & Lathes for various different CNC controller panel with exchangeable screens. - Support ISO-1056 preparatory function code, auxiliary function code and other command codes. - Real time interactive operation of dynamic rotating, zooming, moving and full screen. - In-depth Machine Control Panel application of different industrial models in 1 hardware setup. - Manipulation of virtual CNC machine through real industrial approach. - Support CAD/CAM files such as MTS, UG, PRO-E, MasterCAM etc. - Support self-defined code of each system and canned cycle. - Built in with machine simulation. Open system qualities. - Ability to implement methodical concepts for training. - Free configuration in any type of machine structure & NC code controllers. - Fully customizable operator interface. such as coolant display, tool changes & hand wheels knobs display System configuration: LCD panel : FULL HD LED-Backlight Screen Diagonal : 21.5 inch Aspect Ratio : 16:9 Support Color : FULL High Definition Colors Certificate : CE, FCC, ROHS, UL Touch Technology : 10 Multi Point touch screen Resolution : 1920 X 1080 Touching Density : 10000 Touch point/ square inch Touch Sensibility : 10-100 g Response Time : < 5 ms Durability : > 35,000,000 single touch CPU : Intel-Core i3-3220 3rd Generations Chipset : Intel@ H61 RAM : 4GB/DDR3/1333MHz Hard Disk : 1TB SATA Hard Drive Graphics Card : NVIDIA GeForce GT610M 1GB VRAM Input Voltage : 100-240VAC 50/60Hz Power Supply : 130W Power Adaptor Operating System : Win7 Professional or latest version Configured for : CNC milling technology Training Outline: The Emulator is come together with following training outlines (will change according to improvement & technology flow): CHAPTER 1 SUMMARY OF EMULATOR 1.1 Brief introduction of the emulator 1.2 Function of the emulator

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1.2.1 Controller 1.2.2 Function introduction CHAPTER 2 OPERATIONS OF EMULATOR 2.1 Start up interface of the emulator 2.1.1 Single machine version startup interface 2.2 Setup of toolbar and menu 2.3 File management menu 2.3.1 Machine parameter 2.3.2 Cutter management 2.3.3 Workpiece parameter and accessory 2.3.4 Rapid simulative machining 2.3.5 Workpiece measurement 2.3.6 Rec parameter setup 2.3.7 Warning message CHAPTER 3 PANEL OPERATION 3.1 Machine panel operation. 3.2 NC system operation 3.2.1 Keystroke introduction 3.2.2 Manual operation of virtual NC machine CHAPTER 4 CONTROLLER OPERATION 4.1 Panel operation 4.2 NC system operation 4.2.1 Button introduction 4.2.2 Manual operation of machine 4.3 Auxiliary function (M Function) 4.4 Examples

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SCADA system software for using the stations The CIM system should include the following SCADA packages: Order entry, for user to key in product ID, quantity, User ID. The CIM system has other modules such as Item Master file that allow keying of Finish goods and raw

material stock info. Administrator module that allow creation of user ID and accessibility. Sales order module to key in Order. Inventory and warehouse module that allow keying of opening stock and other stock transactions.

Bill of Material (BOM) Manager, for user to key in simplified Production Planning& Control and maintains part quantity entered manually or automatically by ASRS.

BOM will identify the usage of raw materials for each production of finish goods. Each raw material location will be stated in the Item Master file to provide info to ASRS on the material to automatically pick accordingly.

Process configuration, for user to configure product-manufacturing process (example, assembly of parts model).

Process configuration can be done by user to determine production processes, conditions and requirements, (for example models selection, quantity of production, assembly process, etc.)

Order dispatch, for user to select order to dispatch to cell controllers. After receiving order, with the BOM, the system will identify whether the raw materials required are enough. If raw materials required are available, the system will produce a list of raw materials with quantity and location to the ASRS to start production

Robot program manager, central depository for all robot programs.

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The robot programs may be stored in one of the PC and they may be manually transferred to or from robot through the TCP/IP network.

Order tracking, tracks status of each order. Order tracking in term of order status such as open order, order in progress and order completed.

Machine monitoring, tracks status of each machine in 2D real time simulation layout. The CIM software besides providing ASRS functions, also provide HMI and machine status monitoring.

Computer system for SCADA & vision system Minimum Hardware / operating system requirement

Intel i5 processor Windows 7 4GB DDR2 RAM CD or DVD driver Touch screen Monitor

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EDU VR1 CIM-110 (For Nakhon Si Thammarat Seaboard Industrial College, Thailand) Station 1: Automatic Storage & Retrieval Sub-system

5. EDU CIM / FMS References

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Station 2: Material Handling Sub-system - Conveyor - Pallet Station 3: Flexible Manufacturing System

• - 6-axis articulated robot • - EDU VR1 Mill-TB

(EDU CNC Milling machine with built-in troubleshooting board)

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Station 4: Vision Inspection Sub-system Station 5: Central Control Sub-system - SCADA - PLC - RFID

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On-site system commissioning, tuning & training

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EDU VR1.5 CIM (For Salman University, Al Kharj, Saudi Arabia)

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EDU VR1 CIM-110 (For University Malaysia Pahang, UMP) On-site installation and commissioning

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Application training

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EDU VR1 SMART CIM-101 (For MJII (formerly KKTM Beranang), Malaysia)

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Automated System (AR Finisher) For Automated Enforcement System

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EDU VR2 – CIM

Auto Storage / Retrieve System (ASRS)

Vision Inspection System Assembly System

Materials transfer - FMS (lathe, Mill & robot) / Conveyor

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EDU - CIM (with Custom Made Machine)

Auto Storage / Retrieve System (ASRS) Custom made XYZ engraving machine with Siemens 802C

Inspection System Assembly System

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Computer Integrated Manufacturing (CIM) REFERENCE with EDU Machines In ITE College Centre EDU – CIM CKD

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Computer Integrated Manufacturing (CIM) REFERENCE with EDU Machines

EDU VR2 - CIM Setup at Islamic University Yogyakarta, Indonesia

EDU VR1 - CIM Setup at Perlis University, Malaysia EDU VR1 - CIM Setup at Rajaphat University, Thailand

EDU VR1 -CIM Setup at ITE Yishun with Spinner E-MILL, Singapore

EDU VR1- CIM Setup at ITE Macpherson with Spinner E-MILL, Singapore

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Other CIM / FMS Models

EDU VR1 – CIM with CNC router

EDU VR1 – CIM with EDU Mill VR1.5

EDU IMS – Integrated Modular System

Documents

Proposal Of EDU VR1 CIM-120 TB - mtsdidactic.com … · a Page 4 of 38 COPYRIGHT This document is the sole property of the MTS Didactic Group of Companies. Recipients of the document