MPS500 Manual Robot Assembly CNC105 Siemens A002

Robot Assembly
MPS 500 with
Mitsubishi RV – 2AJ
programmed with
COSIMIR Industrial
Order-NR.:
Type: Manual MPS500
Designation MPS500_Manual_Robot_Assembly_CNC105_Siemens_A002.doc
Printed: July 08
Autor: Schober
Graphics: Schober
Layout: Schober
© Festo Didactic GmbH & Co.KG., D-73770 Denkendorf, 2008
Internet: www.festo.com/didactic
e-mail: did@festo.com
This manual, all text and illustrations contained included, is protected by copyright. Any utilization
outside the limits of the copyright law and other than training purposes are not permissible without
our definite approval. This applies in particular to reproductions, operations, translations, micro
filming and the storing and processing into electronic systems. Parts of this manual may be copied by
the authorized user, exclusively for teaching purposes. Distribution of this documentation, as well as
reproduction, use and spread of its contents is prohibited, insofar not permitted explicitly. Offences
are liable to compensation. All rights reserved, especially the right to execute registrations concerning
patents, designs for use and patterns.
2 © Festo Didactic GmbH & Co.KG • MPS500

1. Intended use
The User Manual must be to hand at all times. Keep it close to the machine.
This installation was developed and manufactured only for use in basic and further
training in the fields of automation and communications. The training company
and/or the training staff must ensure that the trainees observe the safety
precautions described in the accompanying manuals.
Furthermore this manual describes setup and possible uses of the singular stations.
It contains all information and data required for commissioning, maintenance and
operation.
Festo Didactic accepts no liability for injury or harm to trainees, the training
company and/or any third parties occurring when the installation is used for any
purpose apart from training, except Festo Didactic has caused such injury or harm
intentionally or by grossly negligence.
The manual is divided into four parts:
• Part A
In addition to technical data, Part A contains an overview of the possible uses of
the stations.
• Part B
Part B contains some exercises and the solutions for this exercises (Not available
for each station).
• Part C
Part C contains the pneumatic and electrical diagrams for the station and the
listing of the control programs (Not available for each station).
• Part D
Part D contains data sheets and technical information about the electrical and
electronic modules used.
© Festo Didactic GmbH & Co.KG • MPS500 3

List of applicable standards The list below provides an overview of the most important standards and
and regulations regulations relating to mechanical, electrical and safety-engineering design and
production.
• DIN EN 292 -Machine safety

• DIN EN 60204 - Electrical equipment of industrial machines
• DIN VDE 0113 - See DIN EN 60204
• DIN 40719 - Circuit documentation
• VDI 2853 - Technical safety requirements concerning the building, equipping and
operation of industrial robots
• VDI 2853 - Technical safety requirements concerning automated production
systems
• VDI 2411 - Terms and explanations in conveying and handling
• VDI 2860 - Assembly and robotics - terms
• VDI 2861 - Assembly and robotics - characteristic quantities
• DIN 19245 - PROFIBUS Part 1-3
As far as possible, the System is maintenance-free. All bearings are lubricated for
life. The installation was designed in such a way as to keep the number of wearing
parts to a minimum. This does not include machines that are part of optional
expansions (such as industrial robots).
At this point we would like to point out that this manual and the concept of the
operating instructions for a Flexible Training System of this type are regularly
updated. To ensure that the instructions are ever more user-friendly, you would help
us a great deal by passing on your suggestions for improvement. Please let us know
of your suggestions, corrections or ideas, either in writing or via telephone:
+49(711-3467-0)

Contents
1. Intended use _____________________________________________________ 3
2. Introduction ______________________________________________________ 9
2.1. General______________________________________________________ 9
2.2. Robot cell ___________________________________________________ 10
2.3. Didactic structure ____________________________________________ 11
2.4. Scope of tasks of the stations __________________________________ 12
2.4.1. Mechanics ______________________________________________ 12
2.4.2. Pneumatics _____________________________________________ 12
2.4.3. Electrics ________________________________________________ 12
2.4.4. Informatics ______________________________________________ 12
2.4.5. Bus technology __________________________________________ 12
3. General safety instructions _________________________________________ 13
3.1. Use according to regulations ___________________________________ 13
3.2. Handling the system __________________________________________ 13
3.2.1. Dangers in handling the machine ____________________________ 13
3.2.2. Safety precautions in standard operation _____________________ 13
3.2.3. Dangers due to electric current _____________________________ 14
3.2.4. Dangers due to pneumatic energy ___________________________ 14
3.2.5. Maintenance – Servicing – Malfunction removal ________________ 15
3.2.6. Organizational measures __________________________________ 15
3.3. Personnel ___________________________________________________ 15

Contents
3.3.1. Notes on personnel _______________________________________ 15
3.3.2. Training operations _______________________________________ 15
3.3.3. Outside training operations ________________________________ 15
3.3.4. Safety symbols __________________________________________ 16
4. Commissioning __________________________________________________ 17
4.1. Transport ___________________________________________________ 17
4.2. Set up ______________________________________________________ 18
4.2.1. General information ______________________________________ 18
4.3. Commissioning ______________________________________________ 21
4.3.1. Pneumatic commissioning _________________________________ 21
4.3.2. Electric commissioning ____________________________________ 21
4.3.3. Establishing communication connections _____________________ 22
4.4. Connection RIA – Box X1, X2, X3, X4 _____________________________ 25
4.4.1. EMERGENCY-STOP system _________________________________ 25
5. Operation _______________________________________________________ 27
5.1. Start-up process general_______________________________________ 27
5.2. Start up station ______________________________________________ 28
5.3. Reset conditions _____________________________________________ 29
5.4. Process Start ________________________________________________ 29
6. Robot RV-2AJ ____________________________________________________ 31
6.1. Mitsubishi robot RV-2AJ _______________________________________ 31
6.2. Drive Unit RV-2AJ _____________________________________________ 32

Contents
6.2.1. Functions _______________________________________________ 32
6.2.2. Teach pendant RV-2AJ _____________________________________ 34
6.2.3. Set up RV-2AJ ____________________________________________ 35
6.2.4. To operate the robot ______________________________________ 36
6.2.5. Teach position example ___________________________________ 39
6.3. Robot positions ______________________________________________ 40
6.3.1. Position P1 ______________________________________________ 41
6.3.2. Position P2 ______________________________________________ 42
6.3.3. Position P3 ______________________________________________ 43
6.3.4. Position P4 ______________________________________________ 44
6.3.5. Position P5 ______________________________________________ 45
6.3.6. Position P6 ______________________________________________ 46
6.3.7. Position P9 ______________________________________________ 47
6.3.8. Position P99 _____________________________________________ 48
6.3.9. Position PRGR1 __________________________________________ 49
6.3.10. Position PRGR2 ________________________________________ 50
6.3.11. Position WAIT__________________________________________ 51
6.3.12. Position MILL __________________________________________ 52
6.4. Handshake __________________________________________________ 53
6.5. Connection of the drive unit with RIA-box _________________________ 54
6.5.1. Interface Drive unit Inputs _________________________________ 54
6.5.2. Interface Drive unit Outputs ________________________________ 56

Contents
6.6. Program structure ____________________________________________ 57
7. Technology _____________________________________________________ 59
7.1. drawings ___________________________________________________ 59
7.2. Technical datas ______________________________________________ 60
8. Electrical system _________________________________________________ 61
8.1. Power supply ________________________________________________ 61
8.2. I/O-Components _____________________________________________ 62

2. Introduction
2.1. General This manual describes the handling of a MPS500 system with Emco Mill 105. It
contains explanations and descriptions of all the processes required for operation.
Description of facts ensues partly by means of graphics or images, which are to
serve an easier understanding.
The MPS500 system is a successively expandable system consisting of individual

stations. However, the central unit is always the transport system. For this reason,
this manual is not only a general manual, but also a station manual for the transport
system. Each one of the other stations possesses its own manual.
Operation is not dependant on the operating position the material flow is being
started from. Still, the sequential order of the stations require adherence, as it is
pre-defined in the PLC-program.
The MPS500 system is designed in such a way, that the amount and kind of MPS-
stations attached is of no importance. A complete processing cycle of the work-piece
is always warranted. For this, the transport system is required under any
circumstances.
In complete set-up, the work-piece is isolated from the distribution station to be

transferred to the test station. The test station checks the condition of the work-
pieces, ejects rejects in case of occurrence and transfers the faultless pieces to the
transport station. Consequently, the product input into the system ensues from the
distribution station. In case no distribution station exists in the system, the work-
piece can be placed onto a work-piece carrier, anywhere in the system. It is to be
noted that no work-piece carriers are to be retrieved from the system.
The processing station is equipped by means of a PIC-alfa station. The work-piece
receives processing, followed by testing. The PIC-alfa station returns the work-piece
to the transport station.
The work-piece is tested for shape tolerance in the vision station.
The robot station assembles a model cylinder from a basic body. The cover, coming
from the magazine, is processed in the milling machine.
The AS/RS station is able to store work-pieces and, on demand, returns them to the
system.
In the sorting/commissioning station the work-pieces can be re-retrieved from the
system. The work-pieces are transported from the transport system station to the
sorting station by means of a PIC-alfa station, where the work-pieces are arranged
according to colour, ready for product output. From the commissioning station the
work-pieces are not released by colour, but by the number of pieces. Each time 18
pieces are being commissioned. The three upper slides are on stand-by for the work-
pieces, the fourth slide is for parts storage in the adjustment process.

Introduction
2.2. Robot cell The function of the Robot Cell is assembling different cylinders (metal, black and
red). The raw material is provided by the conveyor system without type coding
(check material). Within the cell, the differentiation of the material has to be done
first by using corresponding sensors. Controlling the sensors and actuators of the
assembly process is done directly via the robot drive unit (refer to the RIA-box).
That's why this station can be used independently from other stations or a more
complex process.
The communication between the robot cell and the conveyor system is realized with
digital I/O-communication.
The following chapters comprising the Hardware configuration, this means the
cabling of the Robot, the Software configuration of the user program and the
commissioning of the Robot. To program the Robot, COSIMIR Industrial has been
used.

Introduction
2.3. Didactic structure The installation is structured, to enable methodical learning, i.e. from single use of
modules to the complex and complete installation. Perhaps even in combination
with further systems.
For example, it is possible to pick out a single module to start with the first steps,
e.g. the robot.
• First the mechanical assembly is considered. The robot’s radius of action

requires integration into the location of the robot.
• The following step could be the connection of all cables required for operation
and the set-up of the robot.
• Moving the robot and teaching the required positions are the first real operations
with the robot, which introduces the user how to deal with the teach-box.
• The robot’s programming can be started, as soon as the robot can be moved by
the teach-box. Small programs, which can be created by using the
Cosimir/Cosirob software, are expandable for the complex programs.
• Orders to further stations and from other controls can be installed in the
programs.
Once the learning process of this module has been concluded, these learning steps
can be transferred to the next module. As soon as all of the modules have been
processed individually, the modules can be interconnected and the programs can be
adapted. A complete production process can be simulated.
This is an ideal training area for the professional practice of mechatronics, as well as
all of the technical ranges (mechanical, electrical and pneumatic processes) are
represented in a simple and clearly way, concerning each one of the modules and
the complete system.
© Festo Didactic GmbH & CoKG. • MPS 500 11

Introduction
2.4. Scope of tasks of the The stations are possessing a varied range of functions. A small extraction of the
stations various possibilities of the stations follows.
2.4.1. Mechanics
• Obtaining basic mechanical skills about the assembly of basic modules

• Obtaining complex mechanical skills about the assembly of a complete station or
complex modules
• Assembly provides instructions about the technical connections between the
various components
2.4.2. Pneumatics
• Understanding of a pneumatic circuit by set-up and pipe connection of the

cylinders and valves
2.4.3. Electrics
• Obtaining electrical knowledge of reading a circuit diagram, concerning the

wiring of sensors and valves
• Functional understanding of the individual modules e.g. in case of error
detection, by means of a circuit diagram and a measuring device
2.4.4. Informatics
• Understanding of programs receiving an insight by controlling the individual

components of the programs
• Changing and improving programs recognizing and removing errors in a
complete program
• Writing new programs new programs can be written by combination of the skills
obtained in the steps before.
2.4.5. Bus technology
• Instructions in the various bus technologies avoidance to gain intimate

knowledge about the various bus technologies is made impossible by working
with the programs

3. General safety instructions
3.1. Use according to This installation has been developed and produced exclusively for training purposes
regulations in the fields of automation and communication. The training company, as well as the
instructors have to ensure, that the trainees pay strict attention to the safety
precautions, as described in the accompanying manuals.
Festo Didactic accepts no liability charges for possible damages to any trainee of the
training company and/or further third parties, which might occur during
use/operation of the installation, if it is not part of a real training situation; except
Festo Didactic caused such damages deliberately or by negligence.
Due to the product liability law and various EC-directives, the following directions
are required and are to be strictly observed by the operator.
3.2. Handling the system 3.2.1. Dangers in handling the machine
The installation has been constructed technologically up to date and in conformance

with the recognized rules of safety engineering. Nevertheless, during operation it is
possible that harm might be caused to the user or third parties or that the
installation or other property might get damaged. Therefore, the installation has to
be handled according to specified operational use in perfect technical condition
only.
Safety endangering malfunctions can not be tolerated during training and have to be
removed immediately.
3.2.2. Safety precautions in standard operation
Put the installation into operation only, once all of the protection settings are
completely functional.
At least, before starting operation, check the installation for externally visible
damages and for the reliability of the safety devices.
Do not grip into the installation while in operation.
Before circuit construction, circuit disassembly and circuit modification: switch off
air pressure and power supply.
General safety regulations are to be observed: DIN 58126 and VDE 0100.

General safety instructions
3.2.3. Dangers due to electric current
As soon as maintenance is completed, check the function reliability of the safety

devices.
Only trained experts in electric or electronic engineering are permitted to carry out
work on the electric supply system.
The terminal boxes are to be kept closed at all times. Access must be permitted only
under supervision of a member of the training staff.
Do not activate electric limit switches manually during fault search. Tools are to be
used.
Only low voltage 24VDC is to be used.
3.2.4. Dangers due to pneumatic energy
Accidents might occur due to bouncing off tubes, caused by air pressure. Interrupt
air pressure supply immediately.
Caution! When the air pressure supply is activated, cylinders may move in or out.
Do not uncouple any tubes under air pressure supply. Exception: Fault finding. In
this case, keep on holding the end of the tube.
Do not exceed the permitted operating pressure. See data sheets.

3.2.5. Maintenance – Servicing – Malfunction removal
Carry out adjustments and inspections as instructed, in accordance with the

specified intervals.
Secure the compressed air and electricity supplies to prevent unintentional start-up.
During inspections, maintenance and repair work, the machine must be de-
energized, de-pressurized and secured against unexpected restart.
All screw connections released during maintenance, inspection or repair work must
be checked to ensure correct re-tightening.
3.2.6. Organizational measures
All existing safety devices must be checked at regular intervals.
3.3. Personnel 3.3.1. Notes on personnel
Basically two situations have to be considered, concerning matters on personnel.
• Activities during training operations

• Activities outside training operations
3.3.2. Training operations
Trainees are permitted to work with the machine only under strict supervision of an
experienced person or an instructor.
Activities of trouble-shooting and fault correction are to be checked by the

instructor. Special care should be taken regarding safety aspects.
3.3.3. Outside training operations
Activities in the areas of maintenance, service and repair are to be carried out by
only persons with appropriate technical qualifications.

3.3.4. Safety symbols
In this manual the following danger designations and signs are being used:
This symbol indicates an immediate

threat to a persons health or life.
DANGER !
Failure to pay attention to this symbol may result in serious health damage, which
may even lead to life-threatening injuries.
This symbol emphasizes important

information for correct machine
handling.
IMPORTANT
Failure to pay attention to this symbol may result in damages to the machine or to
its surroundings.
This symbol indicates operational tips

and especially useful directions.
i
INFORMATION
This symbol assists you to make optimal use of all of your machine’s functions.

4. Commissioning
4.1. Transport Care is to be taken that the transport of the stations is to be executed only by a
suitable transport vehicle. The weight amounts up to 500 kg, depending on the
station.
The route of transport is to be cleared in advance, to be accessible to the transport

vehicle. Installation of warning signs or barriers may be required.
i The transport boxes are to be opened with care, as additional components, such as
computers may be contained in the delivery, which are to be protected from falling
out.
Once the transport box has been opened and the possibly contained additional
components removed, the station can be taken out to be transported to its
destination by means of two fork-lifts or one fork-lift truck.
Please check the stability of all of the profile connectors by means of an Allen key
size 6. The connectors may have come loose during transport, due to inevitable
vibration.
Pay special attention to all overhanging components. Sensors and similar small
parts are very easily damaged in case of improper transport.
The stations are not to be picked up by or even under the mounted feet – increased
risk of becoming trapped or contused.

Commissioning
4.2. Set up 4.2.1. General information
The installation is to be set up in a frost-free room with maximum relative air

humidity of 70%.
In countries with an atmospheric humidity over 70% and temperatures above 25

degrees Celsius, the premise is to provide an air-conditioning system for constant
surrounding conditions.
To comply with the levels of the regulatory guidelines, sources of electrical

interference such as welding plants, large motors and contactors are to be checked
for electromagnetic compatibility in advance and screened where necessary.
To ensure faultless operation a load-bearing floor is required to avoid settling.
Allow sufficient distance between the installation and the wall of the room.
Any dust originating from construction work has to be kept off the installation (by
covering).

Commissioning
For a more simple room planning the complete installation design is shown in the
following. The robot station is to line up that a fault-free workpiece handing over can
take place.
Set-up situation MPS 500 example

Commissioning
Dimensional drawing of set-up MPS 500 example

Commissioning
4.3. Commissioning The robot station can be built up only if the transport system stands on its final
position and the commissioning for the transport system has been carried out.
The robot station has to be mounted at the transport system, utilising the included
profiles. Afterwards, the distance of the robot station is fixed in such a way, that the
robot is able to move over operating position. At this point, screw and lean the
profiles lightly onto the basic frame of the transport system station, by means of the
angles. Set up and align the CNC machine by means of a spirit-level and tighten the
connector profiles afterwards.
It may be possible, that the transfer positions must be taught corrected.
4.3.1. Pneumatic commissioning
The mechanical construction must be finished. At the beginning the stations have to
be attached to the pneumatic system of the room. In most cases the maintenance
unit is on the profile plate of the station. The coupling has a 5 mm nominal diameter.
If the available system is equipped with 7.9 mm nominal diameter, it is possible to
change the coupling of the maintenance unit with a greater one. (reducer 1/8 on 1/4
necessary). If this has been carried out, the stations can be provided with 6 bar and
the pneumatic commissioning is realised.
4.3.2. Electric commissioning
The station must be provided with electrical voltage now.

The basic rack is provided with a power supply unit witch is provided with a voltage
of 110/230 V. The delivered cable has a completely protected norm plug, this must
be plugged into an electrical socket protected sufficiently. Distribution strips are,
enclosed to this also for the connection of other stations. If an extension for the
cable is necessary for the distribution strip, this can to be executed only by a trained
expert. The electrical socket must be protected, corresponding to the customer.
The power supply unit (24 VDC) of the sensoric and the actuators of the station is
provided in each case by means of a 2-pin cable.

Commissioning
4.3.3. Establishing communication connections
The communication connections to the transports system is to be set up according

to the following example.
In order that the system “knows” that the station is present and processing can
occur station, it has to be connected to the system by I/O-connectors. At each case,
the connections are established the control panel.
For more detailed information, the connection possibilities are listed below:
Connection by I/O – one side SYS–link plug / one side SYS–link plug
between robot station (RIA-BOX) and transport system

Commissioning
1. The drive unit must be connected with the robot with two cables – CN1 and CN2
on the backside of the unit.
2. The Teach-Panel must be connected to the front side of the drive unit
connection TP.
3. Connect the power-supply to the drive unit.
4. The I/O-interface (Extension) of the drive unit has to be connected via a 50-pin
cable with Centronics connector to the RIA-box2 (X0).
5. The Drive-Unit has to be connected with the DIAG board of the station (X11=>
CN100)
6. Connect the Ria-Box1 with the DIAG-Board (X0 => X13)
7. The I/O Terminal from the robot station has to be connected with the Ria-Box 1
via standardized Sys-Link cable X1=> XMA1
8. The I/O Terminal from the robot station has to be connected with the Ria-Box 1
via standardized Sys-Link cable X2=> XMB1
9. The conveyor system has to be connected to X4 at Ria-Box 1 and the control
panel XMG1 to X3 at Ria-Box1 using a standardized Sys-Link cable
10. The milling machine is connected to the Ria-Box 2 at X1
11. For supervision and programming, please connect the drive unit to the serial
COM port of your computer, using the special RS-232-cable.
12. In addition, an external Emergency Stop switch could be connected to the drive
unit backside (green connector, details refer controller manual). If you don't use
the external Emergency switch, you have to jumper this input (refer to the
controller manual).

Commissioning

Commissioning
4.4. Connection RIA – Box

X1, X2, X3, X4
Wiring of the RIA Box 1
4.4.1. EMERGENCY-STOP system
See transport system manual

Commissioning

5. Operation
5.1. Start-up process For the MPS500-installation the first start-up has been executed at the customer
general already. For the installation to be ready for operation execute the following
directions:
1. Mains supply 230 V AC for power supply unit, connect control cabinet of
transport system and commissioning station.
2. Power supply unit 24V DC with connections +24V/0V/earth are connected
correctly to the stations and activated (except for robot: only after adjustment of
the transport system).
3. Each station is supplied with ca. 6 bar compressed air.
4. I/O-communication connectors (laboratory plugs) are connected according to
communication plan.
5. All of the PLC-programs are loaded into the respective controls. The controls are
switched to RUN and the red error indicators of the controls are not on.
6. All of the EMERGENCY-STOP signal generators (push-buttons, door contact, light
barriers, a.s.o.) are not to be switched on, i.e. activated.
7. Activate the main switch of the transport system station.
8. Acknowledge the EMERGENCY-STOP of the control cabinet of the transport
system.
9. Remove all of the work-pieces from the installation, i.e. stations:
- Remove work-pieces from the palettes on the transport system
- Clear the storage shelves of the AS/RS station (HRL20)
- Clear the slides of the sorting/commissioning station
10. The magazines of all of the stations are to be stocked up:
- Magazines (piston, spring and cover) of the robot station with assembly
- Fill magazine of the distribution station with basic bodies
11. Now adjust the stations and the transport system (see chapter – Operation).
12. The drive unit must be connected with the robot with two cables – CN1 and CN2
on the backside of the unit.
13. The Teach-Panel must be connected to the front side of the drive unit
connection TP.
14. Connect the power-supply to the drive unit.
15. The I/O-interface of the drive unit has to be connected via a 50-pin cable with
Centronics connector to the RIA-box1 (X0).
16. The RIA-box has to be connected with the interface of the station (X1=> XMA),
the robot I/Os (X2=> XMB), the conveyor system (X4) and the control panel
(X3=> XMG), by using a standardized Sys-Link cable
17. For supervision and programming, please connect the drive unit to the serial
COM port of your computer, using the special RS-232-cable.
18. In addition, an external Emergency Stop switch could be connected to the drive
unit backside (green connector, details refer controller manual). If you don't use
the external Emergency switch, you have to jumper this input (refer to the
controller manual).

Operation
5.2. Start up station A first time start up of the system must be realized by Festo Germany.
After switch on the drive unit, please make sure the robot arm is near the position 99
already, because the robot maybe cannot move to position 99 from any other
position (collision with the magazines).
If the robot arm is not near the position 99, please move the arm using the
Teach-Box to P99. To do so, please switch the key-switch of the drive unit to the
position TEACH, then switch the key switch of the Teach-box to position ENABLE.
By pressing the dead-man-switch permanently and pressing the Step/Move button,

you can move the robot-axis using the J1-J6-buttons near to the position 99.
After this, please switch the key-switches back to the positions:
AUTO(OP) on the drive unit and DISABLE on the Teach-box.
Choose the program NO. 1 on the drive unit by pressing the button CHNG/DISP as
long as P.0001 will appear on the screen
Now please activate the servo motors by pressing the SVO ON button-please wait
until the LED of this button is on.
Now please press the START button-LED is on – the program is now active and the
robot starts to work.
Follow the steps to reset the CNC-machine:
1. Switch on main switch CNC milling machine (Key switch)

2. Switch on PC / Mill
3. Application WIN NC 32 is started automatically
4. Switch key switch at CNC- milling machine to FMS- mode
5. Message door closed (only when door is closed)
6. Open door with this button at CNC-keyboard
7. Open vice with this button at CNC-keyboard

Operation
8. If a workpiece is available take out from vice.
9. Close door with this button at CNC-keyboard
10. Turn switch at CNC-keyboard to following position
11. Variant 1 - Press REF ALL (button 5 in NUM- area of keyboard). Axles make their
reference move.
Variant 2 - Press +X, +Y, +Z or –X, -Y, -Z at CNC-Keyboard to make the reference
move.
Variant 3 – Press the button with the reference sign – all axis make their
reference move.
12. After all axis have done their reference move the error message at PC monitor is
off and the CNC- machine is ready with reference mode.
13. Turn switch at CNC-keyboard to following position
14. Choose program 999 and start with start button.
15. Now the station is in automatic mode.
5.3. Reset conditions Press the RESET button on the Control Panel to move the robot to it´s starting
position P99. After reaching P99, the LED of the Reset-button is on.
5.4. Process Start To start the process, press the START button once, the Reset-LED is off and the Start-
LED is on
Missing springs will be shown by LED Q1,

missing covers by LED Q2.
If piston rods are missing (black or metal), the LED´s Q1 and Q2 are on.
Please refill the corresponding material and press START button once to continue
with the process.

Operation

6. Robot RV-2AJ
6.1. Mitsubishi robot The robot is responsible for the workpiece handling.
RV-2AJ
RV-2AJ
Performance
Inputs 15 Inputs for communication
Outputs 14 Outputs for communication
Max. reservation 1 workpiece

Robot RV-2AJ
6.2. Drive Unit RV-2AJ
The Drive Unit is the controller for the robot. It is possible to extract the drive unit
with an I/O module for further functions.
6.2.1. Functions
1. Plug for teach pendant

2. RS 232C– Interface for programming
3. Key switch for teach or auto modes
4. Display
5. Main switch
6. Emergency stop
7. Remove teach box button
8. Servo off button
9. Servo on button
10. Stop button
11. Start button
12. END button
13. RESET button
14. Down button
15. Up button
16. CHNG button

Robot RV-2AJ
On the backside of the drive unit, there are some more plugs and interfaces.
17. I/O- interface

18. Emergency-plug/power supply 24V
19. CN1 for robot communication
20. CN2 for robot communication
21. Power supply 230V

Robot RV-2AJ
6.2.2. Teach pendant RV-2AJ
To operate the robot in stand alone mode, the teach pendant is necessary. The
buttons have different functions, depending on the different modes. With the key
switch at the Drive unit, it is possible to choose the following three modes.
• Position Auto (OP) for stand alone mode.

• Position Auto (EXT) for communication with other controller.
• Position Teach for teach mode.
Teach pendant

Robot RV-2AJ
6.2.3. Set up RV-2AJ
For stand alone mode.
Drive-Unit
CN1
CN2
Ria-Box
I/O-cable 50 pin
Teach box Drive-Unit
Programming PC
Robot RV-2AJ set up

Robot RV-2AJ
6.2.4. To operate the robot
To move the robot, the following points have to be done.
1. Connect power supply Drive unit / 230 V

2. Connect robot cables CN1 and CN2 from Drive unit to robot.
3. Plug teach pendant to Drive unit.
4. Emergency strap at back side of the Drive unit or emergency circuit to ria box.
5. Unlock Emergency stop at Drive unit and teach pendant.
6. Key switch ENABLE/DISABLE at teach pendant to enable.
7. Key switch Drive unit to teach (see example)
8. Switch on Drive unit / takes some time
9. Wait till display at teach pendant is ready
10. Press INP/EXE button – Menu teach pendant available
11. Choose TEACH mode
12. Press the black switch on the back side of the teach pendant, simultaneous
press the STEP/MOVE button. Now the drives are released*. (Click-sound)
* You have to execute this point the hole time to move the robot.
Now it is possible to move the robot.
The following three modes are available for to move the robot.
• Joint mode every axle separate.

• XYZ mode Coordination point in the robots body.
• Tool mode Coordination point in the robots gripper. Here it is possible to make a
tool length correction.
The modes are indicated in the teach pendants display. Choose one, the allocation
off the buttons is shown in the following drawings.
To change the speed of the robot press
• +/FORWARD to get faster

• -/BACKWRD to get slower
The speed is allocated in the teach pendant display in the right top corner. Speed
between 3%-100% is available.

Robot RV-2AJ
Joint-Mode
Z-
Y+ Z+ B-
Y- X+ B+
X- C-
C+
Functions of teach pendant in Joint mode
XYZ-Mode
B+
Z+ A-
A+
X- Y+ B-
Y- X+
Z-
Functions of teach pendant in XYZ-Mode

Robot RV-2AJ
B+
Z-
Tool-Mode
X- B-
X+
A-
A+ Z+
Without tool length correction
With tool length correction
Functions of teach pendant in Tool-Mode

Robot RV-2AJ
6.2.5. Teach position example
To re-teach a position, the following points have to be done.
1. Connect power supply Drive unit / 230 V

2. Connect robot cables CN1 and CN2 from Drive unit to robot.
3. Connect PC with cosimir industrial / educational with Drive unit.
4. Plug teach pendant to Drive unit.
5. Emergency strap at back side of the Drive unit or emergency circuit to ria box.
6. Unlock Emergency stop at Drive unit and teach pendant.
7. Key switch ENABLE/DISABLE at teach pendant to enable.
8. Key switch Drive unit to teach
9. Switch on Drive unit / takes some time
10. Wait till display at teach pendant is ready
11. Press INP/EXE button – Menu at teach pendant available
12. Positions have to be available in Drive unit.
13. Choose teach mode
14. Press INP/EXE to list the different programs.
15. With ADDÇ and RPLÈ choose program. Task2 for program 2 a.s.o
16. Press INP/EXE to choose program
17. Press INP/EXE to activate program
18. Display looks like following
PR:Task2ST:1
LN:10
19. To change a position, press POS.
20. Display looks like following
MS.POS(Px )
21. Choose position with +/FORWRD and -/BACKWRD buttons
22. Select speed with
• +/FORWARD to get faster
• -/BACKWRD to get slower
23. Press the black switch on the back side of the teach pendant, simultaneous
press the STEP/MOVE button. Now the drives are released*. (Click-sound)
24. Press INP/EXE, robot moves to the chosen position
25. Now move the robot to the new position. Movement description see chapter (to
operate the robot) Example with XYZ mode.
26. Press STEP/MOVE and ADDÇ simultaneously
27. Release ADDÇ if you are sure that you want to overwrite the position.
28. Press ADDÇ again, and the new position is stored.
29. Don’t forget to load the position list into the PC.
* You have to execute this point the hole time to move the robot.

Robot RV-2AJ
6.3. Robot positions All positions have been defined by using a red workpiece.
Position Description
P1 Retrieve and return position on the pallet with RED workpiece (outer gripper
jaws)
P2 Workpiece mounting, teach with cone gauge in inner gripper jaws. Rotate
outer gripper jaws into direction of robot. The gripper jaws should be parallel
to the X-axis of the robot.
P3 Identify workpiece if black or not black with optical sensor in gripper jaws
P4 Gripping position at magazine for springs
P5 Position at piston pallet, teach with cone gauge in inner gripper jaws
P6 Release position if there is no detection during rotation of workpieces and

covers
P9 Gripping position for covers
P99 Retrieve and return position on the pallet with RED workpiece (outer gripper
jaws)
PRGR1 Position 1 to turn cover
PRGR2 Position 2 to turn cover
PWAIT Waiting position for CNC
PMILL Feeding position CNC

Robot RV-2AJ
6.3.1. Position P1
Retrieve and return position on the pallet with RED workpiece (outer gripper jaws)

Robot RV-2AJ
6.3.2. Position P2
Workpiece mounting, teach with cone gauge in inner gripper jaws. Rotate outer
gripper jaws into direction of robot. The gripper jaws should be parallel to the X-axis
of the robot.

Robot RV-2AJ
6.3.3. Position P3
Identify workpiece if black or not black with optical sensor in right gripper jaw

Robot RV-2AJ
6.3.4. Position P4
Gripping position at magazine for springs

Robot RV-2AJ
6.3.5. Position P5
Position at piston pallet, teach with cone gauge in inner gripper jaws

Robot RV-2AJ
6.3.6. Position P6
Release position if there is no detection during rotation of workpieces and covers

Robot RV-2AJ
6.3.7. Position P9
Gripping position for covers

Robot RV-2AJ
6.3.8. Position P99
Normal position

Robot RV-2AJ
6.3.9. Position PRGR1
Position 1 to turn the cover.

Robot RV-2AJ
6.3.10. Position PRGR2
Position 2 to turn the cover.

Robot RV-2AJ
6.3.11. Position WAIT
Waiting position for CNC

Robot RV-2AJ
6.3.12. Position MILL
Position to feed the CNC machine

Robot RV-2AJ
6.4. Handshake
M_out (7) 1
Robot ready 0
M_in (6) 1
Assembly start 0
M_in (7) 1
bad part 0
M_out(6) 1
Robot busy 0
M_0ut(4) 1 t=500 ms
Error Bit 0 0
M_out (4) 1 t=500 ms

Errror Bit 1 0

Robot RV-2AJ
6.5. Connection of the 6.5.1. Interface Drive unit Inputs

drive unit with RIA-
box
Name Output / Input Output Input Robot PIN Robot

Input Ria Ria Name
box box
Robot Workpiece not SB1 INPUT 1

X2:14 X0:16 16 IN 1
Station black XMB2:I1 CN100:16
assembly Orientation not SB2 INPUT 2

X2:15 X0:17 17 IN 2
okay XMB2:I2 CN100:17
Operation S1 INPUT 3
START button X3:13 X0:18 18 IN 3
panel XMG1:13 CN100:18
S2 INPUT 4
STOP button X3:14 X0:19 19 IN 4
XMG1:14 CN100:19
S4 INPUT 5
RESET button X3:16 X0:20 20 IN 5
XMG1:16 CN100:20
Robot Spring cylinder 1B1 INPUT 4

X1:13 X0:40 40 IN 8
Station retracted XMA2:I0 CN100:40
Magazine Spring cylinder 1B2 INPUT 5

X1:14 X0:41 41 IN 9
advanced XMA2:I1 CN100:41
Cover cylinder 2B1 INPUT 6

X1:15 X0:42 42 IN 10
retracted XMA2:I2 CN100:42
Cover cylinder 2B2 INPUT 7

X1:16 X0:43 43 IN 11
advanced XMA2:I3 CN100:43
Spring in pick 1S1 INPUT 6

X1:17 X0:44 44 IN 12
up position XMA2:I4 CN100:44
No cover in B1 INPUT 7
X1:18 X0:45 45 IN 13
pick up pos. XMA2:I5 CN100:45
Empty cover B2 INPUT 7

X1:19 X0:46 46 IN 14
magazine XMA2:I6 CN100:46
Downstream IP_FL INPUT 8

X1:20 X0:47 47 IN 15
station free XMA2:I7 CN100:47

Robot RV-2AJ

Input Ria Ria Name
box box
CNC INPUT 32
Door opened A5.7 X1:13 X0:15 15 IN 32
milling CN100:15
machine
INPUT 33
Door closed A5.6 X1:14 X0:16 16 IN 33
CN100:16
Clamping
INPUT 34
device A5.1 X1:15 X0:17 17 IN 34
CN100:17
declamped
Clamping
INPUT 35
device A5.0 X1:16 X0:18 18 IN 35
CN100:18
clamped
Reference- INPUT 36
A4.5 X1:17 X0:19 19 IN 36
mode CN100:19
INPUT 37
Program stop A4.6 X1:18 X0:20 20 IN 37
CN100:20
INPUT 38
CNC ready A4.4 X1:19 X0:21 21 IN 38
CN100:21
Reference- INPUT 39
A4.7 X1:20 X0:22 22 IN 39
position CN100:22

Robot RV-2AJ
6.5.2. Interface Drive unit Outputs

Input Ria Ria Name
box box
Operation H1 OUTPUT 0
Start lamp X3:1 X0:4 4 OUT 0
panel XMG1:1 CN100:4
Initial position H2 OUTPUT 1

X3:2 X0:5 5 OUT 1
lamp XMG1:2 CN100:5
Special
H3 OUTPUT 2
function X3:3 X0:6 6 OUT 2
XMG1:3 CN100:6
Lamp Q1
Special
H4 OUTPUT 3
function X3:4 X0:7 7 OUT 3
XMG1:4 CN100:7
Lamp Q2
Robot Retract spring 1Y1 OUTPUT 8

X1:1 X0:10 10 OUT 8
station cylinder XMA2:O0 CN100:10
Magazine Retract cover 2Y1 OUTPUT 9

X1:2 X0:11 11 OUT 9
cylinder XMA2:O1 CN100:11
CNC OUTPUT 32
Start program E7.3 X1:1 X0:4 4 OUT 32
milling CN100:4
machine
Automatic OUTPUT 33
E7.1 X1:2 X0:5 5 OUT 33
mode CN100:5
OUTPUT 34
referencing E7.2 X1:3 X0:6 6 OUT 34
CN100:6
Auxiliary drives OUTPUT 35

E7.0 X1:4 X0:7 7 OUT 35
on CN100:7
OUTPUT 36
Open door E8.3 X1:5 X0:29 29 OUT 36
CN100:29
OUTPUT 37
Close door DOOR_M X1:6 X0:30 30 OUT 37
CN100:30
Open clamping OUTPUT 38

E7.7 X1:7 X0:31 31 OUT 38
device CN100:31
Close clamping OUTPUT 39

E7.6 X1:8 X0:32 32 OUT 39
device CN100:32

Robot RV-2AJ
6.6. Program structure The robot program is written in a sequence. There is only one program for
downloading to the drive unit.
Peripheral units like valves or sensors are controlled by the drive unit.
In a main program loop subroutines are executed :
• Load cover to machine

• retrieve workpiece
• insert piston (corresponding to workpiece)
• insert spring
• unload cover from machine
• assemble cover
Simultaneous a interrupt function monitors the STOP button of the control panel. If
activated the program will be paused in any position.
Following input signals are the communication between conveyor and robot &
assembly:
• robot output bit No.7 = Assembly ready

• robot input bit No. 6 = Start assembly
• robot input bit No. 7 = bad part → sort out
With the opitcal sensor of the gripper the value for the Z-height between "black"
and "not-black" is evaluated. Therefore all existing positions in the program are
calculated with this parameter. There is only one variable position for all workpieces
"black" or "not-black" "black assembled" and "not-black assembled".
After finishing the assembly the PLC will get a return code for:
• executed assembly
• put back on pallet
• bad part
Than the main loop will start from the beginning.

Robot RV-2AJ

7. Technology
This chapter refers to the technology of the Robot Assembly station.
For better construction understanding of the station, the technical drawings should
be a very helpful data.
The rooms must be checked for their technical datas before built up the
station/system. The size of the door openings and the entrance must be big enough
for the measurements of the system. Even the load-capacity of the floor must be
high enough for the system.
7.1. drawings
Technical drawing Robot Assembly station

Technology
7.2. Technical datas Pos. Designation / Criterion Measurements / Feature
1 Width: 700 mm
2 Max. width 750 mm
3 Length 700 mm
4 Max. length 750 mm
5 height 1 400 mm
6 Max. height 1 800 mm
7 Weight approx. 150 kg

8. Electrical system
To operate the station it is required to connect all of the supply cables and
communication lines included. The cables used to program the system are explained
additionally.
To give you a better survey of the being lines used in the plant, these are explained
in the following.
8.1. Power supply The devices are delivered together with the respective power supply plugs,
protectively contact covered, in case they require power supply.
The customer must ensure that the power supply is earthed correctly and is
equipped with a fault current monitor.
If it is required for several devices to be in operation at the same time, it is possible

to connect these to a switchboard containing distribution board, provided that the
permissible maximum rating is not exceeded.

Electrical system
8.2. I/O-Components The operation panel, the modules from station are pluggable connected via
I/O-terminals to the I/O-cards from the control.
So that a perfect communication can be ensured, the I/O interface is standardised.

The I/O terminal is at all work positions at the disposal.
I/O-Terminal
Technical data
Plug type IEEE 488 24 pins
Inputs 8
Outputs 8
Current consumption Max. 1A/PIN
Power supply 24 VDC

Electrical system
OUT BIT 0 1 13 IN BIT 0

POWER 24 VDC 9 21 POWER 24 VDC
syslink pin assignment

01 Bit 0 Output word white 13 Bit 0 Input word grey-pink
02 Bit 1 Output word brown 14 Bit 1 Input word red-blue
03 Bit 2 Output word green 15 Bit 2 Input word white-green
04 Bit 3 Output word yellow 16 Bit 3 Input word brown-green
05 Bit 4 Output word grey 17 Bit 4 Input word white-yellow
06 Bit 5 Output word pink 18 Bit 5 Input word yellow-brown
07 Bit 6 Output word blue 19 Bit 6 Input word white-grey
08 Bit 7 Output word red 20 Bit 7 Input word grey-brown
09 24 V Power supply black 21 24 V Power supply white-pink
10 22
11 0 V Power supply pink-brown 23 0 V Power supply white-blue
12 0 V Power supply purple 24
Allocation I/O- Terminal
Clamp Bit Function Color Clamp Bit Function Colour
01 0 Output White 13 0 Input Grey-pink
02 1 Output Brown 14 1 Input Red-blue
03 2 Output Green 15 2 Input White-green
04 3 Output Yellow 16 3 Input Brown-green
05 4 Output Grey 17 4 Input White-yellow
06 5 Output Pink 18 5 Input Yellow-brown
07 6 Output Blue 19 6 Input White-grey
08 7 Output Red 20 7 Input Grey-brown
09 Power
24V Power supply Black 21 24V White-pink
supply
10 22
11 Power
0V Power supply Pink-brown 23 0V White-blue
supply
12 0V Power supply purple 24

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Robot Assembly

MPS 500 with

Type: Manual MPS500

© Festo Didactic GmbH & Co.KG., D-73770 Denkendorf, 2008

2 © Festo Didactic GmbH & Co.KG • MPS500

The manual is divided into four parts:

© Festo Didactic GmbH & Co.KG • MPS500 3

• DIN EN 292 -Machine safety

4 © Festo Didactic GmbH & Co.KG • MPS500

1. Intended use _____________________________________________________ 3

2. Introduction ______________________________________________________ 9

2.2. Robot cell ___________________________________________________ 10

2.3. Didactic structure ____________________________________________ 11

2.4. Scope of tasks of the stations __________________________________ 12

2.4.1. Mechanics ______________________________________________ 12

2.4.2. Pneumatics _____________________________________________ 12

2.4.3. Electrics ________________________________________________ 12

2.4.4. Informatics ______________________________________________ 12

2.4.5. Bus technology __________________________________________ 12

3. General safety instructions _________________________________________ 13

3.1. Use according to regulations ___________________________________ 13

3.2. Handling the system __________________________________________ 13

3.2.1. Dangers in handling the machine ____________________________ 13

3.2.2. Safety precautions in standard operation _____________________ 13

3.2.3. Dangers due to electric current _____________________________ 14

3.2.4. Dangers due to pneumatic energy ___________________________ 14

3.2.5. Maintenance – Servicing – Malfunction removal ________________ 15

3.2.6. Organizational measures __________________________________ 15

3.3. Personnel ___________________________________________________ 15

© Festo Didactic GmbH & Co.KG • MPS500 5

3.3.1. Notes on personnel _______________________________________ 15

3.3.2. Training operations _______________________________________ 15

3.3.3. Outside training operations ________________________________ 15

3.3.4. Safety symbols __________________________________________ 16

4. Commissioning __________________________________________________ 17

4.1. Transport ___________________________________________________ 17

4.2. Set up ______________________________________________________ 18

4.2.1. General information ______________________________________ 18

4.3. Commissioning ______________________________________________ 21

4.3.1. Pneumatic commissioning _________________________________ 21

4.3.2. Electric commissioning ____________________________________ 21

4.3.3. Establishing communication connections _____________________ 22

4.4. Connection RIA – Box X1, X2, X3, X4 _____________________________ 25

4.4.1. EMERGENCY-STOP system _________________________________ 25

5. Operation _______________________________________________________ 27

5.1. Start-up process general_______________________________________ 27

5.2. Start up station ______________________________________________ 28

5.3. Reset conditions _____________________________________________ 29

5.4. Process Start ________________________________________________ 29

6. Robot RV-2AJ ____________________________________________________ 31

6.1. Mitsubishi robot RV-2AJ _______________________________________ 31

6.2. Drive Unit RV-2AJ _____________________________________________ 32

6 © Festo Didactic GmbH & Co.KG • MPS500

6.2.1. Functions _______________________________________________ 32

6.2.2. Teach pendant RV-2AJ _____________________________________ 34

6.2.3. Set up RV-2AJ ____________________________________________ 35

6.2.4. To operate the robot ______________________________________ 36

6.2.5. Teach position example ___________________________________ 39

6.3. Robot positions ______________________________________________ 40