iCIM FC Robot RV2AJ Assembly Vision A008

iCIM
Manual
Robot assembly
vision station
Order-NR.:
Type: Manual iCIM
Designation iCIM_FC_Robot_RV2AJ_Assembly_Vision_A008.doc
Printed: November 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 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. • iCIM

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 exercise (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. • iCIM 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 assembly station _______________________________________ 10
2.3 Didactic structure ____________________________________________ 12
2.4 Duty of the operating authority _________________________________ 13
2.5 Duty of trainees ______________________________________________ 13
2.6 Warranty and liability _________________________________________ 14
2.7 Intended use ________________________________________________ 14
2.8 Important notes ______________________________________________ 15
3 General safety instructions _________________________________________ 17
3.1 Handling the system __________________________________________ 17
3.1.1 Dangers in handling the machine ____________________________ 17
3.1.2 Faults impairing safety must be rectified immediately!___________ 17
3.1.3 Safety precautions in standard operation _____________________ 18
3.1.4 Dangers due to electric current _____________________________ 18
3.1.5 Dangers due to pneumatic energy ___________________________ 19
3.1.6 Maintenance – Servicing – Malfunction removal ________________ 19
3.1.7 Organizational measures __________________________________ 19
3.2 Personnel ___________________________________________________ 20
3.2.1 Notes on personnel _______________________________________ 20

Contents
3.2.2 Training operations _______________________________________ 20
3.2.3 Outside training operations ________________________________ 20
3.3 Emergency stop system _______________________________________ 20
3.3.1 Safety symbols __________________________________________ 21
4 Commissioning __________________________________________________ 23
4.1 Transport ___________________________________________________ 23
4.1.1 Unpacking ______________________________________________ 23
4.1.2 Scope of delivery _________________________________________ 23
4.2 Set up ______________________________________________________ 24
4.2.1 General information ______________________________________ 24
4.3 Commissioning ______________________________________________ 28
4.3.1 Pneumatic commissioning _________________________________ 28
4.3.2 Electric commissioning ____________________________________ 28
4.3.3 Connecting communication cables ___________________________ 29
4.3.4 Establishing communication connections _____________________ 30
5 Operation _______________________________________________________ 31
5.1 General operation notes _______________________________________ 31
5.1.1 Behavior rules ___________________________________________ 31
5.1.2 Operation rules __________________________________________ 31
5.2 Process description ___________________________________________ 32
5.2.1 Robot assembly station ___________________________________ 32
5.3 Tasks ______________________________________________________ 33

Contents
5.4 Operation panel ______________________________________________ 37
5.5 Start up system ______________________________________________ 38
5.5.1 Start up conditions _______________________________________ 38
5.5.2 general information _______________________________________ 38
5.6 Reset mode _________________________________________________ 38
5.7 Automatic __________________________________________________ 39
5.7.1 Start automatic __________________________________________ 39
5.7.2 Automatic mode _________________________________________ 39
5.7.3 Stop automatic __________________________________________ 39
5.8 Shut down the station _________________________________________ 39
5.9 Mitsubishi robot RV-2AJ _______________________________________ 40
5.10 Drive Unit RV-2AJ _____________________________________________ 41
5.10.1 Functions _______________________________________________ 41
5.10.2 Teach pendant RV-2AJ _____________________________________ 43
5.10.3 Set up RV-2AJ ____________________________________________ 44
5.10.4 To operate the robot ______________________________________ 45
5.10.5 Choose program _________________________________________ 48
5.10.6 Change program _________________________________________ 48
5.10.7 Teach position example ___________________________________ 49
5.10.8 Interface Drive unit Inputs _________________________________ 50
5.10.9 Interface Drive unit Outputs ________________________________ 51
5.10.10 Program documentation for CR1 and CR2 with ETHERNET ______ 52

Contents
5.10.11 Robot programs ________________________________________ 56
6 Technology _____________________________________________________ 59
6.1 drawings ___________________________________________________ 59
6.2 Technical datas ______________________________________________ 60
6.3 Modules in use ______________________________________________ 61
6.3.1 Pallet reception __________________________________________ 61
6.3.2 Pen/instrument magazine _________________________________ 62
6.4 Assembly module ____________________________________________ 63
6.5 Workpiece direction __________________________________________ 64
7 Pneumatic ______________________________________________________ 65
7.1 The valve terminal ____________________________________________ 65
7.2 Pneumatic supply ____________________________________________ 66
8 Electrical system _________________________________________________ 67
8.1 Power supply ________________________________________________ 67
8.2 Controller ___________________________________________________ 67
8.3 Wiring ______________________________________________________ 68
8.3.1 I/O-Components _________________________________________ 68

2 Introduction
2.1 General This user-defined installation contains parts of the iCIM system, mixed together with
other components. The installation, thus created, is explained in the following
operational manual and the respective station manuals.
In the development of the system, various production technologies have been

combined into one installation. The aim of the installation is the increase of
competence, from a simple setting of examples up to a complete production
process, including all features.
Additionally, to technical and social competence, the comprehension of the process

and the interaction of the respective components appear in clear presentation.
This manual describes working with the iCIM system. Everything is explained and
described for the operation of necessary events. With the help of graphics or
pictures a simple communication should be obtain.
Complete operating instructions which explain the processes of the system are
available for working with the system. Station manuals are also available for the
individual stations.
Festo Didactic succeeded in using the most updated industrial hard- and software
for this model production.

Introduction
2.2 Robot assembly The robot assembly stationis responsible for the assembly of an desk set in different
station variants.
Once a desk set is to be assembled, the required palettes, containing the necessary
components, are requested for placement onto the palette receptions.
At first, a base plate is placed into the assembly position, then the first instrument is
assembled. After assembling the first instrument, the second instrument is
assembled in the same way. The instruments are coming from the magazines. 1 pen
holder, aluminum or brass, depending on the order, is assembled into the base
plate. The pen holder is coming from a palette. At least a pen is inserted in the pen
holder, the pen is coming from the magazine. The assembled desk set is returned to
its retrieval position and stored in the AS/RS station for further use.
The station possesses its own control, which is fitted into the basic frame of the
station. The drive unit of the robot supplies the control.
• Communication from drive unit to COSIMIR FACTORY PC

ensues by means of Ethernet
If the station is operated without the iCIM System, in “stand alone” mode, it is
possible to make training on the robot.

Introduction
Overview AS/RS station
Position Description Position Description
1 Robot RV-2AJ 7 Camera
2 Controller CR1 8 Pen-magazine
3 RIA-Box 9 Assembly module
4 Operation panel 10 Workpiece holder for vision
5 Magazine 1 11 Palette reception
6 Magazine 2

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 mechatronis, 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.

Introduction
Training contents covering the following subjects can be taught:
• Mechanics
– Mechanical construction of a station
• Pneumatics
– Piping connections of pneumatic components
– Vacuum technology
– Pneumatic linear and rotary drives
• Electrical
– Correct wiring of electrical components
• Sensors
– Correct use of limit switches
• Robot training
– Programming and use of a Robot
– Structure of a robot program
– Moving and teaching a robot
• Commissioning
– Commissioning of a production system
• Fault finding
– Systematic fault finding on a production system
2.4 Duty of the operating The operating authority undertakes to ensure that the ICIM is used only by persons
authority who:
• are familiar with the basic regulations regarding operational safety and accident
prevention and who have received instructions in the handling of the ICIM,
• have read and understood the chapter on safety and the cautionary notes in this
manual.
• Safety-conscious working of the persons should be regularly vetted.
2.5 Duty of trainees Prior to commencing work, all persons assigned to working on the ICIM have a duty
to:
• read the chapter on safety and the cautionary notes in this manual and,
• observe the basic regulations regarding operational safety and the prevention of
accidents.

Introduction
2.6 Warranty and In principle all our „Terms and Conditions of Sale“ apply. These are available to the
liability operating authority upon conclusion of the contract at the latest. Warranty and
liability claims for persons or material damage are excluded if these can be traced
back to one or several of the following causes:
• Use of the ICIM not in accordance with its intended purpose

• Incorrect assembly, commissioning, operation and maintenance of the ICIM
• Operation of the ICIM using faulty safety equipment or incorrectly fitted or non
operational safety or protective devices
• Non observance of notes in the manual regarding transport, storage, assembly,
commissioning, operation, maintenance and setting up of the ICIM
• Unlawful constructional modifications on the ICIM
• Inadequate monitoring of components subject to wear
• Incorrectly carried out repairs
• Catastrophes as a result of foreign bodies and vis major.
Festo Didactic herewith rules out any liability for damage or injury to trainees, the
training company and/or other third parties which may occur during the
use/operation of the system other than purely in a training situation, unless such
damage has been caused intentionally or due to gross negligence by Festo Didactic.
2.7 Intended use 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 use of the system for its intended purpose also includes:
• Following all advice in the manual and

• Carrying out inspection and maintenance work.

Introduction
2.8 Important notes The basic requirement for safe use and trouble-free operation of the ICIM is to
observe the fundamental safety recommendations and regulations.
This manual contains important notes concerning the safe operation of the ICIM.
The safety recommendations in particular must be observed by anyone working on

the ICIM.
Furthermore, the rules and regulations for the prevention of accidents applicable to
the place of use must be observed.

Introduction

3 General safety instructions
3.1 Handling the system 3.1.1 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 cannot be tolerated during training and have to be

removed immediately.
The iCIM system is to be used only:
• for its intended purpose and

• in an absolutely safe conditions.
3.1.2 Faults impairing safety must be rectified immediately!

General safety instructions
3.1.3 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.
3.1.4 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.

3.1.5 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.
3.1.6 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.
3.1.7 Organizational measures
All existing safety devices must be checked at regular intervals.

3.2 Personnel 3.2.1 Notes on personnel
Basically two situations have to be considered, concerning matters on personnel.
• Activities during training operations

• Activities outside training operations
3.2.2 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.
3.2.3 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 Emergency stop The emergency stop system is controlled by a higher safety control unit. The
system description is noted in the manual of the transport system.

3.3.1 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.
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.
i 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.
Check the station for any possible damaged once unpacked. The carrier and Festo
Didactic are to be notified immediately of any damage.
4.1.1 Unpacking
Carefully remove the padding material in the container box when unpacking the
station. When unpacking the station, make sure that none of the station assemblies
have been damaged.
Check the station for any possible damaged once unpacked. The carrier and Festo
Didactic are to be notified immediately of any damage.
4.1.2 Scope of delivery
Check the scope of delivery against the delivery note and the order. Festo Didactic
must be notified immediately of any discrepancies.

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 are the premises to provide an air-conditioning system for constant
surroundings conditions.
To comply with 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 fault-free 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).
First, the room has to be measured, if not done so previously. The measures of all
stations have to be marked roughly onto the floor space (i.e. with adhesive tape) to
avoid shifting at a later stage.
If the build up position is fixed, the station has to be mounted at the respective
operating position of the transport system, utilizing the included profiles. At this
point, screw and lean the profiles lightly onto the basic frame of the transport
system station. Align the station by means of a spirit-level and tighten the connector
profiles afterwards.
The robot transfer position to the transport system and the positions for the work-
piece transfer may require to be retaught.

Commissioning
For a more simple room planning the complete installation design is shown in the
following. The robot assembly station is to line up that a fault-free workpiece
handing over can take place.
For a more simple room planning the complete installation design is shown in the
following.
Installation design iCIM system

Commissioning
Dimension drawing iCIM system

Commissioning
Position robot assembly vision station

Commissioning
4.3 Commissioning Commissioning of the system can ensue only, once all of the stations are connected
to their definite position.
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 600 kPA/6 bar and the
pneumatic commissioning is realized.
4.3.2 Electric commissioning
The station must be provided with electrical voltage now.

The station is provided with a power supply unit witch is provided with a voltage of
110/230 V. The delivered cables have 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 (24 VDC) of the sensoric and the actuators of the station is
provided in each case by means of a 2-pin cable. The voltage supply is a 24 V power
supply unit, contained in the control cabinet or somewhere in the station.
To avoid problems during the operational process, individual protection (16A) of the
installation is recommended.

Commissioning
4.3.3 Connecting communication cables
Communication cables example
If the robot assembly stationis to be connected to another installation, for example

as described in complete process, communication takes place via Ethernet. The
Ethernet cable from the Drive unit is fixed and not pluggable.
The following addresses have been allotted.
• Drive Unit IP#192.168.10.11 at Port 9002

• Camera robot assembly station Ethernet address # IP192.168.10.110
Vision Control Port 3246
Vision Data Port 3247

Commissioning
4.3.4 Establishing communication connections
The communication lines inside the components are hardly wired and it is not
necessary to attach them. The pluggable connections are shown as graphics in the
following.
Connections

5 Operation
This chapter describes the necessary control units for starting and stopping the
system, as well as operating with the system.
5.1 General operation The stations require some rules of operation witch should be observed. If they are
notes not complied, faults in the processes are possible. Dangers for the physical health
also cannot be excluded.
It is recommended to observe the following rules strictly.
5.1.1 Behavior rules
• During the operation of the stations it is forbidden to grip in by hand.

• With larger audience a mechanical protection of the stations is necessary.
• Removing any cable under tension is forbidden.
• Water has to be kept away from the plant.
5.1.2 Operation rules
• The stations only may be used by introduced persons.

• The operation has to be carried out according to the operating instructions.
• A pushing the different switches/push buttons of all control units unchecked has
to be stopped.
• No workpiece carriers may be taken by the system.

Operation
5.2 Process description 5.2.1 Robot assembly station
Process description inside robot assembly station.
The robot assembly station is responsible for the assembly of an desk set in
different variants. In Cosimir control it is possible to choose the respective
workpiece.
Type 1 => base plate with two instruments and pen holder made from brass
Type 2 => base plate with two instruments and pen holder made from aluminum
• Once a desk set is to be assembled a palette with a base plate is requested for
placement onto the palette receptions on the station.
• A second palette with a pen holder, brass or aluminum - depending on the
chosen order, is also requested and placed on the station.
• At first, the base plate is placed into the assembly position.
• Then the first instrument is assembled in the base plate, if this option is chosen.
• After assembling the first instrument, the second instrument is assembled and in
the same way, if this option is chosen. The instruments are coming from the
magazines.
• The pen holder, coming from the palette, is assembled into the base plate.
• At least a pen is inserted in the pen holder, the pen is coming from the magazine,
if this option is chosen.
• The assembled desk set is returned to its retrieval position and stored in the
AS/RS station for further use.
The process for the different pen holders is the same, chose the pen holder in
aluminum or brass is done in cosimir control.

Operation
5.3 Tasks For a better understanding, the following graphic should show the discharge of a
task, started in COSIMIR FACTORY.
Task example
COSIMIR FACTORY is starting the robot program „MP.mb4. The following parameters
are written to the program:
• Parameter 1: get a pallet from source position 15 (Transport delivery position)

• Parameter 2: move it to target position 1 (– Pallet place 1)
• Parameter 3 is 0 and is not considered.

Operation
Order Type / Parameter Nr. Description
execprog Name of robot

“MP” Move pallet
program
Parameter 1 1 Pallet place 1
Source position 2 Pallet place 2
3 Pallet place 3
4 Pallet place 4
15 Transport system delivery position
Target position 2 Pallet place 2
3 Pallet place 3
4 Pallet place 4
15 Transport system delivery position
Parameter 3
Return-Code N announce error number / see
xxxxxx:n
table error codes

“MBP” Move base plate
program
3 Pallet place 3
4 Pallet place 4
5 Assembly position
3 Pallet place 3
4 Pallet place 4
5 Assembly position
Parameter 3
xxxxxx:n
table error codes

Operation

“MPH” Move penholder
program
3 Pallet place 3
4 Pallet place 4
5 Assembly position at base plate
3 Pallet place 3
4 Pallet place 4
5 Assembly position at base plate
Parameter 3
xxxxxx:n
table error codes

“MINST” Move instrument
program
Parameter 1 1 Magazine 1
Source position 2 Magazine 2
3 Assembly position 1
4 Assembly position 2
Parameter 2 3 Assembly position 1
Target position 4 Assembly position 2
Parameter 3 -180°/180° Turning angle
xxxxxx:n
table error codes

“ASMP” Assemble pen
program
Parameter 1
Parameter 2
Parameter 3
xxxxxx:n
table error codes

Operation
Error codes
Error codes are valid for all order codes (Return code)
Error Code Describtion
1 "No pallet at source position."
2 "Target position occupied."
3 "No pallet at target position."
4 "Assembly position occupied."
6 "No part in magazine available."
7 "No part in feeder available."
8 "No base plate clamped."
9 "No orientation found."
10 "Run-time-error CNC machine."
11 "Robot not ready for execution"
15 "Runtime error."
30 "Invalid input parameter 1"
999 "Invalid input parameter"

Operation
5.4 Operation panel
The operation panel has the following functions
• START button – start automatic mode

• STOP button – stop automatic mode to cycle end
• RESET button – start reset mode
• AUT/MAN switch – not used
• Q1 Lamp – not used
• Q2 Lamp – Station not ready
• S5 Illuminated pushbutton – quit emergency stop
• S6 Emergency stop
The I/O interfaces and the plug- sockets are not used.

Operation
5.5 Start up system 5.5.1 Start up conditions
For the iCIM system a first commissioning at Festo was already executed. The
following explanation is for the commissioning at customer’s side.
It is required, that all of the stations are set up, aligned and adjusted, before starting
the system. All of the transfer and assembly positions have to be adjusted or taught.
The first start-up and teaching of each station is explained in detail in the station’s
manual and has to be executed before.
5.5.2 general information
• Switch on distribution strips

• Activate air supply for all stations min. 4 bar – max. 6 bar
• Switch on the PC - COSIMIR FACTORY
• Switch on all stations like described in the stations manual, reset the station and
start automatic mode
• Switch on main switch of robot assembly station
• Do not switch on Drive Unit of robot
• Unlock and confirm all emergency switches of the station
• The switch of the robots teach box has to be stand at disable
• Key switch of the drive unit has to be at AUTO/EXT.
• Switch on drive unit of the station
5.6 Reset mode The first start-up of the station is to be completed before the station can be
adjusted. Retrieve partly processed work-pieces, if required. Clear palette places for
the transport system.
CAUTION: DANGER OF COLLISION – DANGER OF INJURY. The robots arm has to

moved out of the danger area. The reset mode is started at the operation panel.
1. If available remove all pallets and workpieces from the working positions and
the machines.
2. Fill up all magazines
3. 'RESET'- lamp is flashing → request reset
4. Press 'RESET'- button for approx. 2 sec.
5. The robot makes his reference move, take care of all danger areas!
6. The 'RESET' lamp lights up if all of the initial positions are reached
7. Switch the 'AUTO/MAN'- key switch to 'AUTO'(permanent cycle).
'MAN'- position without function.

Operation
5.7 Automatic 5.7.1 Start automatic
1. The station is ready with the reset mode.

2. 'RESET'- lamp lights up and the 'START'- lamp is flashing → request to start the
station.
3. Press 'START'- button → automatic mode is active
4. Operating state is announced by lightening 'START' and 'RESET'- Lamp.
5.7.2 Automatic mode
Now the station is ready to get orders from COSIMIR FACTORY and to execute the
orders.
5.7.3 Stop automatic
1. 'START' and 'RESET' – lamps are lightening and auto mode is active.
2. Press the 'STOP'- button
3. Operating state is announced with a flashing 'START'- lamp.
4. Active cycle is done complete.
5. If the cycle is ready the automatic mode is stopped. Press the 'START' button
and the automatic mode is starting again.
5.8 Shut down the To shut down the station it is necessary that the production in COSIMIR FACTORY is
station already ended. Then the drive unit and afterwards the main switch can be switched
off.

Operation
5.9 Mitsubishi robot The robot is responsible for the workpiece handling.
RV-2AJ
RV-2AJ
Performance
Inputs 48 Inputs for communication
Outputs 48 Outputs for communication
Max. reservation 1 workpiece/pallet

Operation
5.10 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.
5.10.1 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

Operation
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

Operation
5.10.2 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

Operation
5.10.3 Set up RV-2AJ
Drive-Unit
CN1
CN2
Ria-Box
I/O-cable 50 pin
Teach box Drive-Unit
Programming PC
Robot RV-2AJ set up example for stand alone mode

Operation
5.10.4 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 axis 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.

Operation
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

Operation
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

Operation
5.10.5 Choose program
Processing cycle should not be active, otherwise stop cycle at operation panel.
Choose program at Drive unit
1. Press CHANG DSP button till P.*** announce in display

2. Press RESET button
3. Chose program with UP and DOWN buttons
Program number is announced in display of the drive unit
4. Press SVO ON button – drives are released
5. For program start press START button
5.10.6 Change program
Change program at Drive unit
1. Press CHANG DSP button till P.*** announce in display

2. Press STOP button to stop active program
3. Press RESET button
4. Choose program with UP and DOWN buttons
Program number is announced in display of the drive unit
5. Press SVO ON button – drives are released
6. For program start press START button

Operation
5.10.7 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. Switch key 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 MENU button – Menu at teach pendant available
12. Positions have to be available in Drive unit.
13. Choose teach mode
14. Delete existing program name with POS and DELETE button
15. Press INP/EXE to list the different programs.
16. With ADDÇ and RPLÈ choose program. Task2 for program 2 a.s.o
17. Press INP/EXE to choose program
18. Press INP/EXE to activate program
19. Display looks as follows
PR:Task2ST:1
LN:10
20. To change a position, press POS.
21. Display looks like following
MS.POS(Px )
22. Choose position with +/FORWRD and -/BACKWRD buttons
23. Select speed, press STEP/MOVE and
• +/FORWARD to get faster
• -/BACKWRD to get slower
24. 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)
25. Press INP/EXE, robot moves to the chosen position
26. Now move the robot to the new position. Movement description see chapter (to
operate the robot) Example with XYZ mode.
27. Press STEP/MOVE and ADDÇ simultaneously
28. Release ADDÇ if you are sure that you want to overwrite the position.
29. Press ADDÇ again, and the new position is saved.
30. Don’t forget to load the position list into the PC.
* You have to execute this point the whole time to move the robot.

Operation
5.10.8 Interface Drive unit Inputs
Name Output/ Input Output Input Robot PIN Robot

Input Ria Ria Name
box box
Operation S1 RIA 1 RIA 1 INPUT 1

START button 16 IN 1
panel XMG1:13 X1:13 X0:16 CN100:16
S2 RIA 1 RIA 1 INPUT 2

STOP button 17 IN 2
XMG1:14 X1:14 X0:17 CN100:17
AUTO/MAN S3 RIA 1 RIA 1 INPUT 3

18 IN 3
switch XMG1:15 X1:15 X0:18 CN100:18
S4 RIA 1 RIA 1 INPUT 4

RESET-button 19 IN 4
XMG1:16 X1:16 X0:19 CN100:19
Robot Pallet 1 20B1/I0 RIA 1 RIA 1 INPUT 5

20 IN 5
Station available XMB2:13 X2:13 X0:20 CN100:20
Pallet 2 20B2/I1 RIA 1 RIA 1 INPUT 6

21 IN 6
available XMB2:14 X2:14 X0:21 CN100:21

22 IN 7

40 IN 8
Fixing cylinder 10B1/I0 RIA 1 RIA 1 INPUT 9

41 IN 9
1 is fixed XMA2:13 X3:13 X0:41 CN100:41
Fixing cylinder 10B2/I1 RIA 1 RIA 1 INPUT 10

42 IN 10
1 is fixed XMA2:14 X3:14 X0:42 CN100:42
10B3/I2 RIA 1 RIA 1 INPUT 11

Pallet available 43 IN 11
XMA2:15 X3:15 X0:43 CN100:43
Magazine 1 10B4/I3 RIA 1 RIA 1 INPUT 12

44 IN 12
part available XMA2:16 X3:16 X0:44 CN100:44
Magazine 2 10B5/I4 RIA 1 RIA 1 INPUT 13

45 IN 13
part available XMA2:17 X3:17 X0:45 CN100:45
10B6/I5 RIA 1 RIA 1 INPUT 14

Pen available 46 IN 14
XMA2:18 X3:18 X0:46 CN100:46
Pusher ballpen 10B7/I6 RIA 1 RIA 1 INPUT 15

47 IN 15
Back position XMA2:19 X3:19 X0:47 CN100:47

Operation
5.10.9 Interface Drive unit Outputs
Name Output/ Input Output Input Robot PIN Robot

Input Ria Ria Name
box box
Operation H1 RIA 1 RIA 1 OUTPUT 0

Display START 4 OUT 0
panel XMG1:1 X1:1 X0:4 CN100:4
Display Initial H2 RIA 1 RIA 1 OUTPUT 1

5 OUT 1
position XMG1:2 X1:2 X0:5 CN100:5
Special H3 RIA 1 RIA 1 OUTPUT 2

6 OUT 2
function1 lamp XMG1:3 X1:3 X0:6 CN100:6
Special H4 RIA 1 RIA 1 OUTPUT 3

7 OUT 3
function2 lamp XMG1:4 X1:4 X0:7 CN100:7
Robot Unclamp fixing 10M1/O0 RIA 1 RIA 1 OUTPUT 4

29 OUT 4
Station cylinder 1+2 XMA2:1 X3:1 X0:29 CN100:29
Clamp fixing 10M2/O1 RIA 1 RIA 1 OUTPUT 5

30 OUT 5
cylinder 1+2 XMA2:2 X3:2 X0:30 CN100:30
Pusher ballpen 21M1/O2 RIA 1 RIA 1 OUTPUT 6

31 OUT 6
forward XMA2:3 X3:3 X0:31 CN100:31
Pusher ballpen 21M2/O3 RIA 1 RIA 1 OUTPUT 7

32 OUT 7
backward XMA2:4 X3:4 X0:32 CN100:32
O4 RIA 1
Not used
XMA2:5 X3:5
O5 RIA 1
Not used
XMA2:6 X3:6
O6 RIA 1
Not used
XMA2:7 X3:7
O7 RIA 1
Not used
XMA2:8 X3:8

Operation
5.10.10 Program documentation for CR1 and CR2 with ETHERNET
The basic structure consists of a main program Main.MB4 which is immediately

started in the Slot 2 after switching the robot on. This is caused by the entry ALWAYS
s in the Slot parameter SLT2. (see also: Parameter) After resetting and starting the
automatic mode of the station, it is possible to start tasks on Slot 1 via Ethernet.
These tasks can consist over respectively 3 parameters, for submit and return. These
submit/return parameters are the global variables M_00-M_02. Before start the task
over Ethernet, the values are written in this variables and at the end of the task, this
values are read again. The tasks must have a certain structure so that Cosimir
Control is been able to call them via Ethernet (s.a. task structure).
Handling 1. Switch on power supply

2. Reset emergency stop board (if available)
3. Turn Key switch of Teach Panel to Disable
4. Turn key switch at Drive unit to Auto/Ext
5. Switch on Drive unit
6. Station is ready it the reset lamp is flashing
7. Press reset pushbutton
8. Station is ready with reset mode if the start lamp is flashing
9. Press Start pushbutton to bring the Station in automatic mode
10. Now it is possible to start tasks via Ethernet
Global Variables • M_00 : Submit/Return Parameter 1

• M_01 : Submit/Return Parameter 2
• M_02 : Submit/Return Parameter 3
• M_10: Automatic active
• M_11: Station ready with reset
• M_12: Emergency stop active
• M_19: Handshake variable

Operation
Parameter The following parameters must set to configure a new Drive unit. After this the Drive
unit must be switched of an on again.
Ethernet parameter:
• NETIP: 192.168.10.10
• NETPORT: 9000,9001,9002,9003,……………..
I/O- parameter:
• START: -1,-1
• ERRRESET: -1,-1
• SRVOFF: -1,-1
• SRVON: -1,-1
• IOENA: -1,-1
Slot parameter:
• SLT 1: ,CYC,START,1
• SLT 2: MAIN.MB4,CYC,ALWAYS,1
• SLT 3: ,CYC,START,1
• SLT 4: ERR.MB4,CYC,ERROR,1
• SLT 5: ,CYC,START,
• ALWENA: 7
Attention To be able to load the program Main.MB4 into the controller newly the Always in the
Slot parameter SLT 2 must be changed into a start.
After this switch of the drive unit and switch it on again.
The program Main.Mb4 can be loaded quite normally again now.
After this reverse the changes in the Slot parameter SLT 2, switch out and on the
drive unit again.

Operation
Main tasks These programs must be loaded into the drive Unit. The program Main.Mb4 and
ERR.MB4 can be loaded without changes. Init.Mb4 is a task adapted on the
application. In the task TOUT.MB4 the period of time (DLY ) must be adapted to the
application.
• MAIN.MB4
• INIT.MB4
• ERR.MB4
• TOUT.MB4
Task structure To call up the different application-specific tasks from Cosimir Control the tasks
must have a specific structure. The following hand shake HShake1 must be
integrated in the header of the program. The real hand shake takes place about the
global variable M_19. Cosimir Control waits for hexadecimal value 55 and then the
value 00 is written in M_19. The rest of the source code call the task TOUT (Timeout)
in the Slot 5 and then the global variable M_10 checks if the station is in automatic
mode.
490 *HShake1
500 M_19=&H55
510 wait M_19=&H00
520 IF M_PSA(5) = 0 THEN
530 XSTP 5
540 WAIT M_WAI(5) = 1
550 XRST 5
560 ENDIF
570 WAIT M_PSA(5) = 1
580 XLOAD 5,"TOUT"
590 XRUN 5,"TOUT",1
600 IF M_10 = 0 THEN
610 M_00 = 10
620 GOTO *HShake2
630 ENDIF

Operation
The following hand shake must be available for Hshake2 at the end of the task.
Here the TOUT task is ended and the hand shake procedure carried out via the
global variable M_19.
1360 *HShake2
1370 XSTP 5
1380 M_19=&HAA
1390 Wait M_19=&H00
1400 END

Operation
5.10.11 Robot programs
• MAIN.MB4 – Main program, starts automatically if the controller is switched on

• INIT.MB4 – Reset program
• ERR.MB4 – Program for error diagnostic
• TOUT.MB4 – Program for timeout diagnostic
• UBP.MB4 – global variables definition
• COMM – Communication program for COSIMIR FACTORY
Program tasks/positions • “MP” – Move palette

for example move palette from conveyor system onto palette holder 1 on station

Operation
• “MBP” Move base plate

for example load a base plate into assembly position
• “MPH” – Move pen holder

for example insert pen holder into base plate, pen holder from magazine

Operation
• “MINST” – Move instrument

for example insert pen holder into base plate, pen holder from feeder
• “ASMP” – Assemble pen

for example insert pen into pen holder

6 Technology
This chapter refers to the technology of the robot assembly vision 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.
6.1 drawings
Technical drawing robot assembly station

Technology
6.2 Technical datas Pos. Name Dimensions
1 Width 700 mm
2 Length 1 110 mm
3 Hight 1 530 mm
4 Plate height 780 mm
5 Min. plate height 770 mm
6 Max. plate height 790 mm
7 Weight approx. 300 kg

Technology
6.3 Modules in use The station is made up of a number of different function modules.
• Palette reception
• Pen/instrument magazine
• Assembly module
6.3.1 Pallet reception
With this module it’s possible to pick up 4 pallets
Pallet reception
Performance
Inputs 4
Outputs /
Max. reservation 4 pallets

Technology
6.3.2 Pen/instrument magazine
The pen and the instrument are made available here. The magazine is also called
feeder!
Pen/Instrument magazine
Performance
Inputs -
Outputs -
Max. reservation 15 pens / 10 instruments each

Technology
6.4 Assembly module In this module the desk set is assembled.
Workpiece assembly module
Performance
Inputs 2
Outputs 2
Max. reservation 1

Technology
6.5 Workpiece direction
Transport direction work piece carrier

7 Pneumatic
With the help of pneumatic cylinders, axes and grabs, the workpieces and the
workpiece carriers get clamped, distributed or just moved.
The valve terminal necessary for the control, consist from different, the use purpose,
individual valves. The cylinders and the valves are described in the following.
7.1 The valve terminal
Example Valve terminal
Pos. Name
1 Odernumber 18 200
2 Ordername 10P-10-6B-IC-N-V-10M+HZ

Pneumatic
7.2 Pneumatic supply The pressure in the supply line must not exceed 10 bar.
A fine filter has to be installed, to prevent contamination by rust or similar.
A stop cock is required for the supply of the installation.
The pressure regulators should be set in between 5 and 6 bar. The filter and water
separators require maintenance according to the instructions of the documentation
of these components.
The exact allocation of the valve terminal can be found in the pneumatic plan.
Service unit

8 Electrical system
To operate the system 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 supply is 230 V.
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.
Each station contains its own individual EMERGENCY STOP switch, which at first
reacts to its respective station only. It has to be clarified in advance, if a central
ROOM EMERGENCY STOP switch is required.
8.2 Controller The control of the station is done by the drive unit of the robot. See respective
chapter.

Electrical system
8.3 Wiring The wiring within the station and the wiring to the other stations are explained in the
following.
8.3.1 I/O-Components
The operating strip, the moduls from the profil plate and the z-axis are pluggable
connected via I/O-terminals to the SM323 I/O-cards from the control.
So that a perfect communication can be ensured, the I/O interface is standardized.

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 Colour 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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iCIM

Type: Manual iCIM

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

2 © Festo Didactic GmbH & Co.KG. • iCIM

The manual is divided into four parts:

© Festo Didactic GmbH & Co.KG. • iCIM 3

• DIN EN 292 -Machine safety

4 © Festo Didactic GmbH & Co.KG. • iCIM

1 Intended use _____________________________________________________ 3

2.2 Robot assembly station _______________________________________ 10

2.3 Didactic structure ____________________________________________ 12

2.4 Duty of the operating authority _________________________________ 13

2.5 Duty of trainees ______________________________________________ 13

2.6 Warranty and liability _________________________________________ 14

2.7 Intended use ________________________________________________ 14

2.8 Important notes ______________________________________________ 15

3 General safety instructions _________________________________________ 17

3.1 Handling the system __________________________________________ 17

3.1.1 Dangers in handling the machine ____________________________ 17

3.1.2 Faults impairing safety must be rectified immediately!___________ 17

3.1.3 Safety precautions in standard operation _____________________ 18

3.1.4 Dangers due to electric current _____________________________ 18

3.1.5 Dangers due to pneumatic energy ___________________________ 19

3.1.6 Maintenance – Servicing – Malfunction removal ________________ 19

3.1.7 Organizational measures __________________________________ 19

3.2 Personnel ___________________________________________________ 20

3.2.1 Notes on personnel _______________________________________ 20

© Festo Didactic GmbH & Co.KG. • iCIM 5

3.2.2 Training operations _______________________________________ 20

3.2.3 Outside training operations ________________________________ 20

3.3 Emergency stop system _______________________________________ 20

3.3.1 Safety symbols __________________________________________ 21

4 Commissioning __________________________________________________ 23

4.1 Transport ___________________________________________________ 23

4.1.1 Unpacking ______________________________________________ 23

4.1.2 Scope of delivery _________________________________________ 23

4.2 Set up ______________________________________________________ 24

4.2.1 General information ______________________________________ 24

4.3 Commissioning ______________________________________________ 28

4.3.1 Pneumatic commissioning _________________________________ 28

4.3.2 Electric commissioning ____________________________________ 28

4.3.3 Connecting communication cables ___________________________ 29

4.3.4 Establishing communication connections _____________________ 30

5 Operation _______________________________________________________ 31

5.1 General operation notes _______________________________________ 31

5.1.1 Behavior rules ___________________________________________ 31

5.1.2 Operation rules __________________________________________ 31

5.2 Process description ___________________________________________ 32

5.2.1 Robot assembly station ___________________________________ 32

5.3 Tasks ______________________________________________________ 33

6 © Festo Didactic GmbH & Co.KG. • iCIM

5.4 Operation panel ______________________________________________ 37

5.5 Start up system ______________________________________________ 38

5.5.1 Start up conditions _______________________________________ 38

5.5.2 general information _______________________________________ 38

5.6 Reset mode _________________________________________________ 38

5.7 Automatic __________________________________________________ 39

5.7.1 Start automatic __________________________________________ 39

5.7.2 Automatic mode _________________________________________ 39

5.7.3 Stop automatic __________________________________________ 39

5.8 Shut down the station _________________________________________ 39

5.9 Mitsubishi robot RV-2AJ _______________________________________ 40

5.10 Drive Unit RV-2AJ _____________________________________________ 41