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FIGURE 9.27
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Device for inserting parts into a lathe for turning.
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FIGURE 9.28 Interface signals between PLC and the machine tools.
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The fully turned part may be either dropped or picked up by a handling mechanism that is located opposite cylinder A and directly passed on after being oriented. A PLC is suitable as a control system for the feed unit. A program must be developed for this purpose. First, the subtasks (1) pass on workpiece to the machine tool and (2) take workpiece from the machine tool are to be analyzed. In order to be able to solve these tasks, signal exchange between the PLC and the machine tool (MT) is necessary. Figure 9.28 shows the necessary interface signals. The subtasks are: 1. The MT informs the PLC that a workpiece has been completed and can be removed. Signal: MT complete. 2. The gripper travels to the MT and grips the workpiece. The PLC requires the MT to release the workpiece. Signal: release workpiece. 3. The MT releases the workpiece and replies with the signal: workpiece released. 4. The gripper can now advance from the MT with the workpiece. 5. The gripper travels with the workpiece into the MT and requires it to clamp. Signal: clamp workpiece. 6. The MT clamps the workpiece and replies with the signal: workpiece clamped. 7. The gripper opens and retracts from the MT. 8. Once the gripper has left the collision area, the PLC reports that the MT can begin machining. Signal: MT start. The function chart in Fig. 9.29 illustrates the specified cycle in detail form. Using this chart is necessary to develop a PLC program.
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FIGURE 9.29
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Function chart.
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FIGURE 9.29
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(Continued)
Communications
FIGURE 9.30
Allocation list.
Inputs must be assigned to sensors. Outputs from the PLC must also be assigned to actuators. Figure 9.30 shows the appropriate allocation lists. The sequencing program for the feed unit is shown in Fig. 9.31.
Packaging Technology
Arranging and feeding of parts for insertion into boxes, including an intermediate layer, with a feed unit is illustrated in Fig. 9.32. Using this inserting machine, many other functions are carried out either simultaneously with or subsequent to feeding. The various parts that are fed by a conveyer belt are lined up independently and then arranged in rows by actuator A, according to a specific pattern. The parts are transferred by the lifting device in accordance with this pattern. The horizontal movement of the feed unit is executed by actuator B; the vertical movement, by actuators C and D. In the position shown in the diagram, the parts picked up by the lifting device are inserted into the box by extending actuator D. At the same time, actuator C also extends and picks up a square board that is used as an intermediate layer as two layers of parts are being inserted. As soon as actuator C has retracted, holding the intermediate layer, the device is moved by the indexing actuator B. The end position actuator C located above the box and actuator D located above the collection point are used for the arrangement of parts. When actuator C has extended, the intermediate layer is inserted and the next layer of parts is taken up by actuator D. When actuator B retracts, the position drawn is reached once again and the second layer is inserted into the box. Then, when actuator B extends once again, an intermediate layer is placed on the second layer and the next parts are picked up.
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FIGURE 9.31 Sequencing program for the feed unit.
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FIGURE 9.32
Insertion machine.
When actuators C and D retract for the second time, box changeover is triggered. Only when a new empty box is brought into position does a new insertion cycle begin. The feed functions carried out by this inserting machine include arrangement, separation, and insertion cycles.
Linear Indexing for Manufacturing Applications
Linear indexing is best-suited in applications where strip or rod-shaped materials have to be processed in individual stages throughout their entire length. An example of linear indexing is shown in Fig. 9.33. A machine stamps holes into a strip of sheet metal at equal intervals. After each stamping process, the metal strip is clamped, pushed forward a specified distance, and clamped again. Pushing forward and clamping are carried out by a pneumatic feed unit controlled by various sensors. This feed unit is a compact handling component specifically intended for strip-indexing tasks. Figure 9.34 illustrates indexing conveyer belts, which are also referred to as linear indexing systems. Suitable devices for driving such a belt are either motors or pneumatic actuators with a mechanism such as a ratchet to convert an actuator linear stroke into a rotary
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