1 Robotassembly Station MPS 2000 Instructors Edition

Robotassembly 

Station 

MPS 2000 

Instructors Edition 

© Festo Didactic GmbH & Co. • MPS 1

Order no.: 

Description: Mechatronics Teachware Station Robotassembly MPS 2000 

Designation: 

Instructors Edition 

Status: July 2003 

Author: 

Graphics: 

Layout: 

Wolfgang Eckart, Intercon-Asia 

Wolfgang Eckart, Festo Didactic GmbH & Co 

Festo Didactic GmbH & Co 

© Festo Didactic GmbH & Co., D-73770 Denkendorf, 2003 

Internet: www.festo.com/didactic 

e-mail: did@festo.com 

All rights reserved, including translation rights. No part of this publication may be reproduced or 

transmitted in any form or by any means, electronic, mechanical, photocopying, or otherwise, without 

the prior written permission of Festo Didactic.

Table of Contents 

Table of Contents _______________________________________________________ 1 

What is Mechatronics _________________________________________________ 3 

Introduction____________________________________________________________ 3 

Project overview _____________________________________________________ 6 

Commissioning _________________________________________________________ 8 

1.1 Analysis – Robot Station Components identification ______________ 8 

1.2 Analysis – Robotassembly Station Components identification _____10 

1.3 Installation – Robot Station Wiring of the System ________________12 

1.4 Installation – Robotassembly Station Wiring of the System ________14 

1.5 Analysis– Robotassembly Station Input and Output adresses______16 

1.6 Commissioning – Robotassembly Station Adjustment of the Station 18 

1.7 Commissioning – Robotassembly Station Download Project/Test __23 

1.8 Maintenance – Robot Station Check the Origin Datas of the Robot__59 

1.9 Maintenance – Robot Station Reset battery usage time ___________62 

1.10 Commissioning – Robot Station Operating modes _______________64 

1.11 Commissioning – Robotassembly Station Changing the Parameters 66 

Programming__________________________________________________________86 

2.1 Programming - Robot Station Edit a new Project_________________86 

2.2 Teach-In – Robot Station Teaching of P1 and P2 _________________93 

2.3 Teach-In – Robot Station Move to P1 and P2 ___________________100 

2.4 Teach-In and Programming – Robot Station Upload Positions _____103 

2.5 Teach-In – Robot Station Change coordinates of P2 _____________112 


Table of Contents 

2.6 Teach-In and Programming – Robot Station Upload P2 to the PC __116 

2.7 Teach-In – Robot Station Add a new P3________________________125 

2.8 Teach-In and Programming – Robot Station Teach-In with PC _____128 

2.9 Programming – Robot Station Preparation for exercises __________145 

2.10 Programming – Robot Station PTP movement __________________165 

2.11 Programming – Robot Station Linear movement ________________174 

2.12 Programming – Robot Station Modify Speed ___________________178 

2.13 Programming – Robotassembly Station Wait for START __________182 

2.14 Programming – Robotassembly Station If-Then-Else with START ___187 

2.15 Programming – Robotassembly Station Digital I/O ______________190 

2.16 Programming – Robotassembly Station Check- Assembly- Sorting _193 

2.17 Programming – Robotassembly Station Subroutine _____________197 

2.18 Project – Robotassembly Station I/O– communication Basics _____202 

2.19 Project – Robotassembly Station Check and Rejection ___________206 

Trouble Shooting _____________________________________________________210 

3.1 Trouble Shooting –Robotassembly Station_____________________210 

2 © Festo Didactic GmbH & Co. • MPS

Introduction 

What is Mechatronics 

Mechatronics is a comprehensive combination of Technologies and is mostly 

mentioned as a new way of thinking and learning and not as a “stand-alone” 

technology. 

The technological part of Mechatronics could be called Automation Technology. 

Structure of Mechatronics 

The structure of Mechatronics training is divided into three levels: 


Introduction 

The Basic Training in the single technologies is another part of training. In the 

following you will see some examples of the different levels: 

Totally Integrated System 

Partly Integrated Systems 

Basic Technologies 


Introduction 

Basically in Automation and Mechatronics training, the contents should cover the 

following learning steps, or functions within a company: 

Commissioning: 

Programming: 

Trouble Shooting: 

Analyse a system, Installation&Commissioning 

Programming single Station, Communication with other Stations 

Programming Errors, Trouble Shooting in the Process 

which are covered within the following projects. 

Further on this Teachware is based on the idea of a Flexible Manufacturing System – 

FMS, this means, this station should be and is connected to another station, called 

Previous Station within this Teachware. Because of the mechanical structure of the 

station and the Robot arm, there is no other function connected after. The 

Robotassembly Station is mostly connected to the Closed Loop Conveyor system, 

the centre station within a Flexible Manufacturing System – FMS. 


Introduction 

Project overview 

The following table give you an overview about all projects within this 

documentation in the structure of: 

Commissioning: 

Programming: 

Trouble Shooting: 

Analysis (Analyse a system) and 

Installation (Cabling of the system) 

Commissioning (Adjustment work and test of the process) 

Maintenance (Origin Data and Rest Battery usage time) 

Teach-In (Teaching of positions with Teach-Box and PC) 

Programming (Programming single Station and 

Project (Communication with other Stations) 

Process * (Trouble Shooting in the Process) 

The table also mention the time which is necessary to work out the respective 

project. This time is based on experience with participants coming with no 

knowledge about the MPS-Stations and programming a Mitsubishi Robot RV-2AJ. 

* 

Regarding the Process-Trouble Shooting, there is no big difference in time between 

the single troubles-based on experience. We can say, that each trouble needs 

around 1,5 hour including the preparation and test of the error by the instructor and 

if the participants follow the three steps carefully and doing the documentation, 

which is very important. 

This structure allows you to put your specific workshop together according to your 

needs and your learning targets. 

This Teachware is also divided into Robot Station and Robotassembly Station: 

Robot Station 

Robotassembly Station 


Introduction 

Learning Step Designation Project Description Proj.. Page Time 

Commissioning 

Commissioning 

Commissioning 

Commissioning 

Commissioning 

Commissioning 

Commissioning 

Commissioning 

Commissioning 

Commissioning 

Commissioning 

Programming 

Programming 

Programming 

Programming 

Programming 

Programming 

Programming 

Programming 

Programming 

Programming 

Programming 

Programming 

Programming 

Programming 

Programming 

Programming 

Programming 

Programming 

Programming 

Analysis 

Robot Station-Components identification: 

description of the function of some components used within the stations 

1.1 8 1,5 h 

Analysis 

Robotassembly Station-Components identification: 

description of the function of some components used within the stations 

1.2 10 1,5 h 

Installation 

Robot Station-Wiring of the system: 

cable connection of the Robot, Drive Unit, Teach-Box and Interface (RIA) 

1.3 12 0,5 h 

Installation 

Robotassembly Station-Wiring of the system: 

cable connection of the Robot, Assembly, Drive Unit, Teach-Box and (RIA) 

1.4 14 1,0 h 

Analysis 

Robotassembly Station-In-and Output addresses: 

find out the hardwareaddresses of in- and outputs in the technical docum. 

1.5 16 1,5 h 

Commissioning 

Robotassembly Station-Adjustment of the Station: 

check the adjustment all sensors, pneumatic and mechanical components 

1.6 18 3,0 h 

Commissioning 

Robotassembly Station-Download Project and Test: 

download the project-program and positions and test the function 

1.7 23 2,0 h 

Maintenance 

Robot Station-Check the Origin Datas: 


1.8 59 0,5 h 

Maintenance 

Robot Station-Reset the Battery usage time: 


1.9 62 0,5 h 

Commissioning 

Robot Station-Operating modes of the Drive Unit and Teach-Box: 


1.10 64 0,5 h 

Commissioning 

Robotassembly Station-Changing the Parameters: 

check/change parameters for the defined in- and output functions 

1.11 66 0,5 h 

Programming 

Robot Station-Edit a new Project: 

edit a new Project with the Project-Wizard 

2.1 86 0,5 h 

Teach-In 

Robot Station-Teaching of P1 and P2: 

teaching and save of 2 Robot positions with the Teach-Box 

2.2 93 1,0 h 

Teach-In 

Robot Station-Move to P1 and P2: 

move the Robot to the teached positions using the Teach-Box 

2.3 100 0,5 h 

Teach-In/Progr. 

Robot Station-Upload positions to the PC: 

upload the teached positions to the Project (PC) and save 

2.4 103 0,5 h 

Teach-In 

Robot Station-Change coordinates of P2: 

change the coordinates of P2 by direct input of the X,Y,Z,A,B-values 

2.5 112 1,0 h 


Robot Station-Upload P2 to the PC: 

upload the changed position P2 to the Project (PC) and save 

2.6 116 0,5 h 

Teach-In 

Robot Station-Add a new P3: 

add a new position P3 using the Teach-Box 

2.7 125 0,5 h 


Robot Station-Change coordinates of P2: 

change the coordinates of P2 by direct input using the Robot-program (PC) 

2.8 128 1,0 h 


Robot Station-Preparation of exercises: 

edit a new Project, delete the Drive Unit, planning of positions 

2.9 145 0,5 h 

Programming 

Robot Station-Point-to-Point (PTP) movement: 

Pick and Place exercise in PTP-movement 

2.10 165 2,0 h 

Programming 

Robot Station-Linear movement: 

Pick and Place exercise in Linear movement 

2.11 174 0,5 h 

Programming 

Robot Station-Modify speed: 

Pick and Place in PTP and Linear movement with different speed 

2.12 178 1,0 h 

Programming 

Robotassembly Station-Wait for START: 

start the sequence by pressing the Start-button on the Control Panel 

2.13 182 1,5 h 

Programming 

Robotassembly Station-If-Then-Else with START: 

like Project 2.14, but with the command If-Then-Else instead of Wait 

2.14 187 1,5 h 

Programming 

Robotassembly Station-Digital I/O: 

start the sequence with Start, check if a workpiece is in place 

2.15 190 2,0 h 

Programming 

Robotassembly Station-Check-Assembly-Sorting: 

process check material, assemble a piston rod and sorting in the feeder 

2.16 193 6,0 h 

Programming 

Robotassembly Station-Check-Assembly-Sorting: 

like Project 2.16, but with assembly of a spring using a Subroutine 

2.17 197 5,0 h 

Project 

Robotassembly Station-I/O-communication Basics 

basics of input/output communication between different controllers 

2.18 202 3,0 h 

Project 

Robotassembly Station-Check and Rejection 

take a workpiece from Previous Station, check material, reject black 

2.19 206 6,0 h 

Trouble Shooting Process Maintenance Trouble Shooting14 Process-Errorstime for each approx. 3.1 210 90min 


Commissioning 

1.1 Analysis – 


Components 

identification 

Please list up all the “sensors” and “actuators” shown in the picture below (1 – 3). 

Name the elements with identification in the wiring diagram/pneumatic plan and 

describe shortly their function generally (not the function within the system). 

Information 

Please use the technical manual-data sheets, pneumatic plan and wiring diagrams. 

Please refer to the example (Ex.1, but not shown in the picture) mentioned below in 

the table of the execution work-sheet. Please follow the numbers (1 – 3) shown in 

the pictures below. 

Instructor: This exercise using the Robot Station alone without the Assembly 

process. Show one example to the participants how to find an in- and output in the 

wiring diagrams and how to find the data sheet using the order number printed on 

the element itself. Show the participants at the station itself which components 

they have to identify, because the example is not shown within the picture. 


Commissioning 

Planning 

Please plan your project within the whole team carefully. Use the technical manual 

and the real station to do this project. Please describe the function of the element in 

general, not within the signal- and material flow of the station. To find the datasheet 

of the elements, please see the list of components first and check the order 

no. printed on the element itself. 

The time to finish this project should be around 1,5 hours. 

Execution/Documentation 

Please complete the list regarding the elements shown in the pictures above. 

No. Name Ident. Description Page # 

Ex.1 

Opto- 

-IP_FL 

Optoelectronic sensor Receiver, PNP with 

SOEG-E-Q30-RS-S-2L 

electronic 

fibre optic cable connection, 24 VDC, 

Robot: inputs 

sensor 

receive an optical signal if another 

Receiver 

station is available and sending an 

optical signal 


1 Single 

1Y 

5/2-Single solenoid valve, 24 VDC, 

CPE-10-M1H-5L-M7 

Solenoid 

compact valve performance, connection 

Robot: inputs 

valve 

M7, to actuate the Robot-gripper, normal 

Robot: pneumatic 

position of the gripper is closed, open by 

actuating the valve-solenoid 

2 Fiber optic 

Part_AV 

Fibre optical device Sender and Receiver, 

SOEG-L-Q30-P-A-S-2L 

device 

PNP, reflex switch triggering, 24 VDC, 

Robot: inputs 

send the information “a workpiece is 

inside the workpiece mounting” to the 

Drive Unit of the Robot 

3 Parallel 

1A1 

Pneumatic parallel gripper, self centring, 

HGP-10-A-R 

gripper 

internal or external use, double acting 


cylinder, 10 mm gripping distance, 

proximity switches for end-position 

detection, gripping force nominal 40 N 

close and 47 N open 


Commissioning 

1.2 Analysis – 



Components 

identification 

Please list up all the “sensors” and “actuators” shown in the picture below (1 – 3). 

Name the elements with identification in the wiring diagram/pneumatic plan and 

describe shortly their function generally (not the function within the system). 

Information 

Please use the technical manual-data sheets, pneumatic plan and wiring diagrams. 

Please refer to the example (Ex.1, but not shown in the picture) mentioned below in 

the table of the execution work-sheet. Please follow the numbers (1 – 3) shown in 

the pictures below. 

Instructor: This exercise using the Robot and the Assembly Station. Show one 

example to the participants how to find an in- and output in the wiring diagrams 

and how to find the data sheet using the order number printed on the element 

itself. Show the participants at the station itself which components they have to 

identify, because the example is not shown within the picture. 


Commissioning 

Planning 

Please plan your project within the whole team carefully. Use the technical manual 

and the real station to do this project. Please describe the function of the element in 

general, not within the signal- and material flow of the station. To find the datasheet 

of the elements, please see the list of components first and check the order 

no. printed on the element itself. 



Please complete the list regarding the elements shown in the pictures above. 


Ex.1 

Opto- 

-A1 Optoelectronic sensor Sender, PNP with 

SOEG-S-Q30-S-L 

electronic 

fibre optic cable connection, 24 VDC, 

Robot: inputs 

sensor 

send an optical signal to another station 

Sender 

(to an optoelectronic receiver) 


1 Double acting 

cylinder 

2A1 Double acting pneumatic ISO-cylinder, 8 

mm diameter and 80 mm stroke, with 

magnet ring to activate proximity 

switches, with flow control valves to 

adjust the piston rod speed, normal 

position front end position 

DSNU-8-80-P-A 


2 Micro switch 1S1 manual switch, changeover contact, 

activated by the spring feeding cylinder 

mechanically, send the information 

“spring is in place” to the PLC-input 

S-3-E 

Robot: inputs 

3 Proximity 

2B2 

Reed switch electrical, normally open 

SME-8-S-LED-24 

switch 

contact, activated by a magnet ring in the 

Station: inputs 

piston rod of the cylinder, send the 

Station: pneumatic 

information “piston rod of the cylinder is 

in front position” to the Robot Drive-Unit 


Commissioning 

1.3 Installation – 


Wiring of the 

System 

Please analyze the cable connections in your station and complete the drawing on 

the next page (Execution and Documentation). 

Information 

Please fill out all in the graphic and draw the connections. Use the real station to 

check the connections. 

Instructor: Leave the cables all connected to help the participants. 

Planning 

Please follow the explanations of the instructor first and then plan your activities 

step-by-step. Use the real station to find out all connections and identifications. Use 

also the technical documentation. 



Commissioning 



Commissioning 

1.4 Installation – 



Wiring of the 

System 

Please analyze the cable connections in your station and complete the drawing on 

the next page (Execution and Documentation). 

Information 

Please fill out all in the graphic and draw the connections. Use the real station to 

check the connections. 

Instructor: Leave the cables all connected to help the participants. 

Planning 

Please follow the explanations of the instructor first and then plan your activities 

step-by-step. Use the real station to find out all connections and identifications. Use 

also the technical documentation. 



Commissioning 



Commissioning 

1.5 Analysis– 



Input and Output 

adresses 

Please complete the below mentioned list of input- and output addresses of the 

Station connected to the Drive Unit via the Robot Interface Box (RIA-Box). 

Information 

To find out the addresses please use the technical manual-wiring diagram for the 

station and the Control Panel. 

Instructor: show the participants how to find out an input and an output using the 

wiring diagrams. Show them also how to find out the communication in- and 

outputs. 

Planning 

Please plan your activities within your team. 

The time to finish this project should be around 1,5 hour. 


Commissioning 


Please complete the list of the inputs and outputs of your station. 

I/O Station 

Address Ident. Description 

M_IN(1) 

M_IN(2) 

M_IN(8) 

M_IN(9) 

M_IN(10) 

M_IN(11) 

M_IN(12) 

M_IN(13) 

M_IN(14) 

M_IN(15) 

M_OUT(8) 

M_OUT(9) 

Out 10-15 

Optical sensor in gripper red/alu=1, black/no workpiece=0 

Optical sensor for measuring orientation 

Feeder of springs in back position 

Feeder of springs in front position 

Feeder of cover in front position 

Feeder of cover in back position 

Spring is available after feeding 

No cover at gripping position after feeding 

Feeder for covers is empty 

IP following station available 

Feeding of a spring 

Feeding of a cover 

Not connected 

I/O Control Panel 


M_IN(3) 

M_IN(4) 

M_IN(5) 

M_OUT(0) 

M_OUT(1) 

M_OUT(2) 

M_OUT(3) 

START button 

STOP button 

RESET button 

START light 

RESET light 

Special function Q1 light 

Special function Q2 lamp light 

I/O Communication 


M_IN(7) 

M_OUT(4) 

M_OUT(5) 

M_OUT(6) 

M_OUT(7) 

Communication with Previous Station – Input for start assembly 

Error Code Bit 0 for feedback to Previous Station 


Robot Assembly Station is in process 

Robot Assembly Station is ready to receive a workpiece 


Commissioning 

1.6 Commissioning – 



Adjustment of the 


Please check the adjustment of all sensors, the mechanical components and the 

pneumatical components of your station to prepare the test of the whole process. 

Check also the cable connections and the power- and air-supply. 

Information 

To find out the function and location of the sensors and pneumatical components 

please use the technical documentation. The inputs can also be checked directly at 

the LED of the I/O-interface XMA2 of the Assembly Station. To move pneumatic 

actuators, please switch off the air-pressure and move them manually by hand. 

Please be very careful, move the actuators back before switching on the air-pressure 

again. 

In the following please find some important informations regarding pneumatic 

actuators and their triggering. These informations are basically. 

• 5 = number of connections (1, 3, 4, 2 and 5) 

• 2 = 2 switching positions (2 rectangles) 

The connections have the following functions: 

1(P) = air connection (supply) 

2(B) = output B for backward stroke 

3(S) = connection exhaust air of forward stroke 

4(A) = output A for forward stroke 

5(S) = connection exhaust air of backward stroke 

In the following drawing you can find letters in brackets behind the standardized 

designation of the connections (1, 3, 4, 2 and 5). These letters are former 

designations, one can still find them on old elements. 


Commissioning 

short 

power 

signal 

(24VDC) 

connected to y2 

4(A) 2(B) 

4(A) 2(B) 

14 12 14 

12 

y2 

5(S) 3(R) 

1(P) 

y3 

y2 

5(S) 3(R) y3 

1(P) 

short 

power 

signal 

(24VDC) 

connected to y3 

Activation of single/double solenoid valve: 

14 

y1 

4(A) 

2(B) 

5(S) 

1(P) 

3(R) 

power 

(24VDC) 

connected to Y1 

14 

y1 

4(A) 

2(B) 

5(S) 

1(P) 

3(R) 

Activation of a single solenoid valve: 

Single solenoid 

Double solenoid 

14 

y1 

4(A) 

2(B) 

5(S) 

1(P) 

3(R) 

4(A) 2(B) 

14 12 

y2 5(S) 3(R) y3 

1(P) 

Activation of a double solenoid valve: 


Commissioning 

Instructor: Work-out the basics of pneumatics first and explain the functions of 

pneumatic valves and actuators. Show the participants how to move pneumatic 

actuators by hand without air-pressure, or activating the manual detection button 

on the valve itself with air-pressure. Show an example how to adjust a sensor to 

define the back or front position of a cylinder and how to adjust the speed of a 

pneumatical actuator. Provide the necessary tools. 

Deadjust the following sensors (bold) 

I/O Station 


M_IN(1) 

M_IN(2) 

M_IN(8) 

M_IN(9) 

M_IN(10) 

M_IN(11) 

M_IN(12) 

M_IN(13) 

M_IN(14) 

M_IN(15) 

M_OUT(8) 

M_OUT(9) 

Out 10-15 

Optical sensor in gripper red/alu=1, black/no workpiece=0 

Optical sensor for measuring orientation 

Feeder of springs in back position 

Feeder of springs in front position 

Feeder of cover in front position 

Feeder of cover in back position 

Spring is available after feeding 

No cover at gripping position after feeding 

Feeder for covers is empty 

IP following station available 

Feeding of a spring 

Feeding of a cover 

Not connected 

Please don´t change any mechanical position!!! 

Disconnect the power- and air supply and disconnect all cable connections. 

Remove also the Control Panel from the trolley. Remove all workpieces from the 

Station. Change the speed of the pneumatical actuators at the one-way flow 

control valves. 


Commissioning 

Work out together with the participants the general steps of Installation. The 

conditions for this example shall be: 

• all cable connections are removed 

• no power supply connection, no air-pressure supply 

• the Control Panel is removed 

1. check the adjustment of mechanical components 

2. check the adjustment of mechanical actuators holder 

3. assemble removed components (like Control Panel) 

4. cable connections (Drive Unit, Teach-Box, RIA, Control Panel, Communication) 

5. connect all power supplies 

6. check the adjustment of sensor holders 

7. check the adjustment of sensors in the holders 

8. check the adjustment of sensitivity of sensor 

9. tubing connections 

10. connect all air-pressure supplies (careful! turn pressure down before) 

11. check the adjustment of the speed of pneumatic actuators 

12. connect the stations together 

13. communication connection 


Commissioning 

Planning 

Please plan your activities within your team. Check the inputs in the wiring diagram 

and at the RIA-Box frontside. Follow the steps worked out together with the 

Instructor. 



Write down the single steps and all useful informations. Write down your single 

steps you did to proceed. Use the tables to proceed. 

Step No.: Description Check 

1 check the adjustment of mechanical components 

2 check the adjustment of mechanical actuators holder 

3 assemble removed components (Control Panel…) 

4 cable connections (Drive Unit, Control Panel, …..) 

5 connect all power supplies 

6 check the adjustment of sensor holders 

7 check the adjustment of sensors in the holders 

8 check the adjustment of sensitivity of sensor 

9 tubing connections 

10 connect all air-pressure supplies (careful! turn pressure down) 

11 check the adjustment of the speed of pneumatic actuators 

12 connect the stations together 

13 communication connection 


Commissioning 




Download 

Project/Test 

Please download the project into the Drive Unit and test the full process. 

Information 

Please make sure that the PC is connected to the Drive Unit with the communication 

cable and make sure, the correct serial port COM1/2 is selected within the program, 

the power supply of the station is on, air-pressure of around 5 bar is available at 

each station, the emergency switch is deactivated (if available). Make sure that the 

Drive Unit memory is empty (delete). 

Instructor: Show how to delete the contents of the Drive Unit. Show how to check 

the serial port connection using the software. Tell the participants, in which 

subdirectory they are able to find the project in the following screen shots, the 

project is located in: 

C:\Dokumente und Einstellungen\Wolfgang Eckart\Eigene Dateien\Eigene 

Daten\Teach_gb\Festo\MPS_Robotassembly_releaseC\Prog_COSIMIR 

if you are using the COSIMIR Industrial-software and 

C:\Dokumente und Einstellungen\Wolfgang Eckart\Eigene Dateien\Eigene 

Daten\Teach_gb\Festo\MPS_Robotassembly_releaseC\Prog_Cosirop 

if you are using the COSIROP-software 

but this can be different on your PC. 

Explain them step-by-step how to download a project to the Drive Unit. Develop 

the process sequence on the white board first this means, what is the process and 

how to start it. Which are the Control Panel functions. 

Basically all screen shots and PLC-projects are based on two different 

programming software versions: COSIMIR Industrial and COSIROP. Please move 

the Robot to the position P99 before starting this Project. 

Planning 

Please follow the description of the Instructor carefully step-by-step. Use the NOTICE 

field to write down the single steps to proceed. 



Commissioning 


Follow the single steps of the Instructor. Write down the single steps and all useful 

informations into the field NOTICE. 

Write down your single steps you did to proceed after checking that the 

communication between the PC and the Drive Unit is ok: 

1. Check the air-pressure = 5 bar 

2. Check cable connection plug should be locked 

3. Refill all feeders with workpieces and empty the workpiece mountings 

4. Release Emergency switch at the Drive Unit and at the Teach-Box 

5. Switch the key on the Teach-Box to DISABLE 

6. Switch the key on the Drive Unit to AUTO (EXT) position 

7. Switch on the Drive Unit and the Power Supply of the Station 

8. Change the offset speed (display o ) to 100 by using the UP or 

DOWN button on the Drive Unit 

9. Open the Project on the PC and delete all contents of the Drive Unit 

10. Download the Project to the Drive Unit 

11. Switch the key on the Drive Unit to AUTO (OP) position 

12. 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 of the Drive Unit 

13. Now please activate the servo motors by pressing the SVO ON buttonplease 

wait until the LED of this button is on 

14. Now please press the START button of the Drive Unit-LED is on – the 

program is now active 

15. 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 

16. To start the process, press the START button of the Control Panel once, the 

Reset-LED is off and the Start-LED is on 


Commissioning 

During the process, the lights of the Control Panel have the following functions: 

• Missing springs will be shown by Special function Q1 light 

• Missing covers will be shown by Special function Q2 light 

• Missing piston rods will be shown by Special function Q1 and Q2 light 

• Please refill the missing parts and press START-button of the Control Panel to 

continue with the assembly process 

• If the robot is not able to detect the orientation of the base, it will be rejected. If 

the robot is not able to detect the orientation of the cover, it will be also rejected 

and the LED´s Q1 and Q2 are flashing alternating, this means also to remove the 

base by hand – the process will be interrupted. By pressing START-button once, 

the LED´s stop flashing and the robot continue with the assembly process 

• The maximum amount of rejected workpieces is controlled via a counter inside 

the robot-program. If the maximum amount of bad workpieces is exceeded, the 

LED´s Q1 and Q2 are flashing alternating and the process will be interrupted. 

Empty the rejection magazine and quit by pressing the START-button again. The 

process continue 

• If there is a vision system available within the FMS to detect good and bad parts, 

the robot will reject the bad parts out of the production process 

The process can be interrupted by pressing STOP-button at each time the STARTlight 

is flashing, continue the assembly process with START-button. 

The Program structure is as follow: 

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: 

• retrieve workpiece 

• insert piston (corresponding to workpiece) 

• insert spring 

• assemble cover 

Simultaneous an interrupt function monitors the STOP button of the control panel. If 

activated the program will be paused in any position. 


Commissioning 

Following input signals are the communication between the Robotassembly Station 

and the Conveyor: 

• Robot input bit No. 6 = Start assembly 

• Robot output bit No.7 = Assembly ready, workpiece back onto the pallet 

• Robot input bit No. 7 = bad part → sort out 

The handshake (communication with Conveyor) is following the steps: 

The process positions are defined as follow: 

Pos. No.: 

P1 

P2 

P3 

P4 

P5 

P6 

P9 

P99 

Description 

Retrieve and return position on the Conveyor pallet with red workpiece 

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. 

Identify workpiece if black/not black with optical sensor in the gripper 

Gripping position at feeder for springs 

Position at piston pallet, teach with cone gauge in inner gripper jaws 

Release position if there is no detection during rotation of workpieces 

Gripping position for covers 

Waiting position 


Commissioning 

Position P1 

Position P1 


Commissioning 

Position P2 

Position P2 


Commissioning 

Position P3 

Position P3 


Commissioning 

Position P4 


Commissioning 

Position P5 

Position P5 


Commissioning 

Position P6 

Position P9 


Commissioning 

Position P99 


Commissioning 

The conditions to download the full project are, that the Drive Unit is connected with 

the PC, the Drive Unit is on and the key-switch of the Teach-Box in DISABLE position 

and the software (COSIROP or COSIMIR) opened. 

How to proceed step 9 and 10 from page 24 to open, delete and download the 

project of the full FMS-process with different software is shown on the following: 

Before starting the process, please make sure, that the offset speed is 100%. Please 

proceed as shown below. 

Switch on the Drive Unit and switch the key to AUTO (Op). 

1. Press CHNG DISP as long as… 

2. …. you can see the actual speed (in % from 10-100 – here 100) 

3. increase the speed by pressing UP until 100 is shown in the display 

After this, please switch the key-switch on the Drive Unit to AUTO (Ext) and proceed 

as shown below. 


Commissioning 

COSIROP – open the project solution 

File Open (Choose the right directory and click onto the file – here IT_CITRES, 

the name can be different within your project) Öffnen 


Commissioning 

COSIROP – check the communication port: 

Extras Settings Communication Port 


Commissioning 

Serial Interface (click onto the selection of Serial Interface if it´s not active already) 


Commissioning 

Serial Interface (Window) (Change the Port: to your interface you are using – here 

COM1) OK 


Commissioning 

COSIROP – connection to the Drive Unit: 

Execute Init Connection 


Commissioning 

COSIROP – open the Program directory of the contents of the Drive Unit: 

Extras Program Directory 


Commissioning 

(Make sure all contents are marked) Delete Program OK (follow the screen to 

proceed) 


Commissioning 

COSIROP – download the original Positions to the Drive Unit: 

(Activate the Window with the Positions first) Execute Download PC Robot 


Commissioning 

(Type in the Program number 1 into the field Name (“N”) OK (Activate the 

Window with the Program after download is finish) 


Commissioning 

COSIROP – download the original Program to the Drive Unit: 

Execute Download PC Robot 


Commissioning 

(Type in the Program name 1 into the field Name (“N”) OK 


Commissioning 

COSIROP – start the process: 

Execute Program Start 


Commissioning 

COSIMIR – open the project solution 

File Open (Choose the right directory and click onto the file – here IT_CITRES, 

the name can be different within your project) Öffnen 


Commissioning 

COSIMIR – check the communication port: 

Extras Settings Communication Port 


Commissioning 

Serial Interface (click onto the selection of Serial Interface if it´s not active already) 


Commissioning 

Serial Interface (Window) (Change the Port: to your interface you are using – here 

COM1) OK 


Commissioning 

COSIMIR – connection to the Drive Unit: 

Execute Init Connection 


Commissioning 

COSIMIR – open the Program directory of the contents of the Drive Unit: 

Extras Program Directory 


Commissioning 

(Make sure all contents are marked) Delete Program OK (follow the screen to 

proceed) 


Commissioning 

COSIMIR – download the original Positions to the Drive Unit: 

(Activate the Window with the Positions first) Execute Download PC Robot 


Commissioning 

(Type in the Program number 1 into the field Name (“N”) OK (Activate the 

Window with the Program after download is finish) 


Commissioning 

COSIMIR – download the original Program to the Drive Unit: 

Execute Download PC Robot 


Commissioning 

(Type in the Program name 1 into the field Name (“N”) OK 


Commissioning 

COSIMIR – start the process: 

Execute Program Start 

After the process run properly, please delete all contents of the Drive Unit like 

mentioned above to prepare the following Programming exercises !!! 


Commissioning 

1.8 Maintenance – 


Check the Origin 

Datas of the Robot 

Please check the Original Datas of the Robot mentioned on the backside of the 

connection cover of the Robot arm. 

Information 

Please open the cover on the backside of the Robot arm first to see the datas. 

Because the Robot comes with an absolute positioning system, the “reference” 

datas must be defined correctly. This have to be done also at the very first 

commissioning of the Robot, or if the batteries of the Robot arm and/or the Drive 

Unit have been changed. 

1 Origin Datas are on the back side (inside) of the cover 

Instructor: Show where the Original datas can be found. Explain about incremental 

and absolute positioning system of an Industrial Robot. 


Commissioning 

Planning 

Please follow the descriptions on the next page very carefully. Please don´t change 

any Original datas if they are ok. Switch the key-switch of the Drive Unit to TEACH 

position and the key-switch of the Teach-Box to ENABLE. Take the Teach-Box and 

press the dead-man-switch permanently as long as you are using it. 


1 Dead-man-switch on the backside of the Teach-Box 


Commissioning 


Commissioning 

1.9 Maintenance – 


Reset battery 

usage time 

Please reset the battery usage time in the Drive Unit using the Teach-Box. 

Information 

After changing the batteries of the Robot arm (5 batteries) and/or the batteries of 

the Drive Unit (1 battery), we have to reset the usage time of it. Please refer to the 

Technical documentation of Mitsubishi of how to proceed to change the batteries. 

Instructor: Show where batteries are located and how to proceed to change it. 

Planning 

Please follow the descriptions on the next page very carefully. Switch the key-switch 

of the Drive Unit to TEACH position and the key-switch of the Teach-Box to ENABLE. 

Take the Teach-Box and press the dead-man-switch permanently as long as you are 

using it (this have to be done always using the Teach-Box and is no more mentioned 

within the following projects). 


1 Dead-man-switch on the backside of the Teach-Box 


Commissioning 


Commissioning 



Operating modes 

Please fill out the exercise sheet below. Please mark the corresponding key switch 

positions for each task. 

Information 

The controller has a ‘Mode changeover’ key-switch. The Teach-Box has an 

ENABLE/DISABLE key-switch. For each possible operating task it is necessary to turn 

the key switches in a specific position. 

Instructor: Please proceed the different modes together with the participants. 

Planning 

Please follow the description of the Instructor carefully. Use the following table to 

proceed. 



Commissioning 

Please write down a task for the specified key switch positions. Be aware that 

sometimes more than one task is possible for a key switch combination. 

Operating Modes of the Mitsubishi Robot RV-2AJ 

Name: Wolfgang Eckart Date: 30.06.2003 

Project: Commissioning - Operating Modes 

Exercise: Operating modes of the Drive Unit and the Teach-Box Sheet 1 of 1 

Key switch 

Controller 

Key switch 

Teach Box 

Task 

AutoOP 

TEACH 

AutoExt 

Disable 

Enable 

Additional Information 

Teach Box X X 

Programming with 

PC X X 

Teach Box X X 

TEACH Mode 

PC X X 

PC X X 

Start program with 

Controller X X 

Teach Box X X 

Read parameter with 

PC X X X X 

Teach Box X X 

Write parameter with 

PC X X 

Teach Box X X 

Change speed with 


Teach Box X X 

Change program with 

PC X X 


Teach Box X X 

Teach positions with 

PC X X 

Download/upload program from PC X X 

Download/upload positions from PC X X 

Reboot controller after changing 

parameter! 


Commissioning 




Changing the 

Parameters 

Please check/deactivate the parameters of START, IOENA, ERRESET, SRVON, 

SRVOFF in the Drive Unit 

Information 

The first in- and outputs of the Drive Unit I/O-port have fixed functions, defined by 

parameters. Because we have to use this in- and outputs for the full process, we 

have to deactivate the function inside the Drive Unit. Switch the key-switch of the 

Teach-Box to DISABLE and the key-switch of the Drive Unit to AUTO (Ext.). Make sure 

the PC is connected to the Drive Unit. 

Instructor: Please explain to be very careful changing parameters within the Drive 

Unit and that the changes are only necessary using the Robot and the Assembly 

Station. Proceed together with the participants. Explain to the participants, that 

normally it´s not necessary to have an extra project for the parameters. Once 

stored within the Driver Unit, they will be active as long as no changes have been 

done by someone, or the battery is working. It´s easier to store the parameters 

once within an extra project to find the original datas later easy if it will be 

necessary. 

Planning 

Please follow the description of the Instructor and the screen-shots very carefully. 

Define a new project first and name it Parameter. Check if the PC is connected to the 

Drive Unit and the serial interface is defined correctly. 



Commissioning 

COSIROP – edit a new project: 

File Project Wizard 


Commissioning 

(Type in the name of the project, created by, the initials and a short description of 

the project) Next 


Commissioning 

Finish 


Commissioning 

Upload of the parameters to the PC: 

Execute Robot Parameters… 


Commissioning 

Deselect All 


Commissioning 

(Activate – click on Date: of the parameters START, IOENA, ERRESET, SRVON, 

SRVOFF) Read Robot PC 


Commissioning 

Change/check the parameters and send to the Robot: 

(Type in/check if -1,-1 is inside the field of the selected parameters and save the file) 

Save: PC File 


Commissioning 

(Only if you changed the parameters you have to send it to the Robot. If there have 

been -1,-1 already, please don´t download it and move to the next screen) 

Send: PC Robot Close 


Commissioning 

File Save All 


Commissioning 

COSIMIR – edit a new project: 

File Project Wizard 


Commissioning 

(Type in the name of the project, created by, the initials and a short description of 

the project) Next 


Commissioning 

Finish 


Commissioning 

Upload of the parameters to the PC: 

Execute Robot Parameters… 


Commissioning 

Deselect All 


Commissioning 

(Activate – click on Date: of the parameters START, IOENA, ERRESET, SRVON, 

SRVOFF) Read Robot PC 


Commissioning 

Change/check the parameters and send to the Robot: 

(Type in/check if -1,-1 is inside the field of the selected parameters and save the file) 

Save: PC File 


Commissioning 

(Only if you changed the parameters you have to send it to the Robot. If there have 

been -1,-1 already, please don´t download it and move to the next screen) 

Send: PC Robot Close 


Commissioning 

File Save All (switch the Drive Unit off and on again to activate the changes) 


Commissioning 


Programming 

2.1 Programming - 


Edit a new Project 

Please prepare a new project on the PC and name it Teach P1 P2. 

Information 

Please make sure that the PC is connected with the Drive Unit and the Drive Unit is 

empty (done during Project 1.7). For the Program itself we won´t use a name, but 

only numbers. So the field of Program Name will be empty. 

Planning 

Please follow the description (screen shots) carefully step by step. Please make 

sure, that every member of your team did the new project definition at least once. 



Programming 

Execution and Documentation 

Screen shots of the Project Wizard, the bold words are commands to click on, the ( ) 

are only comments (ENTER) means click left mouse button once or press ENTER, 

(double click) means double click the left mouse button: 

COSIROP 

File Project Wizard (fill in the Project name, the Initials and the Description like 

shown within the screen shot, please make sure, that you choose the correct 

subdirectory to save all the following projects, Program Name will be empty because 

we will use only numbers) Next 


Programming 

RV-2AJ Finish 


Programming 


Programming 

COSIMIR Industrial Industrial: 

File Project Wizard (fill in the Project name, the Initials and the Description like 

shown within the screen shot, please make sure, that you choose the correct 

subdirectory to save all the following projects, Program Name will be empty because 

we will use only numbers) Next 


Programming 

RV-2AJ Finish 


Programming 


Programming 

2.2 Teach-In – 


Teaching of P1 and 

P2 

Please teach two new positions using the Teach-Box and name them P1 and P2. Use 

the Project Teach P1 P2 defined before. 

Information 

This exercise is to learn about the handling of the Teach-Box. The positions P1, P2 

and later on P3 won´t be used for further programming exercises. Please make sure, 

that Position P1 is around: 

Base: 180° opposite of the cable connections of the Robot arm 

Shoulder: vertical up 

Elbow: horizontal 

Hand Pitch: horizontal 


Programming 

and P2 is around: 

Base: +45° relative to P1 

Hand Pitch: vertical around 15 cm above the ground 

The Shoulder and the Elbow depending on the Hand Pitch which should be vertical 

Instructor: Please explain the participants where the P1 and P2 should be around. 

Show the positions directly at the Robot arm. 

Planning 


sure, that every member of your team did this project at least once. Make sure that 

your Project Teach P1 P2 is still open on your PC.. Turn the key-switch of the Drive 

Unit to TEACH, and the key-switch of the Teach-Box to ENABLE. 



Programming 



Programming 


Programming 


Programming 


Programming 


Programming 



Move to P1 and P2 

Please move to the teached positions P1 and P2 using the Teach-Box. 

Information 

This exercise is to learn about how to move to stored positions using the Teach-Box. 

Planning 




Unit to TEACH, and the key-switch of the Teach-Box to ENABLE. 



Programming 



Programming 


Programming 

2.4 Teach-In and 

Programming – 


Upload Positions 

Please upload the positions P1 and P2 to your PC (Project Teach P1 P2) and save the 

full project. 

Information 

This exercise is to learn about how to move to stored positions from the Drive Unit to 

the PC. 

Instructor: Please explain the participants about the structure of a project and the 

contents. 

Planning 



your Project Teach P1 P2 is still open on your PC.. Turn the key-switch of the Teach- 

Box to DISABLE and the key-switch of the Drive Unit to AUTO (EXT). Activate the 

Positions window within the program (COSIROP or COSIMIR). 



Programming 


COSIROP – upload Positions to the PC 

Execute Init connection 


Programming 

Execute Upload Robot PC 


Programming 

(Type in the Program name 2 into the field of Name („N“) OK 


Programming 

File Save All 


Programming 

COSIMIR – upload Positions to the PC 



Programming 



Programming 



Programming 

File Save All 

Controll 

After uploading the positions to your project you should see the coordinates of P1 

and P2 onto your screen. 


Programming 



Change coordinates 

of P2 

Please change the coordinates of the position P2 by direct input of the coordinates 

using the Teach-Box. 

Information 

The new coordinates of P2 should be: 

X: +330.00 

Y: -8.00 

Z: +430.00 

A: 0.00 

B: +120.00 

Change the coordinates of P2 by direct input of the values with the Teach-Box. Move 

to P2 first and then change it. 

Instructor: Please explain the participants about the difference of Joint and XYZcoordinates 

and movement. 

Planning 



your Project Teach P1 P2 is still open on your PC.. Make sure that the Robot is still at 

position P2. Turn the key-switch of the Drive Unit to TEACH, and the key-switch of 

the Teach-Box to ENABLE. 



Programming 



Programming 


Programming 

Controll 

After changing and saving the values of P2 and move to P2 you must be able to see 

the coordinates on your screen of the Teach-Box if you switch to XYZ-mode. 


Programming 




Upload P2 to 

the PC 

Please upload position P1 and P2 to your PC (Project Teach P1 P2) and save the full 

project again 

Information 

This exercise is to learn about how to store single positions from the Drive Unit to 

the PC. 

Planning 



your Project Teach P1 P2 is still open on your PC. and the position window is active. 

Turn the key-switch of the Teach-Box to DISABLE and the Drive Unit to AUTO (EXT). 



Programming 


COSIROP – upload two Positions to the PC 



Programming 



Programming 

(Deactivate Automatically for upload, type in 1 at From position and 2 at To position 

and type in 2 at the field Name (“N”) OK 


Programming 

File Save All 


Programming 

COSIMIR – upload Positions to the PC 



Programming 



Programming 



Programming 

File Save All 

Controll 

After uploading the positions to your project you should see the coordinates of P1 

and P2 onto your screen. 


Programming 



Add a new P3 

Please add a new position P3 using the Teach-Box. 

Information 

The coordinates of P3 should be around: 

X: +230.00 

Y: 180.00 

Z: +290.00 

A: 0.00 

B: +170.00 

Please teach the position P3 by moving the single axis not by direct input of the 

values. 

Planning 




Unit to TEACH, and the key-switch of the Teach-Box to ENABLE. After teaching the 

position, please upload it to the PC and save it (Save All). 



Programming 



Programming 

Controll 

After teaching the new position P3 you must be able to see the coordinates on your 

screen of the Teach-Box if you switch to XYZ-mode. May be the coordinates are not 

100% the same than described within the Information-this is ok, because you don´t 

teach this P3 by direct input of values. 


Programming 




Teach-In with PC 

Please change the coordinates of the position P2 using your program (PC), save it 

and download the new position P2 to the Drive Unit. 

Information 

This exercise is to learn about how to teach positions using the program (PC) and 

how to download single positions to the Drive Unit. 

The coordinates of position P2 should be around: 

X: +300.00 

Y: -8.00 

Z: +350.00 

A: 0.00 

B: +180.00 

Please define the position P2 by moving the single axis not by direct input of the 

values. 

Planning 



your Project Teach P1 P2 is still open on your PC.. Turn the key-switch of the Teach- 

Box to DISABLE and on the Drive Unit to AUTO (EXT). Make sure, that the position 

window is active. 



Programming 


COSIROP - teach positions with the PC 

Execute Jog Operation 


Programming 

(Choose the position number 2 with the up and down key) 


Programming 

XYZ Jog Set XYZ Position… 


Programming 

(In the field X,Y,Z in the Jog Operation window you can define the value of movement 

whenever you press a button of the Robot X+ X-, Y+ Y- a.s.o. – here 2 mm and for the 

Hand – here 2°) Retrieve Position (if you press this button, you will get the actual 

position coordinates of the Robot on the screen) (move the Robot as long as you 

will reach the coordinates like shown in the screen) 


Programming 

Set Position X (close the window of Set XYZ Position) 


Programming 

Current Position Pos. List (transfer the coordinates to the position list on the PC) 

X (close the window of Jog Operation) 


Programming 

Execute Init Connection Download PC Robot 


Programming 

(Type in 2 inside From Position and 2 inside To Position and also the program 

number 2 inside the field Name (“N”) OK OK File Save All 

Controll 

You can also simulate the real Robot movement on the PC-screen by double click 

onto the position P1, P2 or P3 and watch the Robot on the screen. 


Programming 

COSIMIR – teach positions with the PC 

Execute Jog Operation 


Programming 

(Choose the position number 2 with the up and down key) 


Programming 

XYZ Jog Set XYZ Position… 


Programming 

(In the field X,Y,Z in the Jog Operation window you can define the value of movement 

whenever you press a button of the Robot X+ X-, Y+ Y- a.s.o. – here 2 mm and for the 

Hand – here 2°) Retrieve Position (if you press this button, you will get the actual 

position coordinates of the Robot on the screen) (move the Robot as long as you 

will reach the coordinates like shown in the screen) 


Programming 

Set Position X (close the window of Set XYZ Position) 


Programming 

Current Position Pos. List (transfer the coordinates to the position list on the PC) 

X (close the window of Jog Operation) 


Programming 

Execute Init Connection Download PC Robot 


Programming 

(Type in 2 inside From Position and 2 inside To Position and also the program 

number 2 inside the field Name (“N”) OK OK File Save All 

Controll 

You can also simulate the real Robot movement on the PC-screen by double click 

onto the position P1, P2 or P3 and watch the Robot on the screen. 


Programming 

2.9 Programming – 


Preparation for 

exercises 

Please prepare a new project on the PC and name it P2_09. Please delete the 

contents of the Drive Unit. 

Information 

Please make sure that the PC is connected with the Drive Unit and the Drive Unit is 

empty (done during Project 1.7). For the Program itself we won´t use a name, but 

only numbers. So the field of Program Name will be empty. 

Instructor: Please explain to the participants the functions of the software to edit a 

program, to check the positions on the screen and download the program to the 

Drive Unit according to the screen-shots. 

Planning 

Please make sure, that every member of your team did the new project definition at 

least once. 



Please refer to the following screen-shots, where you will get several helpful 

informations of editing, downloading and testing a program. 


Programming 

COSIROP – editing a program and handling of the software 

(Activate the positions window) File Project Wizard (edit a new project like 

shown before) Execute Init Connection Upload Robot PC (Type in 

number 2 into the field Name (“N”) OK 


Programming 

Settings 

Extras Settings Program Steps/Positions… (Type in the program name 2) 

OK 


Programming 

Extras Settings Program Editor (change the settings like shown within the 

screen) OK 


Programming 

Extras Settings Renumber (change the settings like shown within the screen) 

OK (please be careful to renumber the positions, because then the position 

number P100 will be position P5. To renumber, please activate only the program 

window and renumber it. To sort the positions, click onto the position window 

Edit Sort) 


Programming 

Program editor 

(Activate the program windows and edit a program) (The right mouse button 

opens the command windows) 


Programming 

After editing is finish….) Edit Renumber OK 


Programming 

Syntax check 

Execute Check Syntax (refer to the Messages window to see Errors and/or 

Warnings) 


Programming 

Download of the program 

Execute Init Connection Execute Download PC Robot (type in the 

program name 2) OK 


Programming 

Program start 

Execute Program Start Yes (test your program-if the test was successful…..) 

Execute Program Stop File Save All 


Programming 

COSIMIR – editing a program and handling of the software 

(Activate the positions window) File Project Wizard (edit a new project like 

shown before) Execute Init Connection Upload Robot PC (Type in 

number 2 into the field Name (“N”) OK 


Programming 

Settings 

Extras Settings Program Steps/Positions… (Type in the program name 2) 

OK 


Programming 

Extras Settings Program Editor (change the settings like shown within the 

screen) OK 


Programming 

Extras Settings Renumber (change the settings like shown within the screen) 

OK 


Programming 

Program editor 

(Activate the program windows and edit a program) Edit Command Tools (offer 

you an extensive help function of the Robot commands) 


Programming 

After editing is finish….) Edit Renumber OK 


Programming 

Syntax check 

Execute Compile+Link (refer to the Messages window to see Errors and/or 

Warnings) 


Programming 

Download of the program 

Execute Init Connection Execute Download PC Robot (type in the 

program name 2) OK 


Programming 

Program simulation 

Execute Next Step (or press the Shift + F10 buttons to proceed step by step) 


Programming 

Program start 

Execute Program Start Yes (test your program-if the test was successful…..) 

Execute Program Stop File Save All 


Programming 



PTP movement 

Take a workpiece at the position P2 (don´t use a real workpiece for this exercise) 

and transport it to the position P4. Use only PTP movements and an offset speed of 

50%. 

Information 

Please use the Project P2_09 for this exercise and save it as Project 2_10. Please 

refer to the following screen-shots how to proceed. Teach 4 new positions as shown 

in the picture on the next page using the Teach-Box, upload them to your Project 

2_10 and save the positions. After this, please edit the program and download it to 

the Drive Unit. Please make sure that the program number is higher than 1 always – 

for this exercise we will use program number 2. Please make sure that the PC is 

connected with the Drive Unit. Please change the offset speed at the controller to 

50% as shown in the picture. Please change the key-switch of the Drive Unit to AUTO 

(Op) to change the offset speed and back to TEACH after finish changing. Activate 

the key-switch to ENABLE. 

1. Press CHNG DISP as long as… 

2. …. you can see the actual speed (in % from 10-100 – here 100) 

3. increase the speed by pressing UP 

4. or decrease it by pressing DOWN 


Programming 

Positions for the exercise 

Instructor: Please explain how to change the offset speed on the Drive Unit and 

explain the differences between PTP and Linear movement. Show the participants 

where the new positions are at the station and how to edit and download a 

program to the Drive Unit. Please explain that every team has to upload the 

positions to their PC first, if there is more than one team working with the Robot! 

Please show how to save a project with a new name. 


Programming 

Planning 

Change the offset speed on the Drive Unit first, and then turn the key-switches in the 

correct positions to prepare teaching with the Teach-Box. Teach the 4 new positions 

according the picture above and upload them to your project Pick and Place. Please 

edit the program on a paper first!!! Follow the screen shots carefully step by step 

how to edit a program and download it to the Drive Unit after uploading of the 

positions. 



Programming 


COSIROP – save a project with a new name – preparation with the Explorer 

(Prepare a new Folder first) right mouse button New Folder (name it 

P2_10) 


Programming 

COSIROP – save a project with a new name – Save As 

(Click on the Mod-window, this is the window with the simulated Robot first) File 

Save As (choose the folder P2_10) (type in the name P2_10) Save 


Programming 

COSIMIR – save a project with a new name – preparation with the Explorer 

(Prepare a new Folder first) right mouse button New Folder (name it 

P2_10) 


Programming 

COSIMIR – save a project with a new name – Save As 

(Click on the Mod-window, this is the window with the simulated Robot first) File 

Save As (choose the folder P2_10) (type in the name P2_10) Save 


Programming 

COSIROP – program solution 

Controll 

Please download your program and test the function 


Programming 

COSIMIR – program solution 

Control 

Please simulate your program, download it and test the function 


Programming 



Linear movement 

Take a workpiece at the position P2 (not use a real workpiece for this exercise) and 

transport it to the position P4. Use only Linear movements and an offset speed of 

50%. 

Information 

Please edit a new Project and name it Project 2_11. Please upload the positions from 

the Drive Unit to the PC. After this, please edit the program and download it to the 

Drive Unit. Please make sure that the program number is higher than 1 always – for 

this exercise we will use program number 2. Please make sure that the PC is 

connected with the Drive Unit. Please make sure that the offset speed at the 

controller is still 50%. 



Programming 

Planning 

Check the offset speed on the Drive Unit first, then turn the key-switches in the 

correct position. Upload the positions from the Drive Unit to the PC. Please edit the 

program on a paper first!!!. 



Programming 


COSIROP 

Control 



Programming 

COSIMIR Industrial: 

Controll 



Programming 



Modify Speed 

Take a workpiece at the position P2 and transport it to the position P4. The starting 

and end position of this exercise should be P100. Use PTP and Linear movements 

and speed according to your needs. 

Information 

Please edit a new Project and name it Project 2_12. Please teach the position P100 

with the Teach-Box first and upload the positions from the Drive Unit to the PC. The 

position P100 should be like shown within the picture. After this, please edit the 

program and download it to the Drive Unit. Please make sure that the PC is 

connected with the Drive Unit. Please set the offset speed at the Drive Unit to 100%. 



Programming 

Instructor: Please explain the differences in speed manipulation of PTP and Linear 

movement. 

Planning 

Change the offset speed on the Drive Unit first, then turn the key-switches in the 

correct position to teach P100. Upload the positions from the Drive Unit to the PC. 

Please edit the program on a paper first!!!. 



Programming 


COSIROP 

Controll 



Programming 

COSIMIR Industrial: 

Controll 



Programming 




Wait for START 


and end position of this exercise should be P100. The process starts only after the 

START-button (1) on the Control Panel was pressed shortly. Use PTP and Linear 

movements and speed according to your needs. 

Information 

Please edit a new Project and name it Project 2_13. Please upload the positions from 

the Drive Unit to the PC. After this, please edit the program and download it to the 

Drive Unit. 



Programming 

Instructor: Please explain the WAIT-function and the M_IN(X)=0/1 command to 

the participants and how to open and define the I/O-window. 

Planning 

Upload the positions from the Drive Unit to the PC. Please edit the program on a 

paper first and use the WAIT command for this exercise. Follow the screen-shots of 

how to simulate a digital input on the PC. 



Programming 


COSIROP – definition of the Inputs and Outputs 

Extras I/O-Monitor (Input 3 double click and change the name to START) 

OK 


Programming 

COSIMIR – definition of the Inputs and Outputs 

Extras I/O-Monitor (Input 3 double click and change the name to START) 

OK 


Programming 

Because the handling of the different programs and the programming itself is the 

same for COSIROP and COSIMIR, we will show the following program solutions done 

with COSIROP only. 

Controll 



Programming 




If-Then-Else with 

START 


and end position of this exercise should be P100. The process starts only after the 

START-button (1) on the Control Panel was pressed shortly. Use PTP and Linear 

movements and speed according to your needs. 

Information 

Please edit a new Project and name it Project 2_14. Please use the IF-THEN-ELSE 

command for this exercise. Please upload the positions from the Drive Unit to the 

PC. After this, please edit the program and download it to the Drive Unit. 



Programming 

Instructor: Please explain the difference between the WAIT and the IF-THEN-ELSE 

command to the participants. 

Planning 

Upload the positions from the Drive Unit to the PC. Please edit the program on a 

paper first!!!. 



Programming 


COSIROP 

(To see the actual program line) Execute Monitor Functions Program 

Monitor ON 

Controll 



Programming 




Digital I/O 

A red or an alu workpiece should be transported from the position P2 to P4. The 

starting and end position of this exercise must be P100. The cycle starts only after 

the START-button (1) on the Control Panel was pressed shortly. The Robot check if 

there is a workpiece in place at position P2 using the optical sensor (3) in the gripper 

(at P6). If there is a workpiece red or alu in place, the Robot proceed to put it to P4, if 

not, the Robot move back to P100 and the Special function Q1-light (2) is on. After 

restart the process with START-button (1) the Q1-light (2) is off. Please use PTP and 

Linear movement, as well as the speed according to your needs. 

Information 

Please edit a new Project and name it Project 2_15. Please teach all new positions 

by the Teach-Box first and then upload the positions from the Drive Unit to the PC. 

After this, please edit the program and download it to the Drive Unit. 



Programming 

Instructor: Please explain the function of the optical gripper sensor and the 

command to activate an output (M_OUT(X)=0/1) to the participants. 

Planning 

Teach the new positions first and upload them from the Drive Unit to the PC. Please 

edit the program on a paper first!!!. 



Programming 


COSIROP 

Controll 



Programming 




Check- 

Assembly- 

Sorting 

One red workpiece should be pre-assembled with a piston rod from the pallet 

(P 51/P52) and sorted into the feeder (P81/P82). After a short activation of the 

RESET-button (1) on the Control Panel the Robot move to the starting and end 

position P100. The start position of the workpiece is P2, the assemble position P4. 

The process starts after the START-button (2) was pressed shortly. The Robot 

checks if the red workpiece is in place with the Gripper sensor (3). If not, the Robot 

move to P100 and the Q1-light (4) is on. After restart the process, the Q1-light is off 

again. Assembly and sorting finish is shown by the Q2-light (5). Please use PTP and 

Linear movement, as well as the speed according to your needs. 

Information 

Please edit a new Project and name it Project 2_16. Please teach all new and change 

the old positions by the Teach-Box first and then upload the positions from the Drive 

Unit to the PC. Please provide one piston rod for the red workpiece within the pallet 

(positions P52). Please edit the program and download it to the Drive Unit. 



Programming 

Instructor: Please explain the function of the single acting cylinder and their 

single parts and feeders to the participants. Please explain why we need 4 

positions at the workpiece – 2 for the workpiece base and 2 for the piston rod. 

Please explain, that the position P53 is for prevent collision with the feeders of the 

spring and the cover. 

Planning 

Teach the new/change the old positions first and upload them from the Drive Unit to 

the PC. Provide all necessary workpieces and parts. Please edit the program on a 

paper first!!!. 



Programming 


COSIROP 

(Program lines 10 – 350) 


Programming 


Controll 



Programming 




Subroutine 

Please expand the Project 2_16 so, that after inserting a piston rod into the base a 

spring (P61/P62) will also be assembled within the base. 

Information 


by the Teach-Box first and then upload the positions from the Drive Unit to the PC. 

Please provide one piston rod for the red workpiece within the pallet (positions P52) 

and at least 1 spring within the spring feeder. The assembly of the spring should be 

done by a subroutine called SPRING. After this, please edit the program and 

download it to the Drive Unit. 



Programming 

Instructor: Please explain the function of the different single acting cylinder and 

their single parts and feeders to the participants. Explain the Subroutine 

programming structure and the commands to the participants. 

Planning 

Teach the new positions first and upload them from the Drive Unit to the PC. Provide 

all necessary workpieces and parts. Please edit the program on a paper first!!!. 



Programming 


COSIROP 



Programming 



Programming 

(Program lines until 860) 

Controll 



Programming 

2.18 Project – 



I/O– 

communication 

Basics 

Please complete the following graphics according the description. 

Information 

Work out the basics of input/output communication together with the instructor 

first. 

Instructor: Please explain the basics of I/O-communication. 

Planning 

Please plan your project step by step first within the team. The time to finish this 

project should be around 3,0 hour. 


Please define a 1 Bit bidirectional communication network: 


Programming 

Please define a 1 Bit unidirectional communication network from PLC to Robot- 

Controller: 


Programming 



Programming 



Programming 

2.19 Project – 



Check and 

Rejection 

Please take a workpiece (black or red or alu) from the Previous Station (mostly the 

Conveyor), insert it into the workpiece mounting and check the material. The 

different materials shall be indicated by the Q1 and Q2-lights – Q1-light is on if it´s a 

red or alu workpiece, Q2 is on if it´s a black one. After restart by a new workpiece is 

in place, the lights must be off. If the workpiece is black, please put it into the 

rejection feeder, if the workpiece is red or alu, please put it back to the Previous 

Station (mostly the pallet of the conveyor). After a short activation of the RESETbutton, 

the Robot moves to P100 first. The cycle starts by pressing the START-button 

shortly. The RESET-light and the START-light shall be on to show which button have 

to be pressed and off after the buttons have been pressed. A short activation of the 

STOP-button, interrupts the process immediately. The movement from the conveyor 

to the mounting should be circular. Please teach only the Conveyor up position and 

name it P41. The movement down to take the workpiece should be done by 

mathematical conditions. 

Information 


by the Teach-Box first and then upload the positions from the Drive Unit to the PC.. 

Please empty the rejection feeder first. After this, please edit the program and 

download it to the Drive Unit. 

Instructor: Please plan the communication with the Previous Station first together 

with the participants. If you use the FMS 50 Conveyor, please make sure, that the 

original PLC-program is running for the Conveyor. Please explain the I/Ocommunication 

and the handshake with the Previous Station (Conveyor). 

I/O Communication 


M_IN(6) 

M_OUT(4) 

M_OUT(5) 

M_OUT(6) 

M_OUT(7) 

Communication with Previous Station – Input for start assembly 



Robot Assembly Station is in process 

Robot Assembly Station is ready to receive a workpiece 


Programming 

Planning 

Please plan your project step by step first within your team and define the 

communication with the Previous Station. Provide all necessary workpieces and 

empty all workpiece mountings as well as the rejection feeder. Make a position-plan 

first and teach or change all positions needed and upload them to your PC. Edit your 

project on paper first, then edit it with your program, download and test it. 



COSIROP 

(Program lines from 10 to 350) 


Programming 

(Program lines from 350 to 690) 


Programming 

(Program lines until 990) 

Controll 



Trouble Shooting 

3.1 Trouble Shooting – 



Please test the full process including all conditions. Find out which part of the 

process is not working properly and proceed with the steps: error detection, error 

limitation and error elimination. Please don´t forget to fill out the working-sheet of 

the part Execution and Documentation. Please download the original project to the 

Drive Unit like shown within Project 1.7. 

Information 

Besides Commissioning and Programming, the Trouble Shooting and Maintenance is 

one of the most important tasks in reality, because non-operating manufacturing 

units are causing high costs. 

It is much more important than in installation&commissioning or programming, to 

train operational steps to detect, limit ate and eliminate an error as quick as 

possible. 

At Trouble Shooting there is one difference between so called “Commissioning 

Errors“ and “Maintenance Errors”. Both of them could be different in a way, there 

are NO wrong wirings, tubings as well as programming errors within the 

Maintenance Errors, because the system already has been running perfectly and an 

operational error had happened. Such operational errors could be: 

• break of wire 

• defect of elements like valves, cylinders, motors, sensors, etc. ... 

• break of program 

• mechanical reasons 

Procedure of error elimination divides into three important fields: 

• error detection 

• error limitation 

• error elimination 

which have to be documented respectively by the trainee on the attached work 

sheet. An example help with the further procedure. 

Usually maintenance errors are easier to transform into manual training, therefore 

this teachware is referring only on this field regarding the solutions of its exercises. 



Instructor: Please work out step-by-step the difference of Commissioning- and 

Maintenance Errors and work out the example together with the participants. 

In the following you will find 14 examples of possible error locations in the table. 

Advice: For isolation of wire endings you can use a thin shrink tube slipped on the 

wire ending and heated up. This tube provides good isolation. 

Error Error Location/Page No.: Error Description Installed 

1 Close the one way flow control 

valve of the cover feeder 

feeding a cover 

Pneumatic Diagram Assembly 


2 Close the one way flow control 

valve of the spring feeder 

backward movement 



3 Deadjust the sensor 2B1 for 

cover feeder in front position 

(piston rod in back position) 



4 Isolate +-connection (red) of 

external power supply 

Electrical Wiring Diagram 

Assembly Station page 3 

5 Isolate wire at the backside of 

the RIA-Box connection NA pin 1 


Robot Station page 5 

6 Delete the program from the 

Drive Unit (simulation of 

battery failure) 

7 Delete one position inside the 

Drive Unit 

8 Isolate the wire I1 at XMA2 of 

the Robot Station 



9 Isolate the wire 0V of I2 at 

XMA2 of the Assembly Station 



10 Isolate the clamp directly at the 

micro switch of the spring 

feeder 1S1 



11 Isolate the wire 24V of I2 at 

XMA2 of the Robot Station 



12 Change the offset-speed at the 

Drive Unit to 10% and change 

the display back to the program 

number 

The feeder for covers cannot feed a coverprogram 

stop and wait at this position 

The feeder for springs cannot move back 

after feeding a workpiece 

The magazine not move back after feeding a 

workpiece and no signal to the Robot to take 

the cover 

No power supply on the RIA-Box 

Always Emergency Stop at the Drive Unit 

No program execution 

Error status of the Robot 

The material detection sensor inside the 

gripper is not working-detection of black 

workpiece always 

The sensor 2B1 of cover feeder in front 

position is not working-the Robot will not get 

the signal to take the cover 

The Robot will not get a signal to take the 

spring-the program will go to the “no more 

springs” subroutine 

The robot cannot detect the orientation of 

the workpiece and the cover-the program 

will go into the error subroutine 

Very slow Robot movements 



In the following, there is a step-by-step explanation of a sample Trouble Shooting. 

This wiring diagram is not part of the technical documentation of the Robot and 

Robotassembly Station, but show a very good example how to measure an error 

step by step with different measuring methods. 

24NA/6.8 

24V/6.8 24V/8.1 

-XK1 24V -XK1 24NA 

-XG2 24VB 

-XMG2 21 

-S6 

-S5 

-S4 

-S3 

-S2 

-S1 

3 

4 

3 

4 

3 

4 

3 

4 

3 

4 

3 

4 

COM/5.7 

Disconnection 

at START-Button S1 

-XMG2 7 

-XMG2 13 -XMG2 14 -XMG2 15 -XMG2 16 -XMG2 17 

-XG2 O6 

-XG2 I0 -XG2 I1 -XG2 I2 -XG2 I3 -XG2 I4 

9 

8 

7 

6 

5 

4 

3 

2 

-A2DI1 

/6.4 

-A2DI1 

/6.4 

-A2DI1 

/6.4 

-A2DI1 

/6.4 

-A2DI1 

/6.4 

-A2DI1 

/6.4 

-A2DI1 

/6.4 

-A2DI1 

/6.4 

0V/6.8 0V/8.1 



Although the program is loaded to the PLC and normal position is reached (RESET- 

Light flashing) the Station may not be started (RESET-Light not change to off). 

The starting condition is, that the Station is in normal position, which is indicated by 

flashing of the RESET-light. The reason for malfunction must be the START-button 

itself. 

Measuring of the current path No. 1 may be proceeded in different ways. In the 

following, two examples may be described, and both of them are leading to result. 

• measuring of voltage 

• measuring of continuity 

For better understanding, the current path No. 1 may be shown as an equivalent 

diagram: 

disconnection 

XK1 

24V 

XMG2 

21 

XMG2 

13 

A2DI1 

2 

24V 

0V 

R 

PLC 

input 

0V 

0V-clamp 

PLC-board 



Voltage test procedure 1. step: 

0V 

XMG2 

21 

XMG2 

13 

XK1 

24V 

24V 

0V 

A2DI1 

2 

R 

0V 

0V-clamp 

PLC-board 

Voltage test procedure 2. step: 

12V 

XMG2 

21 

XMG2 

13 

XK1 

24V 

24V 

0V 

A2DI1 

2 

R 

PLCinput 

PLCinput 

0V 

0V-clamp 

PLC-board 

Result: disconnection must be located between clamp XMG2 and A2DI1-2= broken 

wiring 



Continuity test 1. step: 

R> 

no continuity 

XK1 

24V 

XMG2 

21 

XMG2 

13 

A2DI1 

2 

Attention: 

disconnect 

power supply ! 

R 

0V 

Continuity test 2. step: 

0 

continuity 

disconnection 

XK1 

24V 

XMG2 

21 

XMG2 

13 

A2DI1 

2 

Attention: 

disconnect power supply ! 

R 

PLCinput 

PLCinput 

0V 

Result: disconnection must be located between clamp XMG2 and A2DI1-2= broken 

wiring 



The work-sheet for this example looks like: 

Order of Maintenance 

Name: Hellmich Order-No: 001 310800 Date: 31.08.2001 

Location of Error: Distribution Station Sheet: 1 # 1 

Error Detection 

After switch-on the air pressure and the PLC, the RESET-light is flashing, which means, that the system is in normal position 

starting condition OK 

However, the station cannot be started by the Start-Button (RESET-light not change to off). 

MECHANICAL: 

1. Is there a mechanical defect on the Start-button? 

Error Limitation 

ELECTRICAL 

1. Is the Start-button switching regularly? - Continuity test of switching contacts. 

2. Is the signal of the button reaching the PLC? - Control by sight and voltage test. 

Error Elimination 

REASON 

Break of wire (end sleeve) at the button at connection X. 

Attach new end sleeve to the wire and connect again. Control of total sequence = error eliminated. 

Planning 

Please follow the description of the in instructor carefully step-by-step. Make a 

detailed plan of how you want to check the error location step-by-step. 




Follow the three steps of Trouble Shooting carefully. Write down the single steps 

and all useful informations into the work-sheet. Please show your result first to the 

instructor before removing the error!!!!! Please ask your instructor for copies of these 

worksheets!!! 

Order of Maintenance 

Name: Order-No: Date: 

Location of Error: 

Sheet: 

Error Detection 

Error Limitation 

MECHANICAL: 

ELECTRICAL 

PNEUMATICAL 

Error Elimination 

REASON 



Controll 

After error elimination, please check the process again step-by-step carefully, there 

might be another error within the system.

1 Robotassembly Station MPS 2000 Instructors Edition

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