THE CHANGES OF THE AUTOMATED ASSEMBLY WORKPLACE WITH THE CAMERA CONTROL SYSTEM
4. Design of the automated assembly work- work-place with the camera control
The design of the automated workplace based on the arrangement of the elements in the original assembly workplace with the camera control in the manufacturing and assembly system ICIM 3000.
After the change of assembly composition, it is ne-cessary to make several changes. Design and model has been implemented in CATIA V5 from Dassault Systèmes.
New assembly workplace consists of several parts, which are shown Figure 8:
1. camera system, 2. preparation for the estab-lishment of the springs in the control, 3. angular
N. Vetríková, R. Holubek, R. Ružarovský, et al. 97
robot Mitsubishi RV-2SD, 4. pallets for storing the finished assembly compositions, 5. NOK box for the sorting of the wrong springs, 6. buffer of the springs Φ33,5, 7. buffer of the springs Φ20, 8. buffer of the spring covers Φ33,5x6, 9. buffer of the damper pis-ton, 10. buffers for the manual assembly of the was-hers, nuts and cotter pins, 11. assembly module.
Figure 8. Designed automated assembly workplace At the beginning of the process operation control system initiates a request to the assembly of the damper composition, and it enters the specific pa-rameters of the required composition. After ente-ring the system requirements for the assembly if the composition in a particular format (elected bo-dy type and springs Φ33,5 and Φ20) in automated storage using the cartesian robot displacement of the pallet with the competent body of the damper.
Pallet is supplied by the conveyor system to the workplace where the angular robot transfers com-ponents from the palette to the assembly module.
Assembly module shown in Figure 9 contains of several changes compared to the original solution.
Figure 9. Damper body in the assembly module After placing the body of the damper to the assembly place, it activates the activity of the rec-tilinear pneumatic actuators. Jaws 1 on a smaller actuator have been changed. They are designed and centered on the exact shape of the damper
body, and provide better support during assembly.
It had also been removed inductive sensor that detects the presence of the component. Function of the inductive proximity sensor has been re-placed by the color sensor Festo SOEC-RT-Q50 2, which senses the color of an object through a cutout in the wall, which partially eliminates the for-mation of glare and thus erratic sensor. The sensor is easy to setup using the button called teach-in function. It offers three adjustable channels which are preset to concrete color using a teach-in function. It has its own LED light source and it is shown in Figure 10.
Figure 10. Color sensor Festo SOEC-RT-Q50 The sensor simply detects body color of the damper, closes the respective channel and sends information to the control system. The system evaluates if a captured color corresponds to the selected requirement. If all goes well, the system continues operating procedures. If the color doesn´t match, the damper body is returned to the automated storage, where the new require is also initialized for the proper body damper. After the evaluation of the correct color by the sensor, robot grips the spring (diameter Φ33,5) from the catchment buffer in Figure 11, where the springs are arranged in accordance with the requirements precondition to the order of assembly.
Figure 11. Selection of the spring from the buffer by the robot
To verify the correct type of the spring, the robot places the component to the control workstation.
The control workstation has been changed from the original. It has different, customized dimen-sions and there is located also thorn for better stability of the springs. After the establishment of The Changes of the Automated Assembly Workplace with the Camera Control System
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the component to the control workplace, it follows the camera control. The software system using a camera control evaluates:
• color of the springs - compares comply with the type of chosen spring
• diameter of the springs - software measures the outer and inner diameter of the spring - for elimination of the errors caused by the correct color but the wrong diameter. Upon the detec-tion of the errors is the spring moved into the red NOK box. The service for the filling of the box takes the next process of the grading NOK com-ponents. In the case of the successful control, the spring is placed in the body of the damper.
The same procedure follows in the assembly of the spring with a diameter Φ20. The next step in the assembly process is the placement of a circular spring cover Φ33,5x6. Components are placed in a free-fall buffer. The robot picks up the cover and moves it on top of the springs in the assembly composition. After this process, it is added a piston of the damper, which is also delivered by the robot to the gravitational axis of the damper buffer shown in Figure 12.
Figure 12. Inserting of the damper piston The last step in the workflow of the assembly is the application of the three components of the faste-ner rows: Plain washers nut M12 STN 02 1702, hex nut M12 STN 02 1401, pin Φ4x20 STN 02 1781.
Figure 13. Storage places with the completed compositions
After these operations, the process of assemb-ling is complete and final composition is transfer-red to one of storage places as is shown in Fig. 13.
System organizes the transferring of assembled composition on the palette by conveyor system ac-cording to the information about available free palette.
Due to the need for an expanded work area for other active elements that would allow automated assembly of the fasteners, the assembly of the last three components is fitted manually by the service personal. In the future and the future research and proposals made in the system ICIM we do plan not only the mentioned expansions of the workplace of the assembly but also another frameworks of the implementing of more active elements necessary for automated assembly washers, nuts and cotter pins.
5. Conclusion
Given assembly composition has been designed in regard to the possibilities of the system ICIM. It is a prerequisite for further development of a complex system using the given composition. Non-standard components - damper piston and cover springs will be produced directly in the production system within system ICIM 3000 in future. This is related to other changes in the system and change of pallets in an automatic storage. It also creates space for introducing of the mentioned automation for the assembly of plates, nuts and split pins to the suggestion to be assembled manually. There-fore, in the future, we aim to realize and implement further changes to the flexible manufacturing and assembly system, to adapt it to production, assem-blage of the new base parts, which will be based on the requirements from the practice. Foreign aut-hors describe also research in relatively new area such as machine vision in their articles [6,7]. The main purpose is intensive linking of the educational process with the practice, what will increase the competitiveness of our graduates in the current la-bor market in Slovakia and also in the framework of globalization on the pan-European labor market.
6. Acknowledgement
This work was supported by KEGA 027-STU 4/2014: Establishment virtual laboratory of robotics and manipulation techniques
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