1. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 1 ASSEMBLY LINE GAUGING MODULE ASSEMBLY LINE - GAUGING MODULE LEVEL 1 COURSE 1 Siemens Mechatronic Systems Certification Program Gerd Voigt Siemens Technik Akademie Berlin

2. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 2 A gauging station is a device to check part dimensions to determine whether or not the dimensions are within a specific tolerance. This module is designed … to inspect a port location, to inspect a port location, to measure the height of a valve body, to measure the height of a valve body, to transfer the valve body to the next station to transfer the valve body to the next station (good part), or (good part), or to reject the valve body from the process (bad part). MODULE 2 : GAUGING

3. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 3 MODULE 2: GAUGING

4. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 4 GAUGING MODULE – COMMON COMPONENTS CARRIAGE DC MOTOR CLUTCH PULLEY PULLEY BELT BALL SCREW SHAFT SHAFT TRANSFERCYLINDER REJECT REJECTCYLINDER VALVE BODY INDUCTIVE SENSOR SENSOR ULTRASONIC LIMIT LIMITSWITCH SWITCH INDEXING TABLE TABLE PHOTOELECTRIC SENSOR SENSOR

5. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 5 GOOD PART System in initial position System in initial position Photoelectric Sensor B1 performs first inspection. Photoelectric Sensor B1 performs first inspection. PHOTOELECTRIC SENSOR B1 SENSOR B1 Part passes that inspection if B1 sends a 0-signal to the PLC. Part passes that inspection if B1 sends a 0-signal to the PLC.

6. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 6 GOOD PART System in height measuring position System in height measuring position TAB INDUCTIVE SENSOR B2 ULTRASONIC SENSOR B3 SENSOR B3 TAB (mounted on the carriage) activates inductive sensor B2. TAB (mounted on the carriage) activates inductive sensor B2. Sensor B2 sends a signal to the PLC to activate Sensor B3 Sensor B2 sends a signal to the PLC to activate Sensor B3 PLC input signal from sensor B3 is high = PLC input signal from sensor B3 is high = Height is within the sensor`s window boundaries. Height is within the sensor`s window boundaries.

7. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 7 GOOD PART Valve body passed port location and height measurement Valve body passed port location and height measurement Limit switch 4S2 triggered -> end of travel position reached Limit switch 4S2 triggered -> end of travel position reached Motor M1 stops. Motor M1 stops. LIMIT SWITCH 4S2 MOTOR M1

8. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 8 GOOD PART Valve body passed port location and height measurement Valve body passed port location and height measurement Transfer to next module for processing by lift cylinder 2A and Transfer to next module for processing by lift cylinder 2A and transfer cylinder 1A transfer cylinder 1A TRANSFER CYLINDER 1A LIFT LIFT CYLINDER 2A

9. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 9 GOOD PART Retract transfer cylinder 1A and lift cylinder 2A Retract transfer cylinder 1A and lift cylinder 2A TRANSFER CYLINDER 1A LIFT LIFT CYLINDER 2A

10. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 10 GOOD PART Reverse motor starter K5 energized, DC motor M1 switched Reverse motor starter K5 energized, DC motor M1 switched on in reverse direction (carriage moved back toward initial on in reverse direction (carriage moved back toward initial position) position)

11. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 11 BAD PART System in initial position System in initial position Photoelectric Sensor B1 performs first inspection. Photoelectric Sensor B1 performs first inspection. Part fails that inspection if sensor B1 sends a 1-signal. Part fails that inspection if sensor B1 sends a 1-signal.

12. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 12 BAD PART System in measuring position System in measuring position TAB (mounted on the carriage) activates inductive sensor B2. TAB (mounted on the carriage) activates inductive sensor B2. Sensor B2 sends a signal to the PLC to activate Sensor B3. Sensor B2 sends a signal to the PLC to activate Sensor B3. PLC input signal from sensor B3 is low = PLC input signal from sensor B3 is low = Height is outside of the sensor`s window boundaries. Height is outside of the sensor`s window boundaries.

13. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 13 BAD PART Port location or height not correct Port location or height not correct Limit switch 4S2 triggered -> end of travel position reached Limit switch 4S2 triggered -> end of travel position reached Motor M1 stops. Motor M1 stops.

14. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 14 BAD PART Valve body will be rejected by lift cylinder 2A and Valve body will be rejected by lift cylinder 2A and reject cylinder 3A. reject cylinder 3A. LIFT LIFT CYLINDER 2A REJECT REJECT CYLINDER 3A REJECT BIN REJECT BIN

15. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 15 BAD PART Retract reject cylinder 3A and lift cylinder 2A Retract reject cylinder 3A and lift cylinder 2A LIFT LIFT CYLINDER 2A REJECT REJECT CYLINDER 3A

16. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 16 BAD PART Reverse motor starter K5 energized, DC motor M1 switched Reverse motor starter K5 energized, DC motor M1 switched on in reverse direction (carriage moved back toward initial on in reverse direction (carriage moved back toward initial position) position)

17. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 17 GAUGING MODULE – FUNCTION CHART

18. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 18 OPERATION OF THE CARRIAGE (INITIAL POSITION)

19. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 19 OPERATION OF THE CARRIAGE (INITIAL POSITION)

20. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 20 COIL DE-ENERGIZED - CONTACTS OPEN

21. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 21 COIL ENERGIZED - CONTACTS CLOSED

22. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 22 OPERATION OF THE CARRIAGE (INITIAL POSITION)

23. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 23 OPERATION OF THE CARRIAGE (DC MOTOR STARTS TO MOVE THE CARRIAGE FORWARD )

24. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 24 OPERATION OF THE CARRIAGE (THE CARRIAGE IS MOVING FORWARD)

25. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 25 OPERATION OF THE CARRIAGE (THE CARRIAGE HAS REACHED THE END POSITION)

26. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 26 OPERATION OF THE CARRIAGE (THE MOTOR STARTS TO MOVE BACKWARD)

27. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 27 OPERATION OF THE CARRIAGE (THE CARRIAGE IS MOVING BACKWARD)

28. Siemens Professional Education SPE Berlin Siemens Technik Akademie JAN-08 SLIDE: 28 OPERATION OF THE CARRIAGE (THE CARRIAGE HAS REACHED THE INITIAL POSITION)