Overview:

The Connected Smart Manufacturing (CSM) system is an intelligent manufacturing solution incorporating Industry 4.0 technologies, such as advanced robotics, CNC machining, and PLC programming. It serves as a comprehensive training tool for students in Robotics, CNC Machining, and PLC Programming.

CSM Features:

• FANUC LR Mate 200iD/7L robotic machine tender for CNC loading and unloading.
• Automated manufacturing work holder for CNC machining center.
• Vision inspection for machining operations and laser etching.
• Advanced PLC to robot control with Rockwell Logix 5000 series PLC programming.
• HMI PanelView interface touch screens for user interaction.
• Fenceless robot cells with safety area scan.
• Smart sensor technology using Balluff I/O Link with diagnostics.
• Project-based mechatronics at each operation.
• Dual-purpose EOAT on robots with vacuum and mechanical gripping.
• Conveyors with VFD variable speed drives.
• RFID manufacturing process tracking.
• Modular robot work cells that can be used independently.

Manufacturing Process:

• The system features a four-robot manufacturing cell working alongside a CNC Mill and an APT MTEC machine tender CERT cart.
• Three APT LR Mate CERT cart bases, modified for specific tasks, collaborate in the manufacturing process.

Educational Focus:

• Ideal for teaching Robotics, CNC Machining, and PLC Programming.
• Students will machine an anodized aluminum block into a customized dice holder using a 3-axis CNC vertical machining center.
• The APT MTEC CERT cart will function as a robot machine tender, handling tasks like inspection, cleaning, and laser engraving.

Customization and Creativity:

• During laser engraving, students can customize the product with school logos, names, or creative images.
• Vision technology enables the robot to identify and pick up numbered dice in various orders, fostering creativity.

Integration and Collaboration:

• Each station in the manufacturing cell has its own PLC, HMI, robot, and learning station.
• The complete line demonstrates real manufacturing collaboration among different programmers and employees.

Autonomous Operation:

• Fully autonomous operation using Fanuc intelligent robotics with vision, Rockwell PLCs, Smart sensor IO-Link technology, and RFID process tracking.
• The cell performs all material handling and manufacturing tasks without human interaction.

Workstations (OPs):

• Workstations are modular robot stations (OPs) with specific project objectives and ancillary devices.
• Controlled from a PLC control panel attached to the robot cart, communication occurs via Ethernet IP for a completely integrated system.

Production Control:

• The cell master control interface sets production operation schedules, including laser etching, batch count, and packaging quantity.
• Blank parts loaded into the system initiate an autonomous operation to create the promotional item.

Packaging:

• The completed kits are packaged in logo-printed boxes with a choice of colors, presenting a polished final product.

This innovative CSM system provides a hands-on, industry-relevant learning experience, encompassing the latest technologies in connected smart manufacturing.

For more information, take a look at this demo video.