AZ Automotive Weld Tooling &
Assembly Equipment Standards
Revision 1.7
PRINTED COPIES ARE
UNCONTROLLED
Deviations that
improve safety, quality, or cost ARE ALWAYS WELCOME.
4.1.1.
The
Supplier is responsible for the adherence to AZ Automotive design and
construction standards. Preliminary review approval of designs by AZ Automotive
Tool Engineering does not relieve the Supplier of this responsibility. Deviation
from these standards shall not be acceptable without the signed approval of AZ
Automotive's Tool Design and/or an AZ Automotive Tool
Process Engineering representative.
4.1.2.
Tryout
of machine and/or automated line shall include:
(1)
A
manual check of all electrical interlocks to the satisfaction of AZ
Automotive.
(2)
A
machine and/or automated line shall run, in the weld mode, with parts and in the
presence of AZ Automotive.
4.1.3.
All
electrical circuitry must be an ungrounded system with indicating
lights.
4.1.4.
Plug
in relays shall NOT be used without prior WRITTEN permission from an AZ
Automotive Controls Design Supervisor.
4.1.5.
Safety
gate receptacles shall be mounted to the stationary sections of safety fence.
The hardwired installation and routing shall be approved by AZ
Automotive.
4.1.6.
Manual
load stations with PLC controls shall include a "Parts Loaded" light. This light
shall be a white PON type, and it shall be ergonomically located to be visible
by the operator during the manual load operation.
4.1.6.1
Stations
where parts are loaded or unloaded by automation shall include a "Part in
Position" light. This light shall be a white PON type located close to the
tooling.
4.1.7.
Each
machine, before shipping, must have an up-to-date WD in its control
panel.
4.1.8.
The
Supplier shall be responsible for the purchase, installation and wiring of
sensors for detecting empty or full conveyors, carriers, shuttles, etc., at all
automatic and robotic load and unload stations. Installation shall be completed
at the receiving plant when required.
4.1.9.
Part
counters shall be provided on each line and/or machine. Part counters shall not
increment the count until the automatic machine cycle has been completed with
parts.
4.1.10.
All
equipment supplied shall be suitable for operation at 480 Volts, 3-Phase 60
Hertz. Control voltages other than 120 Volts AC (or 24 Volts DC for PLC I/O)
require written approval from an AZ Automotive Manufacturing Engineering
Representative.
4.1.11.
All
equipment shall operate at +10%/-15% of the nominal supply voltage without any
detrimental effect to material, equipment or performance.
4.1.12.
Field
wiring for control circuits shall be No. 14 AWG minimum. Except No.16 AWG used in jacketed multi conductor cables.
As referenced in section 1.1.1.1. (referring to
NFPA), wire colors shall be as follows;
Green/Yellow.......................... Earth Ground
Black ....................................... AC or DC Power
Circuits
Blue w/Black Sleeve or
Black w/Blue Sleeve
............. Neutral of power circuits
Red
......................................... AC Control circuits
Blue ........................................ DC Control
circuits
Yellow
.................................... External Fed Control Circuits
(Interlocks)
4.1.13.
Conductors
carrying potentials of greater than 120 Volts AC shall be a minimum of No.12
AWG.
4.1.14.
I/O
devices shall be 24 VDC, unless prior written approval is obtained from an AZ
Automotive Controls Design Supervisor.
4.1.15.
All
multi-station panels with PLC processors shall be provided with an isolated, 120
Volt grounded power source. This power source shall be maintained in the event
of the operation of the main panel power disconnect. This will be accomplished
by using a separate breaker fed from the line side of the main panel's power
disconnect.
4.1.15.1
All
PLC controlled multi-station lines shall require a constant voltage transformer
(Sola) provided by the Supplier unless otherwise
specified.
4.1.16.
All
PLC systems shall be applied per the controller manufacturer's recommendations.
This includes panel layout, signal and power wire segregation, noise
suppression, proper grounding techniques, etc.
4.1.17.
All
control panels housing pilot lights shall include a local "Lamp Test" feature.
Application shall be as follows:
A.
Pilot
lights will be controlled by PLC outputs.
B.
Each
location will include a "Lamp Test" pushbutton wired to a PLC input.
C.
PLC
program will be designed to permit group "Lamp Test" without affecting machine
operation or causing motion.
D.
All
output driven lamps, including, CLEAR TO ENTER, PARTS LOADED, STYLE etc. will be
tested. Lamps to be tested shall be readily visible from the "Lamp Test"
pushbutton.
Exceptions
will be considered for applications with FEW devices, such as pendants, and will
be addressed on an individual basis.
4.2.1.
When
AZ Automotive is responsible for the controls design, the mechanical design
source shall supply (1) set of blue prints for all of the layout sheets, and
adequate information to permit the design of circuitry (sequence and equipment
requirements, etc.). If the information supplied is deemed inadequate, design
source shall provide additional information or contact as required. This
information shall be supplied immediately after 40% design review
approval.
4.2.2.
When
the Supplier is responsible for the controls design, the Supplier shall contact
the appropriate \AZ Automotive Plant Manufacturing Engineer for the latest
design references, and standards. This shall be done BEFORE the start of design.
Development of all circuit designs will be done with the involvement of
designated AZ Automotive personnel. Coordination is required to permit maximum
use of standards wherever possible. Review and approval of circuitry design
(piping, hard wire, I/O structure, panel layouts, logic etc.) are required prior
to submission of final drawings and should be done before releasing the design
for build.
4.2.3.
The
design source is responsible to produce an error free design. All design errors
shall be corrected by the design source without additional cost to AZ
Automotive.
4.2.4.
All
controls design changes to existing equipment shall be identified with a unique
WD number. This number shall be obtained from an AZ Automotive Controls Design
Coordinator, or the Plant Manufacturing Engineer. The controls design Supplier shall provide a separate control
diagram for each fixture, including the logic specific to that fixture. All
sheets shall be numbered as indicated below:
A.
Sheet
numbers are to run in sequence starting with sheet #1 (1,2,3, etc......). Sheets added after initial packages are
approved shall maintain the same flow as the initial design. Alpha numbered
sheets are allowed to be used, with the approval of an AZ Automotive Controls
Coordinator. For example sheets added to the magnetics
will be placed at the end of the magnetic circuits and utilize the next
available line numbering.
B.
Detail
numbers are to run in sequence starting with detail #1 (1,2,3, etc......).
4.2.5.
Each
Wiring Diagram shall include a complete timing chart showing the continuous
demand during all points of the cycle for the following:
A.
Hydraulic
timing chart showing the peak hydraulic volume demands in G.P.M.
B.
Pneumatic
timing chart showing the peak pneumatic volume demands in CFM.
C.
Electrical
timing chart showing the peak electrical demands in KVA.
D.
Water
demand chart showing the peak water volume in G.P.M.
Note:
When more than one (1) fixture is in a control diagram it must be approved by an
AZ Automotive Controls Design Coordinator.
4.2.6.
Each
multi-station transfer system shall have the capability of running random
skips.
4.2.7.
Logic
documentation shall include data disks with back up, and print out. This
documentation must be compatible with AZ Automotive and the using plant (if
applicable).
4.2.8.
All
controls designs shall be done using AutoCAD drawing software. AutoCAD software
version shall not be earlier than release 14 . All
designs shall be updated before shipment and after launch.
4.2.8.1
The
following criteria shall apply to AutoCAD designs.
A.
AutoCAD
text style shall be set to SIMPLEX. Select the "Type It" dialog box and type
"SIMPLEX" Do not add an extension .SHX OR .SHP.
B.
Data
files shall have the default menu set to "ACAD..".
Under no circumstances shall a full PATH be set. Select the "Type It" dialog box
and type "ACAD.".
C.
All
text shall be no smaller than 0.150". No Pre-Set heights shall be utilized. Text
height may be set via the "TEXT SIZE" Drawing Variable, rather than setting it
in the "STYLE COMMAND".
D.
Drawing
limits shall be set to "0.0" and "36,24" in paper space
or Model Space if no Paper Space View ports are utilized. ANSI
Standard "D" size drawing.
E.
Title
block border shall be 0.020" width polyline with
Origin beginning at: 0.5", 0.5" to 35.5", 234.5" to 0.5", 23.5" to C (closed).
This places the border symmetrically positioned 0.5" inboard from the "Paper
Space" LIMITS in compliance with Standard Mylar drafting Media as utilized in
manual drafting principles.
4.2.9.
The
Supplier is responsible for entering the program into the programmable
controller.
4.2.10.
This
item outlines the documentation and CAD data requirements for Controls Designs,
and the associated timetables for submission.
A.
Upon
completion of each design, Approval drawings for each Wiring Diagram shall be
given to Manufacturing Engineering. This documentation shall be clearly
identified with "APPROVAL PRINT". It shall be 11 x 17 laser prints for AutoCAD
drawings and printouts for all programmable devices; i.e. PLC logic programs,
Panel View screens and program files, etc. Binding is only necessary where
printout thickness exceeds 1".
14
days shall be scheduled for the Controls Design approval
process.
Completed
designs (hardwire, logic, peripherals, etc.) shall be resubmitted within (14)
days after approval corrections or revisions have been returned to the Supplier.
This documentation shall be clearly identified with "APPROVED FOR
BUILD".
B.
The
following documentation is required at the time of tooling shipment. All items
listed are to be delivered to the assigned Controls Design Coordinator no later
than 10 days following shipment of tools from the supplier. CAD files and prints
are to be current and shall have been updated to include ALL changes occurring
through build and tryout. All documentation shall be clearly identified with "AS
SHIPPED" to indicate design status. These requirements are in addition to item
4.1.8.
WD
Drawing Sets (11" x 17")
(1)
Plant Engineering Office
(1)
Plant Production Floor
(1)
Launch Group Technicians
PLC
Printouts
(1)
Plant Production Floor
Printouts
of Other Programmable Devices (Panel View, etc.)
(1)
Plant
Engineering Office
(1)
Plant Production Floor
AutoCAD
Files
(1)
Plant
PLC
Programs
(1)
Plant Engineering Office
(1)
Launch Group Technicians
PLC
Program for 20-hour Run on separate disk
(1)
Launch Group Technicians
Programs
for Other Programmable Devices
(1)
Plant Engineering Office
(1)
Launch Group Technicians
Robot
Program Software
(1)
Plant Engineering Office
(1)
Launch Group Technicians
C.
During
launch, additional PLC printouts may be required. (2) separate requests may be made for (1) printout each request.
The requests will be made by AZ Automotive Launch Group Technicians if need is
determined.
D.
The
following documentation is required after plant launch. All items listed are to
be delivered to the assigned AZ Automotive Tool Follow Engineer or Program
Manager no later than 60 days following "Official" Launch date. All CAD files
and prints are to be current and shall have been updated to include ALL changes
occurring through launch. All documentation shall be clearly identified with "AS
LAUNCHED".
Wiring
Diagram Drawing Sets (11" x 17")
(1)
Plant Production Floor
(1)
Plant Engineering Office
PLC
Printouts
(1)
Plant Production Floor
Printouts
of Other Programmable Devices (Panel View, etc.)
(1)
Plant Production Floor
(1)
Plant Engineering Office
Printouts
of Robot Programs, per robot after Final Buy-off
(1)
Plant Production Floor
(1)
Plant Engineering Office
AutoCAD
Files
(1)
AAME Controls Design file
PLC
Programs
(1)
Plant Engineering Office
Programs
for Other Programmable Devices
(1)
Plant Engineering Office
E. General Notes:
1. All
documentation for Plant Floor and Technicians is required per machine/tool, not
per WD design.
2.
Where
more than one tool is built to a common WD design, complete documentation is
required for EACH tool.
3. All
logic printouts shall include FIS logic.
4. All
printouts shall be bound unless otherwise noted.
5. All
WD drawings shall be original laser printer plots or high quality "Xerox" type
reproductions (Blueline, brownline, velum or rolled drawings are not acceptable).
Each WD shall be bound separately
in commercially available covers. - Binding not required for AAME Controls
Design file.
6.
All
computer disks specified as for plant floor or technicians shall be 3 1/2"
high-density (1.44Mb) floppy diskettes.
7.
All
computer disks for specified as for plant engineering office or AAME shall be
CD. CD's shall be CDR and formatted to be readable on any standard
CD-ROM drive. With approval, AAME Controls Design will accept 3 1/2"
256Mb Magneto-Optical (MO) or Iomega 100Mb ZIP. Specific format requiremenTs for MO can be obtained from assigned Controls
Design Coordinator.
8. Consult
Controls Design Coordinator for filename, disk organization, and labeling
requirements.
9. PLC
Programs shall be completely documented and annotated using Project-specified
Software.
10. Each
WD shall include a unique flat ASCII (DOS) text file entitled "WD_XXXXX.TXT".
The text shall clearly describe the WD contents and any relevant explanations.
Desired format may be obtained from a Controls Design
Coordinator.
11. All
disks/data/software delivered to AZ Automotive shall be virus-free. It is the
OEM's responsibility to implement and police stringent procedures to assure this
requirement.
4.2.11.
All
safety devices shall have a contact run to the inputs of the PLC for
monitoring.
4.2.12.
Any
input device shall be connected to its own discrete input
address.
4.2.13.
In
PLC control systems, the following circuits shall have circuit breakers:
A.
Programmable
Logic Controller (PLC).
B.
One
(1) of the double break outputs used to energize solenoids.
Note:
Supplier shall provide all fuses through final buy-off at the
plant.
4.2.14.
Where
one controller output is wired to another controller input, the output
designation shall be used as the wire designation.
4.2.15.
All
termination points on the I/O rack shall be wired to
terminals.
4.2.15.1
In
addition to the terminals required for the application there shall be a minimum
of twenty percent (20%) spare terminals. These terminals shall be provided and
installed in all I/O enclosures. The enclosure shall be sized to accommodate the
number of terminals and spares for the maximum capability of the chassis
installed.
4.2.15.2
Pushbuttons
and pilot lights mounted on enclosure doors may be wired directly to I/O points
within that enclosure.
4.2.16.
Applications
requiring less than the largest I/O chassis available from the PLC manufacturer
shall require approval of an AZ Automotive Control Design
Coordinator.
4.2.17.
A
line layout is to be shown on sheet number two (2) of the master shuttle WD. The
layout is to show all stations, operators, run-bars, emergency stop buttons, I/O
P.B. panels, consoles or master P.B. panels, shuttle drives, master junctions
boxes, light screens, safety gates, safety fence, etc. Station WD is to show a
station layout on sheet two (2) showing all weld transformers, weld spots, all
cylinder operated devices, limit switches, light screens, drives, safety gates,
P.B. stations, emergency stops, etc.
4.2.18.
A
cable layout will be shown on each Wiring Diagram, which will show how the
components are connected together. The layout will show the location of panels,
run-bars, pendants, light screens, safety gates and pin receptacle, etc. (floor
or balcony) and how each component is connected.
4.2.19.
All
systems shall be able to return to a full automatic mode from an emergency stop
within two (2) minutes of initiating a restart sequence.
4.2.20.
Supplier
shall provide part sensing to ensure that all parts have been properly
loaded.
Also see section 3.1.2.
It is the intention of these part detection methods to insure that an assembly cannot be produced that is missing a part due to machine malfunction or operator error.
In order to assure the sensors are not simply "stuck" on, the logic must check to see the sensor indicates "no part" at the appropriate time in the machine cycle.
4.2.21.
Supplier
shall provide part sensing to ensure that previously loaded parts are present
when absence of the parts creates an unacceptable repair
condition.
4.2.22.
Supplier
shall provide an amber globe light at each manual load/unload position to
indicate if an operator has exceeded his/her load time when the line or system
is in the automatic mode. This light will be identified with a lamacoid tag stating "OVERCYCLE". Also, need an audible device when load
time is exceeded.
4.2.23.
Position
indicating sensors (limit or proximity switches) shall be provided on ALL
actuators. A UNIQUE sensor signal shall be provided to POSITIVELY indicate each
extreme of motion and any intermediate positions necessary to the application.
The exceptions to this requirement are weld guns may be sensed as a group by
pressure switches.
4.2.24.
Sensing
devices that read the position of a drive actuator (i.e. cylinder piston rod)
are acceptable only on simple clamping applications (i.e. ISI or DeStaCo type). All other applications shall require sensing
devices (i.e. proximity or limit switches) that directly read the position of
the driven member itself. This is to preclude potential hazards that may arise
if the driven member becomes disengaged from the drive actuator and is
especially important on large critical motions.
4.3.1.
Cable
identification shall be done within each wiring diagram (WD) package. Each
interconnection cable shall be identified with a unique number within that WD.
Numbers shall begin with "1" and run consecutively (no skips or reserved
numbers).
All
cables shall have approved engraved/embossed tags affixed at each end of the
cable. These tags shall carry the complete cable identification. Mating
receptacles shall likewise be identified with the same information. i.e. "WD
12345 - Cable #1", "WD 12345 - Receptacle #1" All cable connections shall be
shown on WD drawings and identified with cable and pin numbers. To simplify
design, a cable name may be abbreviated within its' own WD drawing package by
omitting the WD number.
4.3.1.1
All
receptacles shall have conductors identified with the cable number and pin
number. This tag will be in addition to the tag with the wire
number.
4.3.2.
Standard
Tag for field devices shall include:
A.
Permanent
identification utilizing an approved tag, mechanically attached adjacent to the
device.
B.
Each
tag shall be engraved to indicate the device P.C. address and Description,
function and direction of motion. Characters shall be a minimum 5/32" in height.
C.
Tag
shall be readily visible from the service side of the line and must not be
mounted on the device it identifies or obscure the manufacturer’s label.
Note:
For an example of approved tag format contact an AZ Automotive Controls Design
Coordinator (reference WD_TAGS)
4.3.2.1
All
devices without a PLC address for identification within a given WD shall be
numbered consecutively and have a unique identification.
Example:
Drawing
Identification
Station
#1 Safety Gate
#1
S01SG1
Station
#1 Pendant
#1
S01PD1
Station
#1 Safety Pin
#1
S01SP1
Station
#2 Safety Gate
#1
S02SG1
Station
#2 Safety Gate
#2
S02SG2
Station
#2 Light Screen
#1
S02LTS1
Note:
For an example of approved tag format contact an AZ Automotive Controls Design
Coordinator (reference WD_TAGS)
4.3.3.
All
cables/receptacles shall have a cable/receptacle chart. All cable charts shall
be located on a single sheet(s) in the hardwire drawings. These charts shall
show the relationship between the pin, and the wire number. Spare wires in the
cable chart are NOT to be labeled spare or sp. leave these lines open for future
use.
4.3.4.
All
pilot lights, pushbuttons, illuminated pushbuttons, and selector switches shall
have an identification tag. The tag shall show the function and address
number.
Note:
For an example of approved tag format contact an AZ Automotive Controls Design
Coordinator (reference WD_TAGS)
4.3.5.
Engraved
pushbutton tags shall be sequential as they appear in the cycle. The devices
shall be arranged in a logical order from left to right.
4.3.6.
The
WD drawings shall identify all limit switches, proximity switches and solenoids
with the address number and function name. Example:
4.3.7.
Devices
with horizontal motions such as shuttles, weld guns, dumps, pivots, and clamps
shall use only the position name:
A.
EXTD
(extended) is based on the position of the driven member and not the position of
the cylinder rod.
B.
RETD
(retracted )is based on the position of the driven
member and not the position of the cylinder rod.
C.
The
color of, and the location of, the position indicator on the HMI are based on
whether the driven member is at the WORK (amber) or Home (green) position.
4.3.8.
Devices
with vertical motions such as presses and lifters shall use only the position
names RSD (raised) or LWRD (lowered).
4.3.9.
Pendants
shall be identified with the WD number and the description as shown on the WD
drawings.
4.3.10.
All
drives and motors must have an arrow indicating the direction of rotation. (See
4.3.2)
4.3.11.
A
function shall be called by only one name. This name shall be used consistently
throughout the WD and ladder logic.
4.3.12.
Wires
and electro-mechanical devices in systems, which are connected to a programmable
logic controller, shall be designated per the I/O address.
4.3.13.
All
portable hard service cords (single ended, double
ended, type STO, SOO etc.) that can be unplugged, require identification on all
plug ends to indicate the I/O address.
4.3.14.
All
major enclosures and junction boxes shall be identified as follows:
A.
Permanent
identification utilizing an approved tag, mechanically attached to the front of
the enclosure.
B.
Each
tag shall be engraved to indicate the tool number/unit number, WD number,
station and/or operation number, and description as noted in the wiring diagram
(WD), and rack number(s) (if applicable).
Note:
Contact a AZ Automotive Controls Design Coordinator for
a reference WD_TAGS package.
4.4.
Construction/Installation
4.4.1.
All
limit switches, pressure switches, water flow switches,
proximity switches and valve solenoids shall be purchased and pre-wired to AZ
Automotive's Engineering Standards, and from an
approved source.
4.4.1.1
Plug
and cord grips with basket weave shall be provided for STO cord flexing
applications.
4.4.1.2
A
90-degree adapter shall be used when cord routing requires a bend into the
device.
4.4.2.
Terminal
boxes shall be provided as required to insure that the exposed length of yellow
STO cord, used to connect the switches and valves, does not exceed (3) feet. Any
deviation must be approved by an AZ Automotive Launch
Technician.
4.4.3.
Portable
hard service cords (STO, SOO, etc.) that are routed through an approved
conveyance i.e. wireway, duct, conduit must have
protection, at both ends to prevent damage to the cords.
4.4.4.
Portable
hard service cords (STO, SOO, etc.) shall be secured every 18 inches with an
approved metal strap.
4.4.5.
A
minimum of (2) part in place switches shall be provided in each fixture unless
approved by AZ Automotive. If Limit
switches are used, arm must be non-rotating, adjustable and substantial to take
abuse.
4.4.6.
Limit
and proximity switch actuators must be of substantial construction (i.e.
elevator bolt) and adjustable in both directions.
4.4.7.
All
limit switch actuator-adjusting screws shall be secured with a jam-nut or
locknut.
4.4.8.
Neutral-position
limit switches shall not be used in applications were actuator travel is (1)
inch or less.
4.4.9.
Open
wire terminals exceeding 120 VAC on control transformers shall be provided with
a clear removable insulator to prevent accidental contact.
4.4.10.
All
wiring that runs through conduit shall have Erickson type connectors at each
break point that requires disassembly for shipping.
4.4.11.
Multi-conductor
cables with plug-in connectors at both ends shall be used to connect all
components that require disassembly for shipping.
4.4.12.
All
multi-conductor cables shall have a minimum of 25% spare
conductors.
4.4.13.
All
spare wires in multi-conductor cables shall be marked with the cable
identification and pin number. These spares shall be secured together in an
individual bundle.
4.4.14.
All
multi-conductor cables shall have a male connector on one end and a female
connector on the other end configured to ensure the absence of "Hot
Pins".
4.4.15.
Supplier
shall size and provide all required multi-conductor cables and related
hardware.
4.4.16.
Multi-Conductor
cables shall:
A.
Be
placed in and secured to a commercial cable tray when the run is greater than
six (6) feet in length.
B.
Be
supported and secured by an approved means every three (3) feet.
C.
Be
run through the balcony floor when connecting to panels on the balcony.
D.
Have
it's routing and method of support approved by AZ
Automotive.
E.
Be
designed to be stored on the balcony when feasible.
F.
All
multi-conductor cables used in continuous flexing applications shall be an
approved type with strain relief and cord grips.
G.
All
multi-conductor cable runs shall be one piece. Extension cord and/or adapter
applications may only be used with AZ Automotive Launch Technician approval.
4.4.17.
Suppliers
shall provide commercial cable trays for all cable runs. These cable trays shall
be installed according to all appropriate codes.
4.4.17.1
All
floor level cable trays shall be secured and covered. The cover shall be
substantial to withstand being stepped on.
4.4.18.
Equipment
grounding conductors shall be terminated in each electrical enclosure on a
common ground bar or terminal strip that is bonded to the unpainted
sub-plate.
4.5.1.
All
motor control circuits shall be hard wired.
4.5.2.
Decel
and Cycle Set circuits shall be hard wired.
4.5.3.
All
hydraulic power units shall include an energy conservation
feature.
4.5.4.
The
Supplier shall provide all sensors necessary to detect unique assemblies within
an operation or system.
4.5.5.
All
circuit breakers shall have visible trip indication.
4.5.6.
Magnetic
switching contactors in the weld circuit shall be used to select the weld
circuits to be powered.
4.5.7.
Motor
starter overload relay contacts shall be wired in series with the motor starter
coil. All motor starter relays and motor overload relays shall include
auxiliary contacts. A contact from each of these relays shall be wired to PLC
inputs for monitoring.
4.5.8.
Control
relays in Hardwire circuits that are necessary to be energized to permit normal
operation shall have a contact wired to an input for
monitoring.
4.6.1.
PLC
ladder diagram construction shall conform to the following guidelines:
A.
Spare
output addresses (Allen Bradley PLC's) shall not be used for internal logic.
B.
Program
only one rung to energize an output instruction.
C.
Maximum
rung size shall be determined by display constraints.
4.6.2.
All
ladder logic programs shall be organized per AZ Automotive Logic Standards.
These standards are in the PLC section, or available from the AZ Automotive Plant Manufacturing Engineer.
4.6.3.
Timers
and counters shall be assigned with every effort to conserve
memory.
4.6.4.
Process
and equipment diagnostics program shall be developed to include the following:
A.
All
position, sequence, and event indicator lights on operator stations shall be
driven from PLC outputs. Separate ladder logic rungs shall be used to control
these lights.
B.
Diagnostic
logic in the PLC shall blink the position or event indicator light of the next
event, action, or sequence programmed, until the event, action, or sequence is
complete. The light shall be held on until the device is no longer sensed by the
detection switch (limit switch etc..),event, action, or
sequence begins.
C.
The
completion of the previous event, action or sequence shall be used to blink the
next event, action, or sequence indicator light.
D.
When
the machine has completed the closing cycle, the indicator lights for all event,
actions, or sequences shall be held on. As the opening cycle begins, the
indicator light for the next event, action or sequence shall begin to blink.
When the machine has completed the opening cycle the functions listed in "B"
through "D" shall be repeated for the next cycle.
4.6.5.
A
logic back-checking feature (using a normally closed contact of the opposing
motion in conjunction with the normally open indicator of the motion being
sensed) shall be provided on all motions.
4.6.6.
PLC
logic for all multi-station lines shall include a shift
register.
4.6.7.
PLC
logic shall include parity checks between the PLC memory and the data detected
by the sensors as follows:
A.
Wherever
style sensitive parts are being introduced into a system. Comparison of shift registers and style sensors.
B.
Wherever
tooling must be shifted to accommodate a unique style before the part can be
married to the tooling. Comparison of style sensors, shift register, and tool
position sensors.
C.
Wherever
Build System (VMS, AVI, or Manually input, etc.) data
is downloaded to the tooling PLC. Comparison of style sensor, Build System, and
shift register data.
4.6.8.
PLC
logic shall not allow a part present sensor to interrupt the welding in progress, if the sensor temporarily indicates "no part" after it has sensed a part and the weld is started.
Also some circumstances may require closing of a clamp before the part can be sensed, because the part may be unstable, giving an unreliable indication of "present" until clamped. In this case, the machine must not continue after the clamp is closed, if the part is not sensed.
4.7.1.
All
PLC enclosures shall include an approved, remote programming receptacle and
duplex outlet (with cover). This receptacle shall be externally
accessible.
4.7.2.
Provide
a separate enclosure to house each Allen Bradley processor and power
supply.
4.7.3.
The
integrator shall furnish, install, and interconnect all fixture control
panels.
4.7.4.
Locations
of all electrical enclosures will be determined with the approval of an AZ
Automotive Launch Technician and shown on installation
drawings.
4.7.5.
Each
I/O rack shall be mounted in a suitable enclosure (NEMA-12
minimum).
4.7.6.
On
press applications provide NEMA-12 junction boxes for each lower fixture, each
upper fixture, fixture valves and press valves.
4.7.7.
A
master junction box shall be provided for each major component of a system, such
as; each fixture, station, or transfer. This shall serve as the collection point
for all wiring within that section that is to be connected back to the power and
interface panel. Supplemental enclosures shall be provided, as required, to
minimize cord lengths to devices. Interconnections between these enclosures
shall be done through hard pipe.
4.7.8.
All
enclosure, junction, and terminal boxes must be mounted with hinges in a
vertical position.
4.7.8.1
All
major enclosures and junction boxes shall be identified as follows:
A.
Permanent
identification utilizing an approved tag, mechanically attached to the front of
the enclosure.
B.
Each
tag shall be engraved to indicate the tool number/unit number, WD number,
station and/or operation number, and description as noted in the wiring diagram
(WD), and rack number(s) (if applicable).
Note:
Contact an AZ Automotive Controls Design Coordinator for a reference WD_TAGS
package.
4.7.9.
Conduit
entering a sheet metal enclosure shall:
A.
Have
a locknut on both sides of the sheet metal.
B.
Have
an entrance bushing on the end of the conduit.
C.
Adhere
to J.I.C. oil tight requirements.
4.7.10.
A
separately powered lighting transformer properly sized for the number of light
fixtures in the equipment shall be provided with circuit breaker(s). Plug-in
wiring shall be used from this source to the light
fixtures.
4.7.11.
The
Supplier shall provide junction boxes with terminal blocks at all balcony break
points, with plug-in connectors at one end, to facilitate tear down, shipping
and reinstallation..
4.7.12.
Power
factor correction capacitor units shall be provided for all motors 15 H.P. and
larger which run continuously. Capacitor units shall be (3)-phase, 480 volts,
completely metal enclosed with external discharge resistors, fuses, (3)
fuse-blown indicator lights, and non-PCB filled. The capacitors shall be
installed on the motor side of the starter before the overloads. The capacitor
KVAR rating shall be sized in accordance with "Manufacturing Standards Volume
A Approved Source List".
4.7.13.
Each
fixture shall be provided with a power and interface
panel.
4.7.14.
Stations
without balconies shall be provided with floor-mounted stands (AZ Automotive
standard #41-79-024-00, #41-79-025-00, #41-79-026-00 or equivalent) for mounting
of all control panels.
4.7.15.
Provide
a motor off pushbutton for each fixture pushbutton box, which has a motor on
pushbutton.
4.7.16.
Conductors
for welding power shall not occupy the same raceway, Junction box, distribution
box or conduit as control, interlock and motor conductors. Exception: Weld power
may be run in the same cable tray using a divider if the equipment manufacturers
documented requirements are achieved.
4.7.17.
Pre-hem
and hem fixture suppliers must provide a master junction box as part of the
fixture. All control components mounted to the fixture are supplied with the
fixture. The control design source will design the pre-hem and hem control
systems and show which components are fixture supplied or line build source
supplied items.
4.7.18.
Control
enclosures shall not sit directly on the plant floor, a minimum 4-inch clearance
shall be maintained between the bottom of the enclosure and the plant
floor.
4.7.18.1
Floor
mounted control enclosures shall have accessible anchoring holes to allow
securing while the control enclosure is in its location.
4.7.19.
All
terminals shall be mounted on 1 1/2" risers
4.7.20.
Approved
cooling equipment shall be provided on all PLC enclosures where required to
maintain internal temperature within the controller manufacturers
specifications. Installation shall be done in such a manner as to not affect the
NEMA 12 rating of the enclosure.
4.7.21.
Wires
entering electrical enclosure should not exceed the distance from the point of
entry to the farthest terminal using the routing provided.
4.7.22.
External
mounting of power and interface panel control transformers
required.
4.8.
Master Control
Panel
4.8.1.
The
Supplier is responsible to build and install the Master Control Panel completely
wired and interconnected to all related equipment.
4.8.2.
The
Master Control Panel shall include but is not limited to the following:
A.
*Emergency
Stop pushbutton (lockable).
B.
Cycle
Stop pushbutton
C.
Start
and Stop for all hydraulic units and electro-mechanical drives.
D.
*Master
Power On/Fault Reset pushbutton which will power up all
stations.
E.
System
Automatic
F.
Cycle
Enable
G.
Automatic/Manual
Reset
H.
System
status indication for: Clear to Transfer, In Cycle, Cycle Complete, Station
Fault
I.
Collective
Manual control of all lifters and/or presses.
J.
Status
indication for all devices manually controlled by this enclosure. A System Programmable Message Display. The message displays
shall indicate event level fault conditions for the entire system, with audible
indicator.
K.
Run
Out On/Off
L.
Single
Cycle On/Off & Cycle Once pushbutton.
M.
A
Production counter and the ability to input style and/or manipulate the shift
register.
N.
Lamp
Test feature.
*These
items shall all be hardwired. All other devices may be designed into a
Programmable Graphic User Interface using AZ Automotive approved equivalent
devices.
4.8.3.
The
design and installation of station status indicators on the Master Control Panel
shall follow line flow as viewed from the enclosure.
4.8.4.
On
systems larger than three (3) stations the supplier is responsible to provide
and install a marquee style light display to provide summary information of the
status for each station and transfer. Details for the content, and operation of this display will be provided by AZ
Automotive.
4.9.1.
The
Station Control Panel shall include but is not limited to the following:
A.
*Emergency
Stop pushbutton (maintained/lockable)
B.
Cycle
Stop pushbutton
C.
*Power
On/Fault Reset pushbutton which will power up all stations controlled by this
panel.
D.
Automatic
pilot light (for press equipment only)
E.
Station(s)
Manual illuminated pushbutton (for press equipment only)
F.
Automatic/Manual
Selector Switch (for press equipment only)
G.
Station
status indication for:
Clear
to Transfer
Station
In Cycle
Station
Cycle Complete
Station
Fault
H.
Status
indication for all devices manually controlled by this enclosure and the status
indication for the robots in each station.
I.
A
Programmable Message Display for each station. The message display shall
indicate required faults for each station(s).
J.
Lamp
test feature.
*These items shall all be
hardwired. All other devices may be designed into a Programmable Graphic User
Interface using AZ Automotive approved devices.
4.9.2.
The
design and installation of station status indicators on the Station Control
Panel shall follow line flow as viewed from the enclosure.
4.10.1.
Provide
a control station for each lifter, which shall have the manual controls to
operate all devices within that station.
4.11.1.
Each
I/O rack shall be provided with the modules necessary to support the addition of
16 input
devices and 16 output devices.
4.11.2.
All
I/O chassis shall include 25% spare unassigned I/O
capacity.
4.11.3.
Supplier
shall provide an additional 25% spare memory to the amount required for the
application.
4.11.3.1
Supplier
shall provide a memory usage report for each PLC prior to delivery of equipment
to AZ Automotive. The usage reported must be inclusive of all AZ Automotive
control and information reporting requirements. The following example contains
the minimum reporting requirements:
|
PLC
Description |
PLC
Type |
Total
Memory |
Program
Memory |
Data
Table Memory |
%
Free Memory |
|
UB1_1 |
5-40 |
16384
words |
5036
words |
3234
words |
50.40% |
4.11.4.
Electrical
characteristics of all solid-state input devices shall be coordinated with the
hardware (electronic equipment) to which they are connected to insure reliable
operation. In cases where additional devices are required to condition signals,
it is the OEM’s responsibility to provide them. If these devices generate
significant heat, they shall not be installed in the same enclosure with the
electronic equipment.
4.11.5.
When
using remote I/O systems, with PLC controllers, (1) I/O rack shall be mounted
within the enclosure to accommodate data highway.
4.11.6.
Serial
communication cables between the processor and all remote I/O racks shall be
routed in separate metal raceways (3/4" minimum) and installed in accordance
with the manufacturers installation and grounding
recommendations.
4.11.7.
Complimentary
I/O is not permitted.
4.11.8.
The
requirements for integration of control systems into plant FIS (Factory
Information Systems) will be outlined in each project's
specification.
4.11.8.1
The
tooling system supplier shall be responsible for development, installation and
debug of the ENTIRE PLC program. This shall include all logic necessary to cycle
the equipment, provide specified level of diagnostics, and interface to all
required plant information networks.
4.12.1.
The
Supplier shall provide the following items with each Allen Bradley PLC-5
programmable controller:
ALLEN
BRADLEY PLC-5 FAMILY
|
ONE
(1) |
#1785-L20B |
PROCESSOR
MODULE PLC-5/20 (16K MEMORY - NO EXPANSION) |
|
ONE
(1) |
#1785-L30B |
PROCESSOR
MODULE PLC-5/30 (32K MEMORY - NO EXPANSION) |
|
ONE
(1) |
#1785-L40B |
PROCESSOR
MODULE PLC-5/40 (48K MEMORY - NO EXPANSION) |
|
ONE
(1) |
#1785-L60B |
PROCESSOR
MODULE PLC-5/60 (64K MEMORY - NO EXPANSION) |
|
ONE
(1) |
#1785-L80B |
PROCESSOR
MODULE PLC-5/60 (100K MEMORY) |
|
ONE
(1) |
#1771-P7 |
POWER
SUPPLY |
|
ONE
(1) |
#1771-CP1 |
POWER
SUPPLY CABLE |
|
AS
REQ. |
#1771-A4B |
UNIVERSAL
16 SLOT I/O CHASSIS |
|
|
OR
#1771-A2B |
UNIVERSAL
8 SLOT I/O CHASSIS |
|
AS
REQ. |
#1770-CD |
TWINAXIAL
COMMUNICATION CABLE* |
|
|
OR
9463 |
BELDON
OR EQUIVALENT |
|
ONE
(1) |
1784-ENET |
ETHERNET
INTERFACE MODULE (10M BITS/SEC) |
|
ONE
(1) |
#1770-XT |
I/O
& DH+ TERMINATION RESISTORS |
*Required
for remote I/O.
4.12.2.
The
Supplier shall provide the following items with each Allen Bradley remote I/O
chassis:
|
ONE
(1) |
#1771-P7 |
POWER
SUPPLY |
|
AS
REQ |
#1770-XT |
I/O
CHANNEL TERMINATOR |
|
AS
REQ |
#1770-CD |
TWINAXIAL
COMMUNICATION CABLE* |
|
|
OR
9463 |
BELDON
OR EQUIVALENT |
|
AS
REQ. |
#1771-IAD |
Series
1771 INPUT MODULE - 16 POINT |
|
AS
REQ |
#1771-OAD |
Series
1771 OUTPUT MODULE - 16
POINT |
|
ONE
(1) |
#1771-CP1 |
POWER
SUPPLY CABLE |
|
ONE
(1) |
#1771-ASB |
|
|
AS
REQ |
#1771-OW |
ISOLATED
OUTPUT MODULE - 8 POINT |
|
AS
REQ |
#1771-A4B |
UNIVERSAL
16 SLOT I/O CHASSIS |
|
|
OR
#1771-A2B |
UNIVERSAL
8 SLOT I/O CHASSIS |
AS
REQ #1771 -
*Required
for remote I/O.
4.12.3.
For
PLC components not specified in items 4.11.10 and 4.11.11, such as with SLC or
Micrologic components, consult the AZ Automotive
program manager.
4.12.4.
Programmable
controller and components must be purchased new and after the order is received.
Component revision code must be the current production.
4.12.5.
All
PLC's shall have the ability to be programmed without opening the door of the
enclosure.
4.12.6.
WHEN
SPECIFIED BY THE PURCHASE ORDER, the Supplier shall provide the Industrial
terminal(s) complete with cart and the appropriate software for programming
instructions, loading, editing and monitoring of a ladder diagram. The quantity
required shall be listed in the specification package for that system. The
Supplier shall also provide all cables and equipment necessary for
installation.
4.13.1.
The
following Standards shall apply to all industrial process equipment where
programmable logic controllers are specified.
4.13.2.
The
use of the word “shall” herein is understood as a requirement; the word “should”
as a recommendation.
4.13.3.
This
standard is not intended to include everything, if any
areas that need clarification arise questions shall be submitted to AZ
Automotive.
4.13.4.
Deviations
from the Standard shall have the approval of the specific section from AZ
Automotive in writing.
4.13.5.
The
selection and installation of PLC accessories shall follow this section of the
AZ Automotive Tooling Standards.
4.14.1
Controllers
4.14.1.1
The
manufacturer of the controllers shall be Allen Bradley. The PLC-5 family
shall be used as master controllers. The SLC-500 family shall be used as
slave controllers. The controller may vary according to what is the most
common at the time.
4.14.1.2
25%
of spare I/O shall be allocated for future upgrades on each
controller.
4.14.2.
Display Units
The
most widely used Panelview model at the time shall be
used. Currently the Panelview 1000 is the most
up to date model. The Panelview will vary
depending what is most commonly used at the time.
4.14.3.
Networks
The
network shall be chosen according to what would be best suited for the hardware
being used. Certain networks work better with items such as computers and
PLC’s together. The network choice shall be discussed with the Engineer in
charge.
4.15.
Communication /
Networking
The
following table shall be used as the communication / networking files for PLC
and SLC Processors:
|
Processor I/O
Status |
|
N11 | |
|
Channel 0
|
|
N22 | |
|
Channel 1A
|
DH+
|
N23 | |
|
Channel 1B
|
Scanner
|
N24 | |
|
Channel 2A |
|
| |
|
|
Master |
Scanner |
N25 |
|
|
Slave |
Adapter |
N25 |
|
Channel 2B
|
Scanner |
N26 | |
|
Channel 3
|
Not Used
|
N27 | |
|
SLC DH485 Node
Assignments |
|
| |
|
Processor |
Node
1 |
| |
|
Panelview |
Node
2 |
| |
4.16.1.
Data Table Memory Map
The
file numbers and types that make up the functions of the PLC comprise the data
table memory map. The table below contains the files and descriptions that
shall be used in the data table memory of each PLC
program:
|
File
# |
File
Type |
Function |
|
0 |
Output |
Output Data Image |
|
1 |
Input |
Input Data Image |
|
2 |
Status |
Processor Status |
|
3 |
Binary |
Internal Bit Storage |
|
4 |
Timer |
Timer Data Storage |
|
5 |
Counter |
Counter Data Storage |
|
6 |
Control |
File Instruction
Control |
|
7 |
Integer |
Integer Value Storage |
|
8 |
Floating |
Floating Point Value
Storage |
|
9 |
Decimal |
Decimal Value Storage |
|
10 |
ASCII |
ASCII Value Storage |
|
11 |
Integer |
I/O Status File |
|
12 |
Undefined |
|
|
13 |
Block Xfer |
Block Transfer Read & Write
Control |
|
14 |
Integer |
Block Transfer Read Data
File |
|
15 |
Integer |
Block Transfer Write Data
File |
|
16 |
Integer |
SLC Panelview Message
Bar Storage |
|
17 |
Integer |
Style Data Storage |
|
18 |
Integer |
Integer Value Storage |
|
19 |
Undefined |
|
|
20 |
Integer |
Global Zero Reference Data
Storage |
|
21 |
Integer |
Indirect Offset Data
Storage |
|
22 |
Integer |
Channel 0 Diagnostics
File |
|
23 |
Integer |
Channel 1A Diagnostics
File |
|
24 |
Integer |
Channel 1B Diagnostics
File |
|
25 |
Integer |
Channel 2A Diagnostics
File |
|
26 |
Integer |
Channel 2B Diagnostics
File |
|
27 |
Integer |
Channel 3 Diagnostics
File |
|
28 |
Undefined |
|
|
29 |
Undefined |
|
|
30 |
Timer |
Fault Diagnostic Timer
File |
|
31 |
Counter |
Fault Diagnostic Counter
File |
|
32 |
Binary |
Internal Fault Storage |
|
33 |
Integer |
Production Count
Storage |
|
34 |
Floating |
Cycle Time Storage |
|
35 |
Undefined |
|
|
36 |
Undefined |
|
|
37 |
Undefined |
|
|
38 |
Binary |
Internal Robot Storage |
|
39 |
Undefined |
|
|
40 |
Integer |
Perceptron |
|
41 |
Block Xfer |
Panelview BT Control File |
|
42 |
Integer |
Panelview BTR Data File, SLC Panelview Input Data File |
|
43 |
Integer |
Panelview BTW Data File, SLC Panelview Output Data File |
|
44 |
Undefined |
|
|
45 |
Undefined |
|
|
46 |
Undefined |
|
|
47 |
Undefined |
|
|
48 |
Undefined |
|
|
49 |
Undefined |
|
|
50 |
Integer |
SLC Scanner Control M0
Storage |
|
51 |
Integer |
SLC Scanner Status M1
Storage |
|
52-99 |
Undefined |
|
|
100 |
Binary |
Station Diagnostic
Setup |
|
101-110 |
Undefined |
|
|
111 |
Binary |
Station Diagnostic Event Bit
File |
|
112-134 |
Binary |
Spare Diagnostic Event Bit
Files |
|
135 |
Binary |
System Diagnostic Event
Bit |
4.16.2
Data File Layouts
Within
the data table memory map, some files are more important for
troubleshooting. One specific file is the robot file 38. The file
contains bits that control specific functions that are used often. The
table below describes the bits in this file that shall be used in the
program:
|
Bit |
Description |
Bit |
Description |
|
X00 |
Robot Enabled |
X36 |
Go to Dropoff #1 Pounce |
|
X01 |
Go to Pounce |
X37 |
Go to Pickup #2
Pounce |
|
X02 |
At Pounce Partial |
X38 |
Go to Dropoff #2 Pounce |
|
X03 |
Robot at Pounce |
X39 |
Go to Pickup #2 |
|
X04 |
Robot at Work Program
#1 |
X40 |
Go to Dropoff #2 |
|
X05 |
Robot at Work Program
#2 |
X41 |
Go to Dropoff #2 Memory |
|
X06 |
Go to Pickup #1 |
X42 |
Reposition 4th Sequence
Clamp |
|
X07 |
Pickup Complete #1 |
X44 |
Reset Dropoff Complete |
|
X08 |
Pickup Complete #1
Memory |
X47 |
Select Program #1
Setup |
|
X09 |
Pickup Complete #2 |
X48 |
Select Program #2
Setup |
|
X10 |
Pickup Complete #2
Memory |
X49 |
Select Program #3
Setup |
|
X11 |
Go to Dropoff #1 |
X50 |
Select Program #4
Setup |
|
X12 |
Go to Dropoff #1 Memory |
X51 |
Select Program #1 |
|
X13 |
Dropoff Complete #1 |
X52 |
Select Program #2 |
|
X14 |
Dropoff Complete #1
Memory |
X53 |
Select Program #3 |
|
X15 |
Dropoff Complete #2 |
X54 |
Select Program #4 |
|
X16 |
Dropoff Complete #2 Memory
|
X70 |
Clear to Pickup
Memory |
|
X17 |
Robot Go to Weld |
X72 |
Clear to Dropoff Memory |
|
X18 |
Robot Cycle Complete
#1 |
|
|
|
X19 |
Program #1 Complete
|
|
|
|
X20 |
Robot Cycle Complete #2
|
|
|
|
X21 |
Program #2 Complete
|
|
|
|
X22 |
Robot Clear to Transfer
|
|
|
|
X23 |
Robot Clear of Pickup
#1 |
|
|
|
X24 |
Robot Clear of Pickup
#2 |
|
|
|
X25 |
Robot Clear of Dropoff #1 |
|
|
|
X26 |
Robot Clear of Dropoff #2 |
|
|
|
X27 |
Robot Clear of TT1 |
|
|
|
X28 |
Robot Cycle Start Seal
|
|
|
|
X29 |
Robot End of Stepper Fault
|
|
|
|
X30 |
Robot Backup Bit |
|
|
|
X31 |
Robot at Service
Setup |
|
|
|
X32 |
Service Complete |
|
|
|
X33 |
Robot Unclamp Fixture
Early |
|
|
|
X34 |
Robot Return From Pounce
Memory |
|
|
|
X35 |
Go to Pickup #1
Pounce |
|
|
The
station fault list is important for troubleshooting. This file is included
in the data table memory map. The table below shall be used as the station
fault list for the B111 station diagnostic event bit file:
|
Word |
Bit #’s |
Description |
|
0 |
00-12 |
Blank – Not Used |
|
|
13-15 |
Master / Slave Communication Error |
|
1 |
16-18 |
Control Power Off |
|
|
19 |
|
|
|
20-31 |
Safety Pins |
|
2 |
32-47 |
E-Stops |
|
3 |
48-63 |
Safety Gates |
|
4 |
64-71 |
Light Screens / Safety Mats Faulted |
|
|
72-79 |
Light Screens / Safety Mats Violated |
|
5 |
80-87 |
Light Screens / Safety Mats Reset Required |
|
|
88 |
Weld / No Weld SS Out of Position |
|
|
89-95 |
Hard Tool Weld Faults |
|
6 |
96-111 |
Hard Tool Weld Faults |
|
7 |
112-115 |
Air Not On |
|
|
116-119 |
Water Not On |
|
|
120-123 |
Motor Drive Safety Switches |
|
|
124-127 |
Motor Drive O/L’s |
|
8 |
128-135 |
Part Out of Position |
|
|
136 |
Operator Cycle Start PB Fault |
|
|
127-143 |
|
|
9 |
144 |
Robot R01 Faulted |
|
|
145 |
Robot R01 Major Weld Fault |
|
|
146 |
Robot R01 Not Ready |
|
|
147 |
Robot R01 Overtime Fault |
|
|
148-159 |
Robots R02-R04 |
|
10 |
160-175 |
Fixture Motion Faults |
|
11 |
176-191 |
Fixture Motion Faults |
|
12 |
192-207 |
|
|
13 |
208-223 |
|
|
14 |
224-239 |
|
|
15 |
240 |
Processor |
|
|
241 |
Forces Enabled |
|
|
242 |
Forces Present |
|
|
243-255 |
Alarms |
4.16.4. Faults, B135 File
The
station fault list is important for troubleshooting. This file is included
in the data table memory map. The table below shall be used as the station
fault list for the B135 system diagnostic event bit
file:
|
Word |
Bits |
Fault #’s |
Description |
|
0 |
00-15 |
00-15 |
Blank – Not Used |
|
1 |
00-15 |
16-31 |
Control Power Off |
|
2 |
00-15 |
32-47 |
Air / Water Off |
|
3 |
00-15 |
48-63 |
Safety Pin Pulled |
|
4 |
00-15 |
64-79 |
E-Stop PB Pushed |
|
5 |
00-15 |
80-95 |
Safety Gate Open |
|
6 |
00-15 |
96-111 |
Safety Mat / Light Screen Violated / Faulted |
|
7 |
00-15 |
112-127 |
Out of Automatic |
|
8 |
00-15 |
128-143 |
Station Miscellaneous Fault |
|
9 |
00-15 |
144-159 |
Blocked Upstream / Downstream |
|
10 |
00-15 |
160-175 |
|
|
11 |
00-15 |
176-191 |
|
|
12 |
00-15 |
192-207 |
|
|
13 |
00-15 |
208-223 |
|
|
14 |
00-15 |
224-239 |
|
|
15 |
00-15 |
240-155 |
|
4.16.5
Standard Logic
Each rung in the ladder logic
shall have a statement attached to it. The statements in the ladder logic
shall be labeled according to what they reference.
4.17.
Programmable
Message Displays
4.17.1.
All
controls designs utilizing PLC’s shall include the functionality of a
programmable message display. This display shall be in color and shall present
information and messages to assist in maintenance and
troubleshooting.
The
specific hardware and application methodology shall be provided by the Controls
Design Coordinator as each project is defined.
4.18.
Control
Functional Features
4.18.1.
A
Return to Home feature shall be provided for each tool that is controlled by a
PLC. This will be a station-level feature selected at the Station Control
Panel. This feature shall be operational only in the manual mode with all
guarding that restricts access to motions intact. This feature shall step the
tooling to its Home position through operation of a momentary pushbutton.
Each successive motion will sequence as long as the pushbutton is held
maintained, and all motion will cease when the pushbutton is
released.
4.18.2.
A
Run Out feature shall be provided for each multi-station transfer system. This
will be a system-level feature selected at the Master Control Panel. It shall be
operational only in the Automatic mode. While Run Out is selected the
system will inhibit automatic load, and "Clear to
Enter", process and purge all assemblies from the system, and then
stop.
4.18.3.
A
Single Cycle feature shall be provided for each multi-station system. This will
be a system-level feature selected at the Master Control Panel. It shall be
operational only in the Automatic mode. While Single Cycle is selected the
system will sequence to the completion of the current cycle and stop. The
sequence will be interrupted immediately prior to the assembly being removed
from the fixture(s). Cycle once will resume sequencing to the same point in the
subsequent cycle.
4.18.4.
A
Clamp & Hold feature shall be provided for each tool that is controlled by a
PLC. This will be a station-level feature selected at the Station Control
Panel. It shall be operational only in the Automatic mode. While
Clamp & Hold is selected the station will perform its work/closing sequence
up to the point where the fixture or robot commences its work process.
De-selection will allow the cycle to continue.