Cycle Time Detail
For a rotary-table design, the production cycle is governed by the longest active station plus index and settling time. It is not calculated by adding all station operations sequentially.
| Station | Operation During Parallel Dwell | Check / Data |
|---|---|---|
| S1 | Load Part A into fixture | Seating / bottom position confirmation |
| S2 | Load Part B into the same fixture | Insertion depth / presence confirmation |
| S3 | Assembly seating check | Top-down probe or sensor confirmation |
| S4 | Servo pressing | Approx. 600 kgf press load + stroke profile |
| S5 | Bottom block test | Approx. 200 g push-force response + displacement |
| S6 | Unload OK / NG | OK route or reject route confirmation |
| Index | Rotary table indexes one station pitch | Example shown: 360° / 6 stations = 60° per index |
Planning Value
Cycle-time values are engineering planning values based on the current simulated process sequence and calculations. Final values are to be validated with actual parts, tooling, feeder behavior and acceptance criteria.
Logging / Failure Logic
Every station decision is recorded. The demo can simulate failure at each station. When the same station fails three times, the machine stops and highlights the station for recovery.
| Station | Logged Data | Failure Response |
|---|---|---|
| S1 | Part A presence and seating depth | Reject / stop depending failure count |
| S2 | Part B presence and insertion depth | Reject / stop depending failure count |
| S3 | Assembly seating check signal | Reject / stop depending failure count |
| S4 | Press force vs time, force vs displacement and stroke | Alarm if load-cell / stroke profile does not match the process window |
| S5 | Block-test reaction force and displacement | Reject if force is low or displacement exceeds the process window |
| S6 | OK / NG route confirmation | Alarm if unload or reject route is unavailable |
I/O & Sensor Diagnostics
Live diagnostic view for PLC input / output status. The table below covers part pickup, gripper status, pneumatic actuator positions, fixture seating, checking, servo press data, block-test data and unload confirmation.
Digital Inputs to Siemens PLC
Typical sensors: 24 VDC PNP proximity sensors, magnetic cylinder sensors, optical presence sensors, gripper open/close feedback, pressure switch and fixture seating sensors.
Digital Outputs from PLC
Typical outputs: solenoid valve coils, bowl feeder enable / air blow, gripper open-close commands, index command, stack light and reject diverter control.
Analog / Fieldbus Process Values
Servo pressing and block testing require actual force and position feedback. These values are logged against each part and used for OK / NG decision logic.
Station Diagnostic Philosophy
- S1 confirms Part A is picked, transferred and seated at the bottom of the fixture.
- S2 confirms Part B is picked, inserted and reaches its fitted position.
- S3 uses a top-down distance / seating sensor to confirm assembled height condition.
- S4 records servo press force and displacement profile during pressing.
- S5 records block-test push force and displacement response.
- S6 confirms OK / NG route and confirms fixture empty before returning to Station 1.
Sensor labels can be enabled in the 3D Simulator panel. Labels are conceptual and will be finalized after tooling layout confirmation.
PLC Control / Siemens Architecture
Recommended control architecture for the simulator concept. The Siemens PLC supervises rotary indexing, feeder readiness, pneumatic valves, servo pressing, block testing, safety interlocks and HMI diagnostics.
Recommended PLC Platform
| Area | Recommended Hardware Class | Purpose |
|---|---|---|
| Main PLC | Siemens S7-1200 / S7-1500 class PLC | Machine sequence, station interlock, recipe and alarm handling |
| Remote I/O | ET 200SP / distributed Profinet I/O | Field sensor and solenoid wiring close to machine modules |
| Digital Input | 24 VDC PNP DI modules | Presence sensors, gripper feedback, pneumatic cylinder reed switches |
| Digital Output | 24 VDC DO modules via fused terminals | Solenoid valves, stack light, buzzer, feeder enable commands |
| Analog Input | 4-20 mA / 0-10 V AI modules or IO-Link masters | Load cell amplifier, distance sensor, block-test force / displacement sensor |
| Motion / Servo | Profinet servo drive for rotary index and servo press | 60° index control and pressing force / stroke profile |
| Safety | Safety relay or fail-safe PLC architecture | E-stop, guard doors, safe torque-off and pneumatic dump valve |
| HMI | Siemens HMI or web HMI panel | Manual mode, fault recovery, recipe selection, sensor diagnostics |
PLC State Machine
The rotary table indexes only after all active station operations are completed or safely rejected. Table movement is blocked when grippers are down, press is not home, block-test actuator is up, unload actuator is not clear or any safety input is not healthy.
Conceptual Ladder Diagram
This is a customer-facing ladder-style logic diagram for discussion. Final rung numbering and tag names will be generated during PLC software design.
--| E_STOP_OK |--| GUARD_CLOSED |--| AIR_PRESSURE_OK |--| SERVO_READY |----------------( M_AUTO_ENABLE )--| START |--| M_AUTO_ENABLE |--| TABLE_IN_POSITION |--| ALL_STATIONS_HOME |-----( M_DWELL_START )--| M_DWELL_START |--| S1_FIXTURE_EMPTY |--| PART_A_TRACK_READY |-------------( S1_LOAD_PART_A_SEQ )--| S1_LOAD_PART_A_SEQ |--| GRIPPER_A_CLOSED |--| PART_A_GRIPPED |-------------( S1_TRANSFER_FORWARD )--| S1_TRANSFER_DONE |--| PART_A_SEATED |---------------------------------------( S1_OK )--| M_DWELL_START |--| S2_PART_A_PRESENT |--| PART_B_TRACK_READY |-------------( S2_LOAD_PART_B_SEQ )--| S2_TRANSFER_DONE |--| PART_B_INSERT_DEPTH_OK |-------------------------------( S2_OK )--| M_DWELL_START |--| S3_ASSEMBLY_PRESENT |------------------------------------( S3_CHECK_CYL_DOWN )--| S3_CHECK_DONE |--| HEIGHT_WITHIN_WINDOW |------------------------------------( S3_OK )--| M_DWELL_START |--| S4_PART_PRESENT |--| PRESS_HOME |-------------------------( SERVO_PRESS_CYCLE_START )--| PRESS_DONE |--| FORCE_PROFILE_OK |--| STROKE_PROFILE_OK |-------------------( S4_OK )--| M_DWELL_START |--| S5_PART_PRESENT |---------------------------------------( BLOCK_TEST_UP )--| BLOCK_DONE |--| BLOCK_FORCE_OK |--| BLOCK_DISPLACEMENT_OK |----------------( S5_OK )--| M_DWELL_START |--| S6_PART_PRESENT |--| ROUTE_READY |-----------------------( S6_UNLOAD_SEQ )--| S1_OK |--| S2_OK |--| S3_OK |--| S4_OK |--| S5_OK |--| S6_OK |-------------( INDEX_PERMIT )--| INDEX_PERMIT |--| ALL_ACTUATORS_HOME |--| PRESS_HOME |---------------------( ROTARY_INDEX_60DEG )--| SAME_STATION_FAIL_COUNT >= 3 |--------------------------------------------( MACHINE_STOP_ALARM )Pneumatic Control Diagram
Pneumatic actuators are used for gripping, transfer slides, station checking, block-test motion and OK/NG handling. Each actuator includes PLC-controlled solenoid valves and position sensors.
Air Supply Concept
Valve / Actuator List
| Valve | Actuator | PLC Output | Feedback Sensors |
|---|---|---|---|
| V1 | Part A gripper open/close | Y0.3 / Y0.4 | Open, close, part-gripped sensor |
| V2 | Part A horizontal slide | Y0.5 / Y0.6 | Home and forward magnetic sensors |
| V3 | Part A vertical pick/place slide | Y0.7 / Y1.0 | Up and down magnetic sensors |
| V4 | Part B gripper open/close | Y1.3 / Y1.4 | Open, close, part-gripped sensor |
| V5 | Part B horizontal slide | Y1.5 / Y1.6 | Home and forward magnetic sensors |
| V6 | Part B vertical pick/place slide | Y1.7 / Y2.0 | Up and down magnetic sensors |
| V7 | Station 3 check actuator | Y2.1 / Y2.2 | Home, down and distance signal |
| V8 | Station 5 block-test actuator | Y2.3 / Y2.4 | Home, up, force and displacement signal |
| V9 | Station 6 unload gripper | Y2.5 / Y2.6 | Open, close, part-gripped sensor |
| V10 | Unload OK / NG transfer slide | Y2.7 / Y3.0 | Home, OK position, reject position |
| V11 | Reject diverter / gate | Y3.1 | OK route ready, reject bin not full |
| V12 | Bowl air-blow / escapement assist | Y3.2 / Y3.3 | Track-ready and part-present sensors |
Pneumatic Design Notes
- All grippers require open/close feedback plus part-present confirmation.
- All pneumatic slides require home and work-position sensors.
- Flow controls should be fitted on pick/place and unload cylinders for stable motion.
- Low-air condition must stop new cycle start and hold machine in a safe state.
- Valve manifold outputs should be labeled by station for easier maintenance.
Pneumatic labels can be enabled in the 3D Simulator panel for quick visual location.
Wiring / Electrical Architecture
Conceptual wiring view showing how sensors, solenoids, servo drives, bowl feeders and HMI connect back to the PLC cabinet.
System Wiring Concept
Wiring Breakdown
| Circuit | Wiring Method | Notes |
|---|---|---|
| PNP sensors | 3-wire 24 VDC to DI modules | Brown +24V, blue 0V, black signal to PLC DI |
| Analog sensors | Shielded cable to AI / amplifier | Load cell and displacement signals should use shielded wiring |
| Solenoids | 24 VDC DO through fused terminal and valve manifold | Flyback / surge suppression required |
| Servo press | Profinet + power + STO safety | Force / displacement profile logged via drive / controller interface |
| Rotary index motor | Servo / indexer wiring to drive | Index command, in-position and fault feedback to PLC |
| Bowl feeders | Feeder controller + track sensors + air-blow solenoids | PLC controls enable, blow, escapement and ready signals |
| Safety | Dual-channel safety wiring | E-stop, door interlock and pneumatic dump valve |
| HMI / logging | Ethernet / Profinet network | Recipe, alarm history, force trace and station fail counters |
Recommended Cabinet Arrangement
- Main isolator, MCBs, 24 VDC power supply and fused distribution.
- Safety relay / safety PLC and STO wiring for servo systems.
- PLC CPU, Profinet switch and remote I/O couplers.
- Separate terminal sections for sensors, solenoids, analog signals and safety.
- Shield termination bar for load cell and displacement sensor wiring.
- Cabinet labels shall follow station naming: S1, S2, S3, S4, S5, S6, Feeder and Safety.
20-Model Family Changeover Strategy
The machine is intended to support multiple product variants in the same family. Changeover is handled by interchangeable tooling plus recipe-based position and height adjustment. Final tooling details will be validated with sample parts.
Items Expected to Change by Model
| Area | Changeover Item | Purpose |
|---|---|---|
| Rotary Table | Six fixture holders / nests | Match Part A outer diameter, seating depth and support geometry |
| S1 Loading | Part A gripper fingers and guide nose | Grip diameter and part drop alignment |
| S2 Loading | Part B gripper fingers and insertion guide | Control part centering and insertion depth |
| S3 Check | Check probe tip and height reference | Match assembled height / seating condition |
| S4 Press | Press tool / upper punch and Z-height setting | Match pressing profile, load path and part length |
| S5 Block Test | Block-test pin / tip and sensor height | Match bottom push location and displacement window |
| S6 Unload | Unload gripper fingers and route guide | Handle OK / NG part without damaging surfaces |
| Feeding | Bowl tracks, rails, escapement fingers and air-blow points | Orient and singulate the selected model family size |
Adjustment Points
- X/Y position of S1 and S2 transfer modules for diameter and pickup-point variation.
- Z height of part placement, assembly check, servo press and block-test actuator.
- Fixture pocket depth, support diameter and location pin geometry.
- Pressing recipe: target load, stroke, speed, dwell and force-window calculation.
- Block-test recipe: push force, displacement window and reject decision logic.
- Bowl feeder tuning: bowl speed, track sensor delay, escapement timing and air-blow timing.
Changeover labels can be enabled in the 3D Simulator panel. They show conceptual adjustment zones, not final mechanical dimensions.
Recommended Changeover Workflow
For variants that require less tooling or fewer checks, the machine sequence can be simplified and cycle time may improve. Additional functions or extra station operations can be added as variation scope after physical validation.