Boxford Computer Integrated Manufacturing System -Micro BCIM1

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13 Νοε 2013 (πριν από 3 χρόνια και 9 μήνες)

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Boxford Computer Integrated Manufacturing System
-
Micro

BCIM1



Introduction

A tabletop educational CIM system, utilizing elements included in a full blown, industrial level
CIM,
on a smaller scale, but having powerful CIM software.

The educational tabletop miniature CIM should include the following main modules:

1.

Vertical articulated
Robotics

systems for three deferent stations

2.

ASRS

(Automatic Storage Retrieval System) statio
n, including a vertical articulated robot
loading and unloading raw materials and finish products from storage array, feeder(s) and
Palletizing plate.

3.

FMS station #1
-

Machine tending station
, including Vertical articulated educational robot
mounted on
Linear slidebase for loading and unloading raw materials and finish products
from and to a table
-
top CNC
Mill
, and interface facilities allowing automatic operation
between the robot and the complete CIM system.

4.

FMS station #2
-

Machine tending station
,

including Vertical articulated educational robot
mounted on Linear slidebase for loading and unloading raw materials and finish products
from and to a table
-
top CNC
Lathe
, and interface facilities allowing automatic operation
between the robot and the com
plete CIM system.

5.

Quality Control station
-

The station should contain an automatic controlled Quality
Control Vision system mounted directly on the closed loop conveyor, working
independently or integrated with the CIM system, for tests and measurement
s of
manufactured parts.

6.

Closed loop tabletop conveyor

with 4 automatic pneumatic stop stations, pallet
-
tracking
device, and should be operated by a Programmable Logic Controller.

7.

Bar code
-
scanning system


Laser Bar code scanning system, for on line

identification and verification of each template
mounted on the moving pallets.

8.

Management software
should include reports generator and graphic simulation of the
process.

9.

Curriculum and learning materials


Complete set of books, activity manuals, video films, and system documentation

10.

CAD/CAM software for CNC Machines


Complete CNC software with CAD/CAM facilities

11.

Installation and training





1.

Robotic systems (Qty


3 units)

Each of these 3 units

should be integrated in the ASRS, FMS stations,


Robot arm:




5 DC servo axes plus gripper



Construction: vertically articulated arm



Load capacity: 1kg at arm extension



Repeatability: 0.5mm



Speed: increments of 1% between 1
-

100%



Maximum speed
: 600mm per second



Feedback: high resolution optical encoders on all axes



Radius of operation


at least 600mm



DC Gripper with opening up to at least 65mm



Gripper can measure object size



Power transmission: gears, timing belts, lead screws



Equipped with aluminum multipurpose gripper attachment for round pieces



Safety features: actual stops prevent user from damaging robot arm, motors stop
automatically should robot arm strike obstacle, without loss of data from memory


Robot controller:



Power requirements: 110/220 VAC, 50/60 Hz, 500 W max



CPU: Motorola 68010



Communications: RS232 serial (Optional


up to 8 ports)



User access to all control parameters (300)



Controls up to 11 axes (8 axes standard)



16 outputs with LED display (
4 relay, 12 open collector, PNP/NPN definable)



16 inputs with LED display (PNP/NPN definable)



Emergency brake switch (red): disconnects power to motors and to I/Os, and resets the
microprocessor (for safety)



Protection systems:



impact protection,



thermal protection,



boundary protection



Automatic breakers on each axis



Stand alone controller: no need for external computer while programs run



PWM controller (20 KHz)



Multiasking: can run up to 20 independent programs concurrently. User can

edit programs
while others are running



XYZ and ROBOT JOINTS coordinate systems with absolute and relative positions definition



Continuous path control (linear, circular, mathematical functions): 10ms response time



Two velocity control profiles: parabolic and trapezoidal
-
user definable



Teach Pendant
:



An advanced teach pendant could be connected to the controller



enables movement of each axis independently or along the XYZ axes



provides functions that are inc
luded in industrial units



has two lines 32 characters LCD display



enables movement of all 11 controller axes



enables robot movement along straight lines: X+, X
-
, Y+, Y
-
, Z+, Z
-
.



Software specification:

Software type A:

Advanced Control Language provides advanced, real
-
time control
programming capabilities. Should enable continuous path control, linear and circular
interpolation, event driven programming, path optimization, different control profiles and full
interrupt c
apabilities. The end effector path can be defined as a general formula within the robot
work envelope. Includes all the necessary tools for programming and operation:

Robot control commands such, Real
-
time control commands, Mathematical and logical
functio
ns, Program flow commands, I/O control commands, Variables, positions and parameters,
RS232 communication commands, etc.



Software type B
: Menu driven commands to integrate complex robot, work cell and sensor
operations. Enables Cartesian, linear, and cir
cular robot control. Interrupt programming enables
external machine operations to be controlled and synchronized with the robot. Safety sensing
equipment can be programmed to stop the robot or cell in operation. Real
-
time position teaching
in the run mode
allows the robot to learn new positions while in an automatic operational mode.
The cell control display shows real
-
time robot operation, and I/O status using user defined
symbolic names.


2. Automatic storage and retrieval system (ASRS)

Should Include 3
modules (in additon to the robotic system described before):

Storage unit



Slant type (wide at the bottom, narrow at the top)



Loading/unloading by a robot



Six bays for parts templates, each bay includes fixtures for the template



Template can be approached by the robot from the top or side



Affixed to a table top



Dimensions: 390mm (W) x 300mm (L) x 320mm (H)



Six parts templates, including six sets of various size and shape pins: by positioning the
different sized pins in the m
atrix of holes on the templates, one can form easily and without
machining requirements, various fixtures in a very short time.


Pneumatic Adjustable Gravity Feeder



Extruded aluminum base.



Feeding compartment for square and round stock



Minimum diame
ter of 30mm, maximum diameter of 50mm for cylinders,



Minimum size 40mm x 40mm, maximum size 50mm x 50mm for square stock.



Operated by means of an air cylinder (internal diameter 12mm, stroke 125mm)



Solenoid valve 4/2 type, 24Volt



Air fittings incl
uded



Two air flow control valves, M5 size



Inductive and photo electric sensors to distinguish between plastic/metal, black/white parts



Inductive sensor specifications


Palletizing unit

For placing finished products and/or raw materials in process. By

positioning the different sized
pins in the matrix of holes, one can easily and without machining requirements, form various
fixtures in a very short time, and economical fashion



Overall size 260mm x 260mm



Distance between the hole centers app. 12mm



Different sets of five different sized and shaped pins


3. Machine tending station
-

Robotics system with CNC mill

Vertical articulated robotics system, mobile on high speed long linear slide base is required for
load / unload application to/from CNC mi
ll machine.

The robotics system as well as the CNC machine should be operated as stand alone or as a part of
the CIM and should support full flexibility application design.

The robotics system should enable multitasking programming and operating via at le
ast 2 types
of software (one with open structure and one with menu
-
driven Windows based s/w).


CNC Mill Specifications:

A CNC training machine tool that is both a CNC milling and a CNC lathe machine

(Dual purpose). The machine should convert from a lathe

to a mill, with milling table, toolholder
and simultaneous 3
-
axis movement in a short time. All Critical components of the machine
should be moulded from the latest advanced composite materials to offer high strength, rigidity
and precision.

The machine s
hould be included with Fail
-
safe cut out switches and totally enclosed guarding to
provide safety levels for students.

The machine in the mill mode must have all required accessories and software as standard for
integration with a second machine in the l
athe mode into a Flexible Manufacturing (FMS) or a
Computer Integrated Systems (CIM).

The software should include 3D solid graphics with rotation and zooming. Programming should
be by ISO G & M codes.


Essential Software Features




C
omputer
A
ided
D
esign package with Import/Export to/from most known
CAD

packages



C
omputer
A
ided

M
anufacturing Processing package



M
anual
D
ata
I
nput facility



G

&
M

Program Import facilities



Graphical Views and Simulations facilities, 2D, 3D, Zooming etc.



Manufactu
re facility



An optional Off
-
Line Fanuc Panel Emulation on screen of Fanuc

OT/OM

Control Operators
Panels or
Sinumeri
k 810/820/850/880 or
Heidenhain
135/450.



Administrator (Tutor) Functions



Specification


Mechanical


Lathe mode

Swing over bed

225mm

X axis travel

125mm

Z axis travel

360mm

Distance between centres

330mm

Maximum turning diameter (swing over cross slide)

70mm

Maximum turning lathe

330mm

Spindle bored to pass

20mm


Mill mode

Axis travel




X (longitudinal)

125mm




Y (cross)

75mm



Z (vertical)

260mm

Spindle to column

115mm

Distance spindle to table

335

Working Table area

180 x 110mm

Spindle mounting

40mm,M5


Slides

Precision ground bar and


phosphor bronze bearings



Specification Summary


Machine

Programmable and variable spindle speeds

200 to 2500rpm

Programmable feed rate

0 to 500mm/min

Rapid traverse rate

500mm/min

Feed modes

2 feed modes(mm/rev,mm/min)



Airmist Coolant capacity (Optional)

3.3 litre water soluble fluid


transported by local air

supply


Pneumatic Vice

Capacity 100mm


Tailstock (Standard)

Tailstock with centre


Tooling package


Standard

3 Milling cutter holders





5mm, 5mm and 10mm

End mill








5mm dia.





Optional (In addition)

Centre drill

Twist drills







5mm and 10
mm

Slot drill/End mill







3mm, 6mm and 10mm dia.

Ripping cutter






10mm dia.

Ball end mill HSS






6mm dia.


Spot drill








10mm dia.


Dimensions

Machine Net Weight

52kg

Machine Net Weight

100kg


Machine Dimensions

910 (H) x 480 (W) x 455mm (H)


Specification
-

Electrical

Main supply

110/240 volts 50/60 Hz 1ph

Main drive motor

320w (0.43 HP)

Spindle motor

DC motor

Axes motors

Stepping motors controlled by


bi
-
polar chopper drives

Control


Personal Computer (Not included), the minimum specification is for Pentium P166 computer,
running MS
-
Windows 95, with 16MB RAM and 10MB space hard disc capacity, VGA colour
screen, mouse, 3.5” disc drive and one free serial port and CD
-
ROM


Standard Equipm
ent



Low volt light



Pneumatic 100mm vice



Automatic air powered guard



Robot port



Tailstock with centre



Quick change 4 position programmable drilling/boring tool changer



Spindle centre and carrier



Quick change milling table



3 milling cutter holders (5mm, 5mm, 10mm)



End mill 5mm diameter



Keys, oil can, and swarf brush



Mains cable, parallel cable 25 way, serial cable 9 way



Software on 3.5" discs



Operating manual



Turning and milling programming manuals and coursewar
e



Site Licence, off
-
line programming CAD/CAM software for 10 Workstations



5 years spare parts



Optional Equipment




Airmist coolant system



Emergency foot switch for bench mounted model



Curriculum Optional


The optional curriculum with standard So
ftware package should allow:




In
-
depth and practical experience of Information Technology and Computer Control to
Students



A facility for quickly producing complex, high quality artefacts too satisfy Design and Make
tasks



An opportunity to manufactur
e artefacts for practical use in Fabrics and Food Technology.



A Platform for creating links with Art, Science, Business Studies, Electronic and Industry.



A practical, real life application of mathematics


And offer:




10 Session Curriculum Book in 3 levels taking the Student from novice to expert user via a
systematic and easy to follow route. All curriculum should be fully supported by detailed
Teacher Notes and Students Workbooks.



Extensive library of fully prepared

components complete with program disk and illustrated
step by step guide of the manufacture and assembly procedure.



Extensive library of detailed project material including Teacher resources, Lessons structures
and Student worksheets.


Optional Student
Projects should include:




Crocodile



Desk tidy



Seal



Shark



Floppy disc rack



Maze game



Duck



Letter/ toast rack



1.0m Linear Slidebase

Belt driven linear slide for robots. Rollers on highly ground hardened bars provide smooth and
quite motion. The belt should be driven by DC servo motor, under closed loop control

Specifications:



Overall size 1300mm



Overall travel 1000mm



Travel velo
city 500mm/sec



Repeatability

0.2mm



Homing carried out with an optical switch



Payload capacity 200kg



Predrilled mounting holes for fastening to table or stand



24V DC motor with optical encoder



Mounting thread for robots


Work bench



Heavy Duty Aluminum Frame with Wood/Formica Top



Work bench 1,580 (l) * 900 (w) * 700mm (h) and slotted aluminum legs



Underneath shelf


4. Machine tending station
-

Robotics system with CNC lathe

Vertical articu
lated robotics system, mobile on high speed long linear slide base is required for
load / unload application to/from CNC lathe machine.


The robotics system as well as the CNC machine will be operated as stand alone or as a part of
the CIM and will support

full flexibility application design.

The robotics system will enable multitasking programming and operating via at least 2 types of
software (one with open structure and one with menu
-
driven Windows based s/w).


CNC Lathe Specifications
:

A CNC training m
achine tool which is both a CNC lathe and a CNC milling machine

(Dual purpose). In the lathe mode the machine should provide slant
-
bed construction and
automatic tool changing. The machine should convert from a lathe to a mill, with milling table,
toolhol
der and simultaneous 3
-
axis movement in a short time. All Critical components of the
machine should be moulded from the latest advanced composite materials to offer high strength,
rigidity and precision.

The machine should be included with Fail safe cut ou
t switches and totally enclosed guarding to
provide safety levels for students.

The machine in the lathe mode must have all required accessories and software as standard for
integration with a second machine in a mill mode into a Flexible Manufacturing (
FMS) or a
Computer Integrated Systems (CIM).

The software should include 3D solid graphics with rotation and zooming. Programming should
be by ISO G & M codes.


Essential Software Features



C
omputer
A
ided
D
esign package with Import/Export to/from most known
CAD

packages



C
omputer
A
ided

M
anufacturing Processing package



M
anual
D
ata
I
nput facility



G

&
M

Program Import facilities



Graphical Views and Simulations facilities, 2D, 3D, Zooming etc.



Manufactu
re facility



An optional Off
-
Line Fanuc Panel Emulation on screen of Fanuc

OT/OM

Control Operators
Panels or
Sinumeri
k 810/820/850/880 or
Heidenhain
135/450.



Administrator (Tutor) Functions



Specification


Mechanical


Lathe mode

Swing over bed

225mm


X axis travel

125mm

Z axis travel

360mm

Distance between centres

335mm

Maximum turning diameter (swing over cross slide)

70mm

Maximum turned length with chuck

330mm

Spindle bored to pass

20mm

Mill mode

Axis travel




X (longitudinal)

125m
m



Y (cross)

75mm



Z (vertical)

260mm

Spindle to column

115mm

Distance spindle to table

3354mm

Working Table area

180 x 110mm

Spindle mounting

40mm,M5



Slides

Precision ground bars and


phosphor bronze bearings



Specification Summary


Machine

Programmable and variable spindle speeds

200 to 2500rpm

Programmable feed rate

0 to 500mm/min

Rapid traverse rate

500mm/min

Feed modes

2 modes(mm/rev,mm/min)



Airmist Coolant capacity (Optional)

3.3 litre water soluble fluid


transported by local

air

Tooling system

Programmable turning tool changer

10 position


6 external,4 internal tools

Shank height & width for external tooling

10mm x 10mm

Diameter for internal tool

8 mm


Pneumatic Chuck

100mm, 3
-
jaw air operated chuck


Tailstock (Standard)

Ta
ilstock with centre







Tooling package


Standard

Turning toolholder






SDJCL 1010
-

03


5 tips for above






DCGT090202SCT12A

Parting toolholder






SGTFL 101
-
1.6


5 tips for above






GFN1.6 IC354P3

Optional (In addition)

RH turning toolholder





SDJCR 1010
-
03

10 inserts for above






DCGT090202SCT12A

External threading toolholder





SDTML 101
-
03

10 inserts for above






TNMC 32NV

Boring bar







A08MSEUPL06

10 inserts for above






EPMT0602E
-
S3X5

Centre drill



Dimensions

Machine Net Weight

52kg

Machine Net Weight

100kg


Machine Dimensions

910 (H) x 480 (W) x 455mm (H)


Specification
-

Electrical

Main supply

110/240 volts 50/60 Hz 1ph

Main drive motor

320w (0.43 HP)

Spindle motor

DC motor

Axes motors

Steppers


Control


Personal Computer (Not included), the minimum specification is for Pentium P166 computer

running MS
-
Windows 95, with 16MB RAM and 10MB space hard disc capacity, VGA colour
screen, mouse, 3.5” disc drive and one free serial port and CD
-
ROM drive.



Standard

Equipment



Low volt light



Pneumatic chuck, 100mm, 3 jaw.



Automatic air powered guard



Robot port



Tailstock with centre



6 position programmable turning tool changer



Spindle centre and carrier



Turning toolholder and 5 tips



Parting toolholder

and 5 tips



Keys, oil can, and swarf brush



Mains cable, parallel cable 25 way, serial cable 9 way



Software on 3.5" discs



Operating manual



Turning programming manuals and courseware



Site Licence, off
-
line programming CAD/CAM software for 20 Wo
rkstations



5 years spare parts


Optional Equipment




Airmist coolant system



Emergency foot switch for bench mounted model


Optional Curriculum


The optional curriculum with standard Software package should allow:




In
-
depth and practical experience of Information Technology and Computer Control to
Students



A facility for quickly producing complex, high quality artefacts too satisfy Design and Make
tasks



An opportunity to manufacture artefacts for practical use in

Fabrics and Food Technology.



A Platform for creating links with Art, Science, Business Studies, Electronic and Industry.



A practical, real life application of mathematics

And offer:




10 Session Curriculum Book in 3 levels taking the Student from no
vice to expert user via a
systematic and easy to follow route. All curriculum should be fully supported by detailed
Teacher Notes and Students Workbooks.



Extensive library of fully prepared components complete with program disk and illustrated
step by st
ep guide of the manufacture and assembly procedure.



Extensive library of detailed project material including Teacher resources, Lessons structures
and Student worksheets.


Optional Student Projects should include:




Hammer design



Salt and pepper pots



Chess set


1.0m Linear Slidebase

Belt driven linear slide for robots. Rollers on highly ground hardened bars provide smooth and
quite motion. The belt should driven by DC servo motor, under closed loop control


Specifications:



Overall size 1300mm



Overall travel 1000mm



Travel velocity 500mm/sec



Repeatability

0.2mm



Homing carried out with an optical switch



Payload capacity 200kg



Predrilled mounting holes for fastening to table or stand



24V DC motor with opt
ical encoder



Mounting thread for robots


Work bench



Heavy Duty Aluminum Frame with Wood/Formica Top



Work bench 1,580 (l) * 900 (w) * 700mm (h) and slotted aluminum legs



Underneath shelf


5. Quality Control station


The station contains an automati
c controlled Quality Control Vision device mounted on the
closed loop conveyor, working independently or integrated with the CIM system, for tests and
measurements of manufactured parts.

The Machine vision hardware and software application package, designe
d for industrial machine
vision training and industrial applications based on
real
-
time
frame grabber with advanced
graphic vision software.


Machine vision system specifications:



Real time Framegrabber card (512*512 pixels, controls up to 4 frames, 256

gray scale levels)



software, manual and cabling



CCD camera with cables



stand for camera



9" Video monitor with cables



light table with adjustable jig



software based on advanced graphic user interface (Windows type format)



enables

image processing



single / automatic / multiple threshold binarization



save and retrieve binarized & gray level images



binary image zooming and pixel editing



full graphical representation of the recognition algorithms and statistical methods



pattern recognition features



robot guidance applications



CAD
-
like measurements (distances, angles, surfaces, mathematical combination of them)


6. Table top, closed loop pallet conveyor with stop assemblies & pallet tracking system


Table top closed l
oop conveyor with 4 stop stations, pallets, pallet sensors, and pallet stops, to be
integrated into a CIM system. Used for transferring parts/raw materials to various stations.

Pallet tracking system, one located at each workstation, enabling unique on
-
lin
e identification of
each pallet.

The conveyor is based on mono rail constructed of extruded anodized aluminum. The conveyor is
operated by single DC motor.

The conveyor’s PLC controls the stop stations and interface between the conveyor operation and
the m
ain management software. The PLC should include a PLC with (min) of 16 Inputs, 16
outputs, Battery backed
-
up memory and RS232 port.


Conveyor specifications



Affixed to a table top



Overall length app. 2,000 mm



Conveyor size (min) 740mm (L) x 500mm (W) x 100mm (H)



Includes 4 (four) conveyor stations



Each station includes:



magnetic sensors for pallet arrival, pallet in station and pallet identification



pneumatic piston stopper for pallet



air pressure con
trol valve



Drive mechanism is DC motor, 24V



Start/stop control each pallet’s ID via PLC



Pallets are coded by means of magnetic indicators



Pallet size 170mm x 120mm (+/
-

2%)


Central Work bench



Heavy Duty extruded Aluminum Frame with Wood/Formica

Top



Work bench 1,800 (l) * 900 (w) * 700mm (h) and slotted aluminum legs



Underneath shelf


7. Bar code
-
scanning system

Laser Bar code scanning system, for on line identification and verification of each template
mounted on the moving pallets.

Bar code specifications



Barcode laser scanner, with power supply 4.75 to 14VDC



Mounting for scanner



Decode depth of field:



maximum typical working distance is 610mm



minimum element width resolution is 5.5mils



Print contrast minimum 25% absolute dark/light reflectance differential



Dimensions:



height 51mm



length 89mm



width 71mm



RS232 port



System cabling



100 barcode stickers


8. CIM’s management and simulation Software

Windows based, software driven
CIM system environment, enabling definition of the CIM
structure, definition of the products to be manufactured by the CIM system, production of the
products by the CIM system, tracking of activities within the CIM system, simulation of the
activities with
in the CIM system, testing and diagnostics of the CIM system hardware, as well as
on
-
line help.


Specifications of the Software



Flexible cell definition



Flexible parts definition



Flexible order definition



Flexible simulation: Can be run without the

CIM hardware being connected, allowing for
off
-
line programming testing and analyzing of the results. The system has a MANUAL
MODE, allowing the user to send all commands to the system, as if they were made by the
Micro CIM hardware.



Each component at a

station of the Micro CIM system can work in MANUAL MODE,
SIMULATION MODE and REAL MODE, without affecting the operating modes of other
devices (even those at the same work station), allowing the user to debug the production and
work, as a stand
-
alone devi
ce.



The user can define the simulation clock speed, and run several simulations under different
conditions.



The simulation program can run coincidentally on many computers (limited only with a
protection key).



Malfunction detection, treatment and recovery.



Optimization of the production process and of the CIM structure.



Importation and exportation of files with a commercial database (such as dBase).



Object orientated CIM system design and layout.



The use
r interface is based on Windows 95 and supported by a mouse and keyboard. The
CIM s/w includes the following programs represented by icons: PART definition, ORDER
definition, MACHINE definition, STORAGE definition, MANAGEMENT program and
station device dri
ver program, ON LINE HELP, REPORT generator



The graphics editor of the cell simulation is used to define the graphic presentation of the
CIM system. It is possible to display pictures from a library.



Stages in the CIM definition: Library, RUN Simulatio
n



Machine Definition
-

The machine definition program is used to define,
create, view or modify the connections between processes and machine.
Machine t ype (one or more).



Parts Definition
-

The parts definition program is used to define, view or modify

the bill of
materials, and processes for an existing part.



Order Definition
-

The order entry form let you create, view or modify an
order. The screen contains the following fields:



Storage Definition
-

The storage definition form lets you create, modify or view parts and
template locations.



Device Drivers
-

Each device at a staion is controlled by a CIM device driver
program, running on the station manager’s PC.



On
-
Line Help
-

The CIM software includes an On
-
Line Help program, with full details for
screen, buttons and other features.



Micro CIM Reports
-

The CIM software includes an off
-
line reports generator
program. The following reports are included:



parts reports



sub p
arts reports



order reports



machine reports



storage reports



analysis reports



location status



plan reports



three
-
user reports generator


9. Curriculum and learning materials

Complete set of books, activity manuals, video films, and system documentation

(1 of each). Including:



CIM User's Manual,



CIM Design Projects Book,



CIM Technology
-

Fundamentals and Applications,



Robotics s/w Reference Guide



Instructor Manuals +

Sets of transparencies,



6 * robotics’ Textbooks



4 * robotics’ Workbooks



Set of robotics’ User's Manual,



Experiments Manual,



Machine vision system User's Manual,



PLC Manual,



Videotape: The Robot
-

Its Role in Industry,



Videotape: Factory of

the Future


10.CAD/CAM Software for CNC Machines

(See machine specifications)


11. Installation and training

The CIM system should be supplied as turn
-
key project including:



pre
-
engineering, pre
-
manufacturing, pre
-
programming



Installation including demo and setup



on
-
site training of 10 days for 2 trainees.



Optional “in
-
factory” training should be offered if required .