Station 1 – mMS4.0 (Material Transport and Detection)

For the mechatronics learning topics (Basic to Professional), real production equipment, a mechatronics system, is provided, which consists of 3 stations. All 3 work stations can be used individually or be connected to form a larger system. The work stations described here are made of industrial components (industry standard).

The stations have interfaces (compressed air, power, data,
Ethernet) to connect more stations.

For connected stations, the emergency stop for each individual station is effective for the entire connected system. The individual stations are fully installed and fully functional on delivery.

The modular mechatronics system (mMS4.0) features the assembly of a cube-shaped housing. The 2 housing cubes are prepared, connected to each other or joined together and stored. In order to provide various product types, a different color is used for each housing cube.

At Station 1, the housing cubes are available on a conveyor. Using different sensors, position and color (light/dark) are detected and the housing cubes are forwarded or rejected. To wire the system components, a Profibus coupler is used on the grooved panel, to which the component cables are clamped. In addition, it is connected to the control with a Profibus cable.

Station 1 has its own control (IndraLogic L25).

The (industry-standard) control offers several specific possibilities:
1. PLC programming according to IEC61131-3 with the languages Instruction List, Ladder Diagram, Function Block Diagram, Sequential Function Chart, Structured Text.
2. Convertible into a CNC control via Flash card (Station 3)
3. As preparation for Industry 4.0 (i4.0) learning topics: the control can be accessed with other programming languages (e.g. Visual-Basic, C++, C#, Java, …) using OpenCore Engineering and control via a software program (e.g. LabView, MatLab/Simulink, Excel, Power Point,…) is possible. This is possible without PLC programming.

By using high-level language programming it is possible to read data directly from the PLC, even parallel to a running PLC program (conversion of Big Data). Example of an i4.0 application that is possible with the control described above: direct control of a system with a LabView program (from the appropriate LabView lab) via the control, without needing to translate into a PLC programming language.

The following practice topics are addressed:
▶▶ Getting to know the system and PLC program
▶▶ Understanding the emergency stop circuit
▶▶ Detecting material with sensors
▶▶ Visualizing and operating equipment functions
▶▶ Visualizing system conditions
▶▶ Single-step and automatic modes
▶▶ PLC programming according to IEC 61131-3

The exercises are available online.
Exercises with solutions are available to the trainer.

The work station is equipped with the following components:
▶ Setup on an 800 x 550 mm aluminum profile plate
▶ Base: profile carriage 800 x 800 x 1350 mm (L x W x H) with electrically pre-wired
▶ IndraLogic L25 PLC, IEC 61131-3 compatible (see page 216 for description)
▶ Safety relay for emergency stop circuit
▶ Energy supply for 24V power supply
▶ Industrial machine control desk with quick-connect for grooved panel/perforated p
▶ Maintenance unit for compressed air
▶ Conveyor with 24 V DC motor w/ 800m length to achieve transfer to next station wi
▶ Separator magazine for the housing cubes. These are pushed to the conveyor via a
▶ Sensor, reed contact, pneumatic cylinder in out or in position
▶ Sensor, roller, housing detection in magazine
▶ Sensor, capacitive, housing on conveyor
▶ Sensor, inductive, metallic housing
▶ Sensor, optical, light or dark housing
▶ Sensor, light sensor, housing at end of conveyor
▶ Pneumatic cylinder for contour detection with analog path measurement sensor an
▶ Removal unit for sorting of rejected parts
▶ Profibus coupler on grooved panel for wiring the system components
▶ Housing cubes made of aluminum, PVC (white) and PVC (black)
▶ Programming software (IndraWorks license)
▶ Documentation CD (operating instructions, operating diagrams, etc.)
▶ Ethernet switch for other needed network participants, e.g. PC, route, RFID etc