Mechatronics I Lab Manual

Testing Station

The Testing Station

According to VDI 2860, testing, in the same way as measuring, forms part of the handling function of checking. Information acquisition (ACTUAL) and the comparison of specified characteristics (REQUIRED) and the resulting decision of Workpiece acceptable/rejected i.e. Yes/No, represent important component parts of testing. An important component part of measuring is the comparison of characteristics (ACTUAL values with specified reference values (REQUIRED values). Typical testing characteristics are
Availability checking, Identity checking, Contour checking, Size checking, Color checking, Weight checking or Checking the availability of a workpiece.

In automated production, in contrast with manual production testing assumes a key role. In manual production, reject parts can be immediately rejected, whereas in automated product, reject parts can lead to malfunction of the production process or a halt in production. The function of the Testing station is
to determine the material characteristics of a workpiece, to check the workpiece height and to either reject a workpiece or make it available to a subsequent station.

The Testing station is made up as follows:

Recognition module Lifting module Measuring module Air cushioned slide module Slide module Profile plate

Trolley Control console PLC board

Testing station with trolley, control console and PLC board

Lab 1 Project Phases

Testing Station
Create the project Phases for the Testing Station using a Gantt Chart and a Network Analysis. You are given an 18 hour time frame from development of ideas to documentation.
Lab 1 Project Phase Name: Exercise: 1.1 Gantt Chart Date: Sheet 1 of 1

Create a Gantt Chart for the Testing Station.

Lab 1 Project Phase Name: Exercise: 1.2 Network Analysis Date: Sheet 1 of 1

Create a Network Analysis for the Testing Station

Lab 2 Material Flow

Testing Station
Sequence Description

A Sequence Description consists of 3 parts Start Prerequisites, Initial Position and Sequence. In the Start Prerequisites there needs to be a list of prerequisites for the machine to start. For Example: Work piece at start of the conveyor. In the Initial Position there needs to be a list of the machines major components in there initial position before startup. For Example: Stopper Advanced, Conveyor Motor Off In the Sequence there needs to be a written description of how the machine operates and materials flow. For Example: 1. Work piece detected 2. Conveyor motor on

Complete the worksheet on the next page.

Lab 2 - Sequence Description Name: Exercise: Sequence Description Date: Sheet 1 of 1

Complete the following Sequence Description for the Testing Station.

Start Prerequisites:

Initial Position:

Sequence:

Lab 3 Planning of Automated Systems

Testing Station Function Chart
In the main, function charts describe two aspects of a control system in accordance with defined rules: The actions to be executed (commands) The sequence of execution A function chart is therefore divided into two parts. The executive part indicates the time related sequence of the process. For additional information read the section Function Charts IEC 848 or DIN 40 719, P.6 or next page.

Function chart to IEC 848 or DIN 40 719, P.6

In the main, function charts describe two aspects of a control system in accordance with defined rules:
the actions to be executed (commands) the sequence of execution

A function chart is therefore divided into two parts (fig. 2.9). The executive part indicates the time-related sequence of the process.

N Initial position Part in lifting bracket

L Colour and material definition t = 0.5 s Timer expired

S Lifting cylinder raise Lifting cylinder up

L Defining thickness t = 1 s Timer expired

N Ejecting cylinder advance Ejecting cylinder advanced

N Ejecting cylinder retract Ejecting cylinder retracted

S Lifting cylinder lower Lifting cylinder down

Figure 9: Function chart for a testing process

The executive part does not describe the individual actions to be executed. These are contained in the action part of the function chart which, in the case of the example shown, consists of the blocks to the right of the steps.

A brief description follows below of the individual elements of a function chart.

Steps
Functions charts are structured by means of steps. These are represented in the form of rectangles which are denoted by the respective step number. The output status of the controller designated by means of the initial step. Each step is assigned actions (commands), which contain the actual execution parts of the controller.
Initial step Transition Step 2 1 directed connections

Action

Figure 10: Elements of a function chart

Transitions
A transition is a connection from one step to the next. The logic transition condition linked with the transition is entered next to the horizontal line crossing the transition line. If the condition is met, the transition to the next step takes place, which is then executed via the controller.

Sequence structures
Three basic forms of sequence structures may be created by means of combining the step and transition elements:
linear sequence sequence branching (alternative branch) sequence splitting (parallel branch)

Irrespective of the form of sequence structure, steps and step enabling conditions always have to alternate. Sequence structures are executed from the top down.

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In the case of linear sequence, there is only one transition after a step and one step after each transition. Fig. 2.9 illustrates a linear sequence.
2 d 3 e 4 f 6 i 5 h g

Figure 11: Alternative branch

With the alternative branching shown in fig. 2.11, two or several transitions follow after a step. The subprocess, whose transition condition has been met first, is activated and executed. Since it is possible with alternative branching to select exactly one subprocess, the transition conditions d and g in fig. 2.11 must be mutually exclusive.

2 d 3 e 4 g 7 6 5 f

Figure 12: Parallel branch

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In the case of parallel branching, satisfying a transition condition always leads to the simultaneous activation of several subprocesses. These are executed simultaneously, but independently of one another. The merging of subprocesses is always synchronized. Only when all parallel subprocesses have been completely executed, can a transition to the next step below the double line take place in this example to step.

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Lab 3 - Testing Station - Function Chart Name: Exercise: Function Chart Date: Sheet 1 of 1

Create a function chart for the Testing Station.

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Lab 4 Assembly and Installation

Testing Station
Lab 3 - Testing Station Assemble and Install Name: Exercise: Assemble and Install Date: Sheet 1 of 1

Your task is to Assemble and Install all mechanical and electrical systems. Most of the components that we will work with on the Testing Station are already assembled. What we will do is cross check the assembly sheets with the assembled parts for the correct placement and configuration. The following pages contain the assembly instructions.

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Testing Station Assembly Instructions

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Intended use
This station has been developed and produced exclusively for vocational and further training in the field of automation and communication. The training authority and/or the instructors are to ensure that trainees observe the safety instructions described in the manual provided. Festo Didactic herewith rules out all liability for damage or injury to trainees, the training authority or other third parties which may occur during the use/operation of this equipment other than purely in a training situation, unless it can be proved that Festo Didactic has caused such damage or injury through malicious intent or gross negligence.

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Contents
1. Notes on safety

2.

Short description

3. 3.1 3.2

Views and tools Views 9 Required tools

4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8

Assembling the station Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8

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1.

Notes on safety

In the interests of your own safety, please observe the following safety instructions:

General Trainees must only work on a station under the supervision of an instructor. Observe the data in the data sheets for the individual components, particularly all safety instructions!

Electrical Electrical connections are to be wired-up or disconnected only when the power supply is turned off! Use only extra-low-voltages of up to max. 24 V DC.

Pneumatic Do not exceed the maximum permissible pressure of 8 bar (800 kPa). Do not switch on the compressed air supply until you have established and secured all tubing connections. Do not disconnect air lines under pressure. Particular care is to be taken when switching on the compressed air supply. Cylinders may advance or retract as the compressed air is switched on.

Mechanical Attach all components securely on the mounting plate. No manual intervention is to take place unless the machine is at rest.

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2.

Short description

The Testing station

According to VDI 2860, "testing", like "measuring", forms part of the handling function "checking". The major elements of a testing operation are the acquisition of information (actual) and the comparison of specified characteristics (required), and the resulting decision "Workpiece acceptable/rejected" or "Yes/no". An important component part of a measuring operation is the comparison of characteristics (actual values) with specified reference dimensions (required values). Classic types of testing include workpiece availability checking, identity checking, contour checking, size checking, color checking, weight checking or orientation checking. In automated production, in contrast to manual production, monitoring is very important. In manual production, rejected workpieces can be separated out immediately,

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while in automated production rejects may disrupt production operations or halt these completely.

The purpose of the Testing station is as follows:

To To To To determine the material characteristics of a workpiece check the workpiece height and either reject the workpiece concerned or feed the workpiece to the next station.

The Testing station consists of the following:

Profile plate Sensing module Lifting module Measuring module Slide module PLC board with control panel

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3.1 Views

Testing Station plain view

Testing Station front view

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Testing Station r.h. side view

3.2 Required Tools

Tube spanner, 9 x 10 mm Open-ended spanners 6 x 7, 12 x 13, 22 x 24 mm Slot-head screwdriver, 3.5 mm Allen key, 5 mm

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4.
4.1 Step 1

Assembling the Station

1
13. 12. 11. 10. 9. 8. 7. 6. 5. 4. 3. 2. 1.

14. Nut

Profile plate

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4.2

Step 2

2.1 (2x)

2.5 2.2 (4x) 2.3 (4x) 2.6 (2x) 2.7 (2x)

2.4 (4x)

2.8 (2x)

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

Cable duct Socket-head screw M5 x 10 Washer B5.3 T-head nut M5-32 Mounting rail Socket-head screw M5 x 10 Washer B5.3 T-head nut M5-32

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4.3 Step 3

5. 3. 1.

Mounting the electrical system

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4.4

Step 4

3
13. 12. 10.

7. 6.

9 8 (2x)

7 (5x)

4 5

3 4 5 6 7 8 9

I/O terminal Comparator Interface unit CP valve terminal Cable clip (5x) Connectors (2x) Service unit

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4.5

Step 5

Position of cable clips

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4.6

Step 6
14

13

(11)

12

11 (12)
10.

15
7. 6.

2.

2.

10

10 11

Station Link receiver Sensing module (retro-reflective sensor to be fitted to the mounting bracket of the lifting module) Retro-reflective sensor and reflector Measuring module Lifting module Station Link transmitter

12 13 14 15

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4.7

Step 7

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18
7.

16

17

16

Cable clip

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17 18 19

Slide module, 210 mm Air cushioned slide module Cable guide Loosen the two screws M5 x 12 on the lifting module (securing the lifting bracket). These screws are used to secure the mounting bracket of the cable guide and the lifting bracket to the slide of the pneumatic linear drive.

4.8

Step 8

Station fully assembled

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Lab 5 Electrical Circuit Diagram

Testing Station
Lab 5 Electrical Circuit Diagram - Testing Station Name: Exercise: Electrical Circuit Diagram Date: Sheet 1 of 1

Verify that the wiring is correct.

Documents Circuit Diagrams Electrical Circuit Diagram Testing in the directory English\1_Testing\Circuit Diagrams on the CD-ROM supplied.

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Lab 6 Pneumatic Circuit Diagram

Testing Station
Lab 6 Pneumatic Circuit Diagram Testing Station Name: Exercise: Pneumatic Circuit Diagram Date: Sheet 1 of 1

Verify that the pneumatic connections are correct.

Documents Circuit Diagrams Pneumatic Circuit Diagram Testing in the directory English\1_Testing\Circuit Diagrams on the CD-ROM supplied.

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Lab 7 Adjust Sensors

Testing Station
Complete the following Work Sheet Exercises. 7.1 Capacitive Proximity Sensor
7.2 7.3 7.4 7.5 7.6 Diffuse Sensor Retro-reflective Sensor Proximity Sensor Proximity Sensor Linear Displacement Sensor

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Lab 7 Adjust Sensors Distribution Station Name: Exercise: 7.1 Capacitive Proximity Sensor Date: Sheet 1 of 1

7.1 Capacitive proximity sensor (Recognition, detection of workpiece)

The capacitive proximity sensor is used for detection of workpieces. The workpiece changes the capacity of a capacitor build in the sensor head. Workpieces are detected independent of color and material.
Prerequisite Lifting module assembled. Cylinder is tubed up. Compressed air supply switched on. Lifting cylinder in lower end position. Capacitive proximity sensor pre-assembled in mounting bracket. Proximity sensor is wired up. Power supply unit switched on.

Execution 1. Place a workpiece into the workpiece retainer. 2. Assemble the proximity sensor in the mounting bracket, avoid contact with the workpiece retainer. The distance between proximity sensor and workpiece is about 2 mm to 3mm. 3. Adjust the potentiometer of the proximity sensor by means of a screwdriver until the switching status display switches to on. 4. Check position and setting of the proximity sensor (place/pick up workpieces).

Documents Data sheets Proximity sensor, capacitive (258172) in the directory English\2_Testing\Data sheets on the CD-ROM supplied. Assembly instructions Testing station in the directory English\2_Testing\Assembly instructions on the CD-ROM supplied.

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Lab 7 Adjust Sensors Distribution Station Name: Exercise: 7.2 Date:

Diffuse Sensor

Sheet 1 of 1

7.2 Diffuse sensor (Recognition, color detection)

The diffuse sensor is used for color detection. The diffuse sensor uses infrared light. The diffuse sensor detects the light reflected by the workpiece Different surfaces or color changes the amount of reflected light.
Prerequisite Lifting module assembled. Diffuse sensor assembled in the mounting bracket of the workpiece retainer of the Lifting module. Diffuse sensor is wired up. Power supply unit switched on.

Execution 1. Place a red workpiece into the workpiece retainer. 2. Assemble the diffuse sensor in the mounting bracket. The distance between diffuse sensor and workpiece is about 15 mm to 20 mm. 3. Adjust the potentiometer of the diffuse sensor by means of a screwdriver until the switching status display switches to on. 4. Check the setting of the diffuse sensor (place/pick up red and metallic workpieces). Red and metallic workpieces must be detected securely. Note No black workpieces should be detected. Re-adjust the setting of the potentiometer.

Documents Data sheets Diffuse sensor (165342) in the directory English\2_Testing\Data sheets on the CD-ROM supplied. Operating instructions Diffuse sensor (366448) in the directory English\2_Testing\ Operating instructions on the CD-ROM supplied. Assembly instructions Testing station in the directory English\2_Testing\ Assembly instructions on the CD-ROM supplied.

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Lab 7 Adjust Sensors Distribution Station Name: Exercise: 7.3 Date:

Retro-reflective Sensor

Sheet 1 of 1

7.3 Retro-reflective sensor (Lifting, working space)

The retro-reflective sensor is used for monitoring the working space of the Lifting module. If the working space is occupied, it is not possible to move the lifting cylinder. A retro-reflective sensor consists of transmitter and receiver in the same housing. The retroreflective sensor emits visible red light. The light is reflected by an external reflector. If the light beam is interrupted by an object, the switching status of the retro-reflective sensor changes.
Prerequisite Lifting module assembled. Cylinder is tubed up. Compressed air supply switched on. Retro-reflective sensor and mounting bracket with reflector assembled. Retro-reflective sensor is wired up. Power supply unit switched on.

Execution 1. Align the retro-reflective sensor and the reflector. 2. Place an object of about 10 mm size in the middle between retro-reflective sensor and reflector. 3. Adjust the potentiometer of the retro-reflective sensor by means of a screwdriver until the switching status display switches to on. Note Maximal 12 revolutions of the adjusting screw are permissible.

Documents Data sheets Retro-reflective sensor (165331) in the directory English\2_Testing\Data sheets on the CD-ROM supplied. Operating instructions Retro-reflective sensor (369673) in the directory English\2_Testing\ Operating instructions on the CD-ROM supplied. Assembly instructions Testing station in the directory English\2_Testing\ Assembly instructions on the CD-ROM supplied.

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Lab 7 Adjust Sensors Distribution Station Name: Exercise: 7.4 Date:

Proximity Sensor

Sheet 1 of 1

7.4 Proximity sensor (Lifting, lifting cylinder)

The proximity sensors are used for end position sensing of the cylinder. The proximity sensor is sensitive to a permanent magnet mounted on the piston of the cylinder.
Prerequisite Lifting module is assembled, proximity sensors are pre-assembled. Cylinder is tubed up. Compressed air supply switched on. Proximity sensor is wired up. Power supply unit switched on.

Execution 1. Use the manual override of the solenoid valve to place the cylinder piston in the position which you wish to interrogate. 2. Shift the sensor along the cylinder axis until it switches, switching status display (LED) is on. 3. Shift the sensor a few millimeters further in the same direction until it switches back (LED is off). 4. Place the switch half the way between the switch-on and the switch-off position. 5. Tighten the clamping screw of the sensor with a hexagon screwdriver A/F 1.3. 6. Start a test run to check if the sensor switches at the correct point (raise/lower lifting cylinder).

Documents Data sheets Proximity sensor SMTO-1 (151685) in the directory English\2_Testing\Data sheets on the CD-ROM supplied. Operating instructions Proximity sensor, electronic (346709) in the directory English\2_Testing\Operating instructions on the CD-ROM supplied. Assembly instructions Lifting module in the directory English\2_Testing\ Assembly instructions on the CD-ROM supplied.

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Lab 7 Adjust Sensors Distribution Station Name: Exercise: 7.5 Date:

Proximity Sensor

Sheet 1 of 1

7.5 Proximity sensor (Lifting, ejecting cylinder)

The proximity sensors are used for end position sensing of the cylinder. The proximity sensor is sensitive to a permanent magnet mounted on the piston of the cylinder.
Prerequisite Lifting module is assembled, proximity sensors at the ejecting cylinder are preassembled. Cylinder is tubed up. Compressed air supply switched on. Proximity sensor is wired up. Power supply unit switched on.

Execution 1. Use the manual override of the solenoid valve to place the cylinder piston in the position which you wish to interrogate. 2. Shift the sensor along the cylinder axis until it switches, switching status display (LED) is on. 3. Shift the sensor a few millimeters further in the same direction until it switches back (LED is off). 4. Place the switch half the way between the switch-on and the switch-off position. 5. Tighten the clamping screw of the sensor with a hexagon screwdriver A/F 1.3. 6. Start a test run to check if the sensor switches at the correct point (advance/retract ejecting cylinder).

Documents Data sheets Proximity sensor SME-8 (150857) in the directory English\2_Testing\Data sheets on the CD-ROM supplied. Operating instructions Proximity sensor SME-8 (646518) in the directory English\2_Testing\ Operating instructions on the CD-ROM supplied. Assembly instructions Lifting module in the directory English\2_Testing\ Assembly instructions on the CD-ROM supplied.

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Lab 7 Adjust Sensors Distribution Station Name: Exercise: 7.6 Date:

Linear Displacement Sensor

Sheet 1 of 1

7.6 Linear displacement sensor with comparator (Measuring, height of a workpiece)

The linear displacement sensor is used for measuring the height of a workpiece. The analogue output signal of the linear displacement sensor is converted to a binary signal (0/1 signal) by means of a comparator.
Prerequisite Lifting module is assembled, Measuring module pre-assembled. Cylinder is tubed up. Compressed air supply switched on. Linear displacement sensor and comparator are wired up. Power supply unit switched on.

Execution 1. Mount the Measuring module with a distance of 240 mm to the profile plate. Notes The adaption of the height of the workpiece retainer to the air cushioned slide is made by adjustment of the shock absorber (end stop).

2. Place a red workpiece (height 25 mm) into the workpiece retainer of the Lifting module. 3. Loosen the screws of the retaining clamps of the linear displacement sensor. 4. Advance the lifting cylinder to its upper end stop. 5. Shift the linear displacement sensor until the feeler is retracted about 15 mm. Fix the linear displacement sensor in this position.

Documents Data sheets Linear displacement sensor (326498) and comparator (526214) in the directory English\2_Testing\Data sheets on the CD-ROM supplied. Assembly instructions Testing station in the directory English\2_Testing\ Assembly instructions on the CD-ROM supplied.

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Setting the comparator 1. Place a red workpiece in the workpiece retainer. Workpiece height = 25 mm 2. Move the lifting cylinder upwards by actuating the manual override on the valve plate designated with C . 3. Set the two potentiometers LEVEL1 and LEVEL2 in such a way that the operating status display of the output MID (green) is illuminated. Note LEVEL1 about 5. mark of the scale, LEVEL2 about 6. mark of the scale

4. Move the lifting cylinder downwards by actuating the manual override on the valve plate designated with C. 5. The operating status display of the output LOW (yellow) is illuminated. 6. Remove the workpiece; the comparator is set.

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Lab 8 Adjusting One-way Flow Control Valves

Testing Station
Lab 8 Adjust One-way Flow Control Valves Testing Station Name: Exercise: Adjust One-way Flow Control Valves Date: Sheet 1 of 1

8 Adjusting one-way flow control valves

One-way flow control valves are used to regulate exhaust air flow rates with doubleacting cylinders. In the reverse direction, air flows through the non-return valve with full cross-sectional flow. Uncontrolled supply air and controlled exhaust hold the piston between air cushions (improves motion, even with load changes).
Prerequisite Cylinder is tubed up Compressed air supply switched on.

Execution 1. Screw in the restrictors of the one-way flow control valves at first completely and then loosen again one turn. 2. Start a test run. 3. Slowly open the one-way flow control valves until the desired piston speed is reached.

Documents Data sheets One-way flow control valve (175056) in the directory English\2_Testing\Data sheets on the CD-ROM supplied. Operating instructions Pneumatic cylinders (391172) in the directory English\2_Testing\Operating instructions on the CD-ROM supplied.

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Lab 9 Visual Check

Testing Station
Lab 9 Visual Check Testing Station Name: Exercise: Visual Check Date: Sheet 1 of 1

Visual check
A visual check must be carried out before each commissioning! Prior to starting up the station, you will need to check: The electrical connections The correct installation and condition of the compressed air connections The mechanical components for visual defects (tears, loose connections etc.)

Eliminate any damage detected prior to starting up the station!

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Lab 10 PLC Cable Connections

Testing Station
Lab 10 Cable Connections Testing Station Name: Exercise: Cable Connections Date: Sheet 1 of 1

Complete the following cable connections on the next page.

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Cable connections

Cable connections from PLC board to control console and station

1. PLC board station Plug the Port 1 plug of the PLC board into the XMA2 socket of the I/O terminal of the station. 2. PLC board control console Plug the Port 2 plug of the PLC board into the XMG2 socket of the control console. 3. PLC board power supply unit Plug the power cord into the 110v receptacle 4. PC PLC Connect your PC to the PLC by means of a programming cable.

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Lab 11 PLC Input Connections

Testing Station
Lab 11 PLC Input Connections Testing Station Name: Exercise: PLC Input Connections Date: Sheet 1 of 1

Verify that all Input connections are working properly by Testing each input and describing what its signal means.

Input Description 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

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Lab 12 PLC Output Connections

Testing Station
Lab 12 PLC Output Connections Testing Station Name: Exercise: PLC Output Connections Date: Sheet 1 of 1

Verify that all Output connections are working properly by Testing each output and describing what its function is.

Input Description 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

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Lab 13 Write and Load the Program

Testing Station
Lab 13 Load the Program Testing Station Name: Exercise: Load the Program Date: Sheet 1 of 1

Write a program for the Testing Station and then Load the Program into the PLC using what ever communication means necessary.

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Lab 14 Testing Program Functions

Testing Station
Lab 14 Testing Program Functions Testing Station Name: Exercise: Testing Program Functions Date: Sheet 1 of 1

Verify that the Testing Station runs in the same manner as stated in the sequence description and function chart. Make adjustments accordingly.

This product was funded by a grant awarded under the Presidents High Growth Job Training Initiative as implemented by the U.S. Department of Labors Employment & Training Administration. The information contained in this product was created by a grantee organization and does not necessarily reflect the official position of the U.S. Department of Labor. All references to non-governmental companies or organizations, their services, products, or resources are offered for informational purposes and should not be construed as an endorsement by the Department of Labor. This product is copyrighted by the institution that created it and is intended for individual organizational, non-commercial use only.

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