Meclab Getting Started Workbook

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<ul><li><p> Festo Learning Systems </p><p>MecLab Getting Started </p></li><li><p> 2008 Festo Corporation 2 U </p><p>By A. Huttner R. Pittschellis M. Klaus M. Hubsch M. Striegel T. Lust J. Schwarz Graphics: D. Schwarzenberger Layout: F. Ebel 05/2008 Editor: F. Ebel F. Zierau </p><p>Copyright 2008 This document and its contents are the property of Festo Corporation. No part of this document may be reproduced, utilized, transmitted or disclosed in any form or by any means without prior written consent of Festo Corporation </p><p>Festo Corporation 395 Moreland Rd. Hauppauge, NY, USA 11788 </p></li><li><p> 2008 Festo Corporation 3 U </p><p>Table of Contents Introduction 4 Course Objectives 5 Safety 6 Training Systems Operations 7 Overview 9 Commissioning 14 Sample Programs 15 Safety and Maintenance 16 Stack Magazine Station 18 Conveyor Station 40 Handling Station 56 Lesson Planning 77 Projects 86 </p></li><li><p> 2008 Festo Corporation 4 U </p><p>Introduction This workbook contains both information and exercises designed to introduce the student to basic automated systems components commonly used in industry. The information is intended for use in a mechatronics environment and is aimed at supporting continued education in industrial automation. The topics cover basic components used in in-dustrial automation. It also provides exercises for developing pneumatic and electrical sche-matics using FluidSim-P software. Overall the topics are intended to prepare the student to study more advanced systems. </p></li><li><p> 2008 Festo Corporation 5 U </p><p>Course Objectives Upon completion of the exercises in this workbook, the student will be able to: Identify machines and their function in a process. Familiarization with industrial components. Familiarization with industrial component symbols and designations. Understand the term sequence of operations. Become familiar with pneumatic and electrical schematics. Understand control of linear actuators. Understand principles of relays. Understand limit switches. </p></li><li><p> 2008 Festo Corporation 6 U </p><p>Safety * Due to the potential hazards in any automated system, good safety practices are important in the classroom, as well as on the production floor. Students should never be allowed to place their hands on or near the system while operating. Safety glasses should be worn around the equipment during operation. </p><p> *See also page 7, Operation of the Festo Training System, for additional safety considerations. </p><p>All information in this workbook is intended for educational use only. It has been carefully compiled and checked, and we believe the material to be accu-rately presented. However, Festo Corporation assumes no responsibility for published technical errors. Additionally, Festo Corporation assumes no re-sponsibility for the safe and/or satisfactory operation of any machine. </p><p>All information in this workbook is intended for educational use only. It has been carefully compiled and checked, and we believe the material to be accu-rately presented. However, Festo Corporation assumes no responsibility for published technical errors. Additionally, Festo Corporation assumes no re-sponsibility for the safe and/or satisfactory operation of any machine. </p></li><li><p> 2008 Festo Corporation 7 U </p><p>Operation of the Festo Training System </p><p>Festo training systems have been designed for ease of use by both the student and the in-structor. Compressed air should be handled with respect. Care should be taken to ensure that com-pressed air is not directed at open cuts or against the skin, since serious physical damage and/or dangerous embolism may result. Compressed air should be applied to the service unit at the port next to the regulator/filter. Air service for the automated system is drawn from the right side of the service unit. The ser-vice unit is fitted with a normally closed 3/2 directional control valve with a red knob. The valve is opened to provide air to the manifold by moving the knob in line with the direction of airflow. All connections should be made with this switch turned off. All pneumatic components are fitted with quick-connect air line fittings. Tubing to be con-nected to these fittings should be cut squarely. Tubing is pushed into the fitting until a resis-tance is felt; this is a metal ring. The tubing is pressed further until it stops. The tubing is then checked by pulling gently back on the tubing. Leaks at the quick-connect fittings may sometimes be traced to failure to fully set the tubing in the fitting. Another common cause of air leaks may be a tubing end not cut at a shallow angle or tubing, which has become worn and ragged through use. These tubing faults may be corrected by cutting a short section from the end of the tubing to expose a fresh surface. The instructor should check the connections on the circuits to ensure that the tubing is se-cured properly before the circuits are pressurized. Compressed air escaping to atmosphere from a loose and uncontrolled tube will cause the tube to whip, therefore safety glasses should be worn whenever students or instructors are working or observing any of the auto-mated systems. </p></li><li><p> 2008 Festo Corporation 8 U </p></li><li><p> 2008 Festo Corporation 9 U </p><p>Getting Started with Festo MecLab </p><p>Overview Automation technology has become increasingly important in engineering. It helps to im-prove both working and living conditions by ensuring high productivity and quality while at the same time satisfying the ever-growing need for technological know-how. Automation technology combines knowledge from virtually all other technical sciences. This interdisciplinary field could not have developed without the fundamentals of electrical, me-chanical and process engineering as well as information technology to name just a few. We see and use automated technical systems every day. Escalators, automatic doors and ATMs. At the supermarket, our groceries are move by conveyors which seem to know ex-actly when to stop. In this sense, automation technology is everywhere. Everyone is regularly confronted by something that can be classified as an automated system. Thus technical education must emphasize this technology in order to keep up with the demand for skilled workers. Training should include: Overview of automated systems. Developing skills in the use of automated systems. Developing skills in the commissioning and maintenance of automated technical systems. In addition, training must be designed so that students are given the opportunity to work with technology, investigate its effects and discover their own capabilities. Automation technology is one of the most challenging subjects because of its complexity. It can not be taught through lectures alone. Students must be given hands-on practice with automated technical systems in order to observe and understand how subsystems and com-ponents interact. They must be able to disassemble and assemble a system. MecLab, developed by Festo Learning Systems, includes a stack magazine, a conveyor and a handling station. These simulate parts of an automated production line. It is designed to familiarize students with automated technical systems. </p></li><li><p> 2008 Festo Corporation 10 U </p><p>Getting Started with Festo MecLab </p><p>Overview MecLab is a modular multimedia teaching and learning system. It is supplemented with: Computer software Video Technical drawings Diagrams The combination of theory and practice is an essential aspect of MecLab and its compo-nents. For every theory related to engineering sciences, there is a corresponding applica-tion. The connection between theory and practice will encourage students to put in to practice what they have learned. Additionally students can learn how to analyze practical applications to prove a theory. Individuals do not acquire a skill by simply listening to a description of the skills, rather they learn by doing. It is in the doing where problem solving skills are developed. Theory and practical applications of automation technology can be addressed with Me-cLab, including: Types of control systems. Fundamentals of sensors. The link between sensors and drives in automated systems. Basic logic functions. Basics of programming automated systems. MecLab is intended for use in technically-oriented subjects. Basic knowledge of production engineering, mechanical engineering, electrical engineering and information technology is helpful, but not essential. Basic knowledge, such as physical fundamentals of drive and sen-sor technology, relays or logic operations can be learned with the help of the appropriate theory section as well as the exercises. The focus, however, should be less on teaching fun-damentals than on applying them. </p></li><li><p> 2008 Festo Corporation 11 U </p><p>Getting Started with Festo MecLab </p><p>Overview The MecLab learning system consists of three stations that carry out the following func-tions: Storage and separating Transporting (conveying) Handling. These three processes are typical for all automated production. Figure 2.1 shows a production line that manufactures formed sheet metal parts. The material is transported by means of a roller conveyor (3) to the machining stations (1, 2, 7), where it is shaped. The first robot (4) places the sheets from the conveyor into a magazine (5 storage), the second robot (6) takes the sheets from the magazine and feeds them to the third machin-ing station (7) (handling and separating functions). </p><p>Figure 2.1: Automated manufacture of bent sheet metal parts </p></li><li><p> 2008 Festo Corporation 12 U </p><p>Getting Started with Festo MecLab </p><p>Overview The MecLab stations perform the following functions: Stack magazine station: Stores and separates work pieces. An additional function, either stamping or insertion, can be performed by the stamping unit. Conveyor station: Transports work pieces. An additional function, sorting or rejection, can be performed by the ejecting solenoid. Handling station: Transfers work pieces between two points which can not be covered by conveyor. The function of each station can be modified by adding or removing components. For exam-ple if the ejecting solenoid is removed from the conveyor station, it can still convey but no longer sort. If the solenoid is moved from one side of the conveyor to the other, the deflector becomes a stopper. Stations are controlled using FluidSIM simulation and control program in combination with a modified EasyPort. This allows FluidSIM to read sensor signals from the stations and to ac-tuate the drives of each station. It is also used to connect the stations with the USB interface of the PC. The software contains sample programs designed to help the student get started with pro-gramming. Since the Meclab system is made of industrial components, it is also possible to perform manual override operations. Students are encouraged to use the provided tools to disassemble and reassemble the sta-tions. The stations can be used independently or joined together to form a production line. </p></li><li><p> 2008 Festo Corporation 13 U </p><p>Getting Started with Festo MecLab </p><p>Overview The Meclab system consists of the following: 1 compressor for supplying the stations with compressed air 6 licenses of FluidSIM for MECLAB simulation and control program 3 modified EasyPorts for connecting the stations to a PC 3 power supply units for supplying power to the EasyPort 3 sets of workpieces 3 sets of tools and small parts All instruction material (e.g. this book) on CD-ROM The following information can be found on the supplied CD-ROM: Introduction: Teaching with Meclab (this document) Instructions for commissioning the three stations Theory section: Explains key technologies, components and other relevant information Exercise sheets: Designed to assist the student in becoming familiar with automated sys-</p><p>tems , relevant technologies and project planning PowerPoint presentation </p></li><li><p> 2008 Festo Corporation 14 U </p><p>Getting Started with Festo MecLab </p><p>Commissioning Install FluidSIM The FluidSIM simulation and control program must be installed on a computer which has a CD-ROM drive as well as a USB interface (version 1.1 or higher). To install FluidSIM, insert the enclosed CD-ROM, open the FluidSIM directory, double-click on the "setup.exe" file and follow the installation instructions. Assemble the stations MecLab stations are delivered assembled. To commission a station, perform the following steps: Insert the EasyPort interface module (1) to the Sub-D socket on the multi-pin plug distribu-</p><p>tor (2). Connect power supply unit to the EasyPort (3). Connect EasyPort to the PC using the USB cable (4) provided. Launch FluidSIM: Click on "Open file" Open a sample program (see table below). Start operating the program sample program by clicking on the start arrow on the tool bar </p><p>at the top of the screen. </p><p>Figure 3.1: Connecting the EasyPort </p></li><li><p> 2008 Festo Corporation 15 U </p><p>Program Station Function </p><p>1-4.ct </p><p>Stack magazine </p><p>Manually activate single-acting cylinders </p><p>1-5.ct </p><p>Stack magazine </p><p>Manually activate double-acting cylinders </p><p>1-7.ct </p><p>Stack magazine </p><p>Separate and press lids onto containers (automatic) </p><p>2-5a.ct </p><p>Conveyor </p><p>Activate conveyor by means of a through-beam sensor </p><p>2-7.ct Conveyor </p><p>Activate conveyor by means of a through-beam sensor. Sort metal work pieces and de-activate the conveyor after 5 seconds. </p><p>2-8.ct </p><p>Conveyor Activate conveyor by means of a through-beam sensor. Sort metal work pieces and de-activate the conveyor after 5 seconds . Manually reverse conveyor direction. </p><p>DC MOTOR RELAY. ct </p><p>Conveyor Manually activate/deactivate conveyor. Reverse conveyor di-rection. </p><p>3-4.ct Handling Manually advance z axis 3-6.ct Handling Automatically advance z axis in continuous operation. 3-7.ct </p><p>Handling Automatically reposition work piece from rear to the front storage plate. </p><p>Getting Started with Festo MecLab </p><p>Sample Programs The FluidSim software contains sample programs to help the Instructor and the student get started in programming the MecLab stations. These samples are located in the ct file\MecLab Samples. Use these files to become familiar with how the softwar...</p></li></ul>

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