tnpsskillsusa.org · SkillsUSA Mechatronics Virtual Project Scope of the Contest To evaluate each team’s preparation for employment and to recognize outstanding students for excellence

SkillsUSA Mechatronics Virtual Project

Scope of the Contest To evaluate each team’s preparation for employment and to recognize outstanding students for excellence and professionalism in the field of Mechatronics. Mechatronics is a career and educational discipline that combines the industrial skills of mechanics, electronics and computer-based controls with a team- oriented approach to problem solving. Skilled Mechatronic technicians are required for the maintenance, repair and operation of modern automated manufacturing systems. Knowledge Performance The contest will include a Resume, Portfolio, and Video with Oral Presentation. See SkillsUSA Virtual Technical Standards for competencies measured. Contest Information (All items must be received by due date) • PDF Resume o Upload one file with all contestant’s one-page resume’s and include the digital link(s) to Portfolio and Zoom Recording o Click link below for Resume Rubric and scoring details https://drive.google.com/file/d/1-9YpfjykXVDSCVtVEJFMHeVnrQHxYd-O/view?usp=sharing Written Submission The contestant is to create a written submission of the steps taken to complete the tasks. Upload your written submission to a cloud-based storage platform and embed the link to the file folder into your resume. Pre-recording Submission Students are to use to cameras to record the demonstration of tasks. One camera should film the team up-close and the second camera should be at a 6-10 ft distance to show the workspace the competitors are working in. The video presentation should be uploaded to a cloud-based platform. The hyperlink should be copied and embedded into the contestant’s resume for submission. Scoring Information The following pre-submission items will be judged by industry professionals prior to virtual in-person Zoom session. *See Technical Standards for specific judging criteria 1. Resume with embedded links to written submissions and video 2. Written submission of steps taken to complete the task 3. Video recording of contestants completing the tasks and narrating throughout the video Zoom Interview/Role Play You will receive a specified date/time to participate in a virtual interview/role play via Zoom with industry professionals. You should be dressed in your SkillsUSA attire for this session. You will be asked questions about your resume, and your completed tasks.

https://drive.google.com/file/d/1-9YpfjykXVDSCVtVEJFMHeVnrQHxYd-O/view?usp=sharing

Task #1: Assembly, Commissioning, and Programming of Distribution/Belt Station Time Limit 3 hours

Situation Your task is to assemble, commission and program a Distribution/Belt station. You will be given a set of documentation to build the station to. For pneumatic tubing, blue is used for extend and black is used for retract. The task is fulfilled when the station is completely assembled and commissioned according to the professional practice agreement. The system has to fulfill the specifications according to the evaluation sheet. Task Description Different workpieces (red, silver or black) are manually put into the stack magazine. Parts are able to be placed on the left side of the station, then go through the diverter arm to the right end of the station. When the part reaches the right end of the station, the Q2 light is illuminated. If there is already a part at the right end of the conveyor belt, the part placed on the belt at the left side is held by the diverter arm until cleared. If no part is present on the conveyor for five (5) seconds, the stack magazine will eject a part onto the conveyor, and it will continue to the right end of the station. The cycle continues until the stack is empty, at which point operation stops and the LED in the start button and the lamp Q1 are illuminated. It is necessary to reload the stack magazine and press the start button again before the machine starts up and cycle resumes. PLC program: Initial situation: No workpieces are on the station On power up, LED in reset button is “on” Press reset to reset machine. Part ejector on stack magazine is retracted, and the diverter arm is in its left position. If successful, LED in reset button goes “off” and green start button is lit up. Place 3 parts in

magazine

Task #2: Integrating a Pick and Place Station to the Distribution/Belt Station for workpiece transfer

Time Limit 3 hours Situation Your task is to add a partially assembled pick and place station so that a workpiece from the right side of the conveyor belt on the distribution/belt station will be picked up and the pick and place station will move the part to a stage on the pick and place station. The task is fulfilled when the station is completely assembled and commissioned according to the professional practice agreement. The system has to fulfil the specifications according to the evaluation sheet. Collisions are not allowed and will be heavily penalized.

Task Description Three pieces are placed in the stack magazine of the Distribution station. The station will move the parts to the right end of the conveyor on the distribution/belt station. The pick and place station will move each individual part from the conveyor belt to the stage on the pick and place station. The operator will remove the part from the stage on the pick and place station. The distribution station must wait for the pick and place station to finish processing a part before another part can be introduced. When the stack is empty, Q1 on the front of the panel must come on. PLC program: Initial situation: A number (3) of workpieces are in the stack.

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Station Verteilen - Band Distributing - Converyor station

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Index page Anlage / Station Seite / Page Seitenbenennung Page description Datum / Date Bearbeiter X

1 Titelblatt Title page 16.06.2015 muse

2 Inhaltsverzeichnis Index page 16.06.2015 muse

3 Aufbauplan Layout 16.06.2015 muse

4 Mini E/A-Terminal mini I/O-terminal 16.06.2015 muse

5 C-Interface C-interface 16.06.2015 muse

6 Modul Band digital conveyor module digital 16.06.2015 muse

7 Modul Stapelmagazin Stacking Magazine module 16.06.2015 muse

8 MPS® Station Verteilen - Band MPS® Distributing - Converyor station 16.06.2015 muse

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Modul Band

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x1 x1

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I0 I1 I2 I3 AI0 AI1 Q0 Q1 Q2 Q3 AQ0 AQ0

X3 24VB 24VB 24VB 24VB 24VB 24VB 24VA 24VA 24VA 24VA 24VA 24VA

X4 GND B GND B GND B GND B GND B GND B GND A GND A GND A GND A GND A GND A

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Alternative Bauform

alternative configuration

Mini E/A Terminal

mini I/O-terminal XG1

X2

X3

X4 X1

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Bit Mini E/A-Terminal mini I/O-terminal

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-G1BG1 BN

24V

-G1BG2 BN Q

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X3 -Q WH

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-G1KF1 567245

I-out

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BK A1 -G1MB2

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C-Terminal c-terminal

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BASIC CONTROLS 4-19

EXERCISE OBJECTIVE

• Connect reversing starter circuits with jogging capabilities.

DISCUSSION

Some machine tool processes require both forward and reverse jog controls. When repeated clockwise and counterclockwise inching is necessary, a jogging control circuit with a reversing starter can be implemented.

Figure 4-9 is a schematic diagram of a jogging control circuit made of a reversing starter and a control relay. This circuit can be jogged while the motor is at a standstill or is rotating in either direction.

Pressing the FWD push button starts and runs the motor in the forward direction. Pressing the REV push button runs the motor in the reverse direction. The FJOG/STOP, or RJOG/STOP, push button must be pressed to stop the motor before changing direction, due to the mechanical interlock between the two contactors.

Pressing the FJOG/STOP push button runs the motor in the forward direction. Once the push button is released, the motor stops. The RJOG/STOP push button operates in the same manner, only in the reverse direction.

4-3

REVERSING STARTERS WITH JOGGING

4-20 BASIC CONTROLS


Figure 4-9. Reversing starter circuit with push button jogging.

Many other configurations of reversing circuits with jogging can be implemented. For example, a selector switch may be utilized to switch between jogging and running modes. Such a circuit is shown in Figure 4-10 and is proposed as an additional exercise.


BASIC CONTROLS 4-21

Figure 4-10. Reversing starter circuit with selector switch jogging.

Procedure Summary

In the first part of this exercise, you will implement a reversing starter having jogging and running capabilities in both motor rotation directions. The circuit will use push buttons, as well as a control relay and a dual contactor with mechanical interlock to provide the aforementioned features. You will subsequently test the different push button combinations to verify that the circuit functions correctly.

An additional exercise is also proposed, in which you are asked to set up a comparable circuit that uses a selector switch to enable and disable jogging.


4-22 BASIC CONTROLS

EQUIPMENT REQUIRED

Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment required for this exercise.

PROCEDURE

WARNING!

The AC Power Supply provides high voltages. Do not change any AC connection with the power on.

Basic setup

G 1. Perform the Basic Setup and Lockout/Tagout procedures.

Reversing starter with jogging circuit using push buttons and a control relay

G 2. Install the Brake Motor, Inertia Wheel, and Safety Guard.

Connect the circuit shown in Figure 4-9.

G 3. Perform the Energizing procedure.

Press the FWD push button. Does the motor start and keep running?

G Yes G No

G 4. Which NO contact(s) is(are) kept closed?

G F (forward contactor) G CR (control relay) G R (reverse contactor) G None

G 5. What happens when you momentarily press the FJOG/STOP push button?

G The motor keeps running. G The motor stops and restarts. G The motor stops completely.

G 6. Does the FJOG/STOP push button act as a stop push button?

G Yes G No


BASIC CONTROLS 4-23

G 7. Press the FJOG/STOP push button. What happens to the motor while you keep the FJOG/STOP push button pressed?

G The motor starts and stops. G The motor stays off. G The motor starts and keeps running.

G 8. What happens when the FJOG/STOP push button is released?

G The motor stops. G The motor stays off. G The motor keeps running.

G 9. Does the FJOG/STOP push button act as a jog push button?

G Yes G No

G 10. Which contact(s) is(are) closed while you keep the FJOG/STOP push button pressed?

G F (forward contactor) G CR (control relay) G R (reverse contactor) G None

G 11. Explain how the control circuit operates while you keep the FJOG/STOP

push button pressed?

G 12. Repeat your observations in the reverse direction.

G 13. Make the motor run in the forward direction.

Press and hold the RJOG/STOP push button.

What happens to the motor when the RJOG/STOP push button is pressed?

G The motor keeps running in the same direction. G The motor stops completely. G The motor stops rapidly and starts in the reverse rotation direction.


4-24 BASIC CONTROLS

G 14. What happens to the motor when the RJOG/STOP push button is released?

G The motor keeps running in the same direction. G The motor comes to a stop. G The motor stops rapidly and starts in the reverse rotation direction.

G 15. Do your observations confirm that the control circuit acts as a reversing

starter having jogging and running capabilities in both motor rotation directions?

G Yes G No

G 16. Turn the individual power switch of the AC Power Supply off, disconnect the

circuit, remove the magnetic labels, and return the equipment to the storage location.

ADDITIONAL EXERCISE

Jog/Run reversing circuit using a selector switch

Your client wants you to change the control circuit of Figure 4-9 to incorporate a selector switch. He does not like the idea of having a control relay and wants the circuit to be simpler. He also wants a push button interlock permitting immediate reversal of motor rotation direction.

Finally, he would like to have a selector switch that, when turned to the JOG position, permits switching off a motor running continuously.

To fulfill the demands of the client, implement the Figure 4-10 circuit and verify that it corresponds to what the client wants.

CONCLUSION

A jogging control circuit using a reversing starter can be implemented when repeated clockwise and counterclockwise inching is necessary.

Push buttons and control relays can be utilized to set up a reversing control circuit with jogging. Using a selector switch permits employing the same push buttons for jogging and running modes.


BASIC CONTROLS 4-25

REVIEW QUESTIONS

1. In the Figure 4-9 circuit, what happens if the lead between the RJOG/STOP NC contact and the control relay coil is disconnected?

a. The control circuit acts as if the stop button was pressed. b. The FWD and REV buttons will also act as jogging buttons. c. The control relay activates and the motor runs continuously as soon as

power is applied to the circuit. d. The overload relay trips and the motor is stopped.

2. In the Figure 4-9 circuit, what happens if both jog buttons (FJOG/STOP and RJOG/STOP) are pressed simultaneously?

a. The control circuit acts as if the stop button was pressed. b. The mechanical interlock prevents the two contactors from being energized

simultaneously. c. The control relay activates and the motor runs continuously. d. The overload relay trips and the motor is stopped.

3. In the Figure 4-9 circuit, what happens if both start buttons (FWD and REV) are pressed simultaneously?

a. The motor runs continuously. b. The mechanical interlock prevents the two contactors from being energized

simultaneously. c. The control relay activates. d. All of the answers above are correct.

4. In the Figure 4-10 circuit, what happens when the selector switch is turned to the JOG position?

a. The holding circuits are closed. b. The holding circuits are opened. c. The mechanical interlock is disabled. d. The overload relay is disabled.

5. In the Figure 4-10 circuit, what happens if the emergency button is pressed?

a. The motor only runs in one direction. b. The motor only runs in JOG mode. c. The motor only runs in RUN mode. d. The whole control circuit is deactivated.


4-26 BASIC CONTROLS

Distribution/Belt Station Pneumatic Diagram

1 1

2 2

4 2

C2MB2 5 3

1

C2BG2 C2BG1

2

1 3

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02

7

03

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04

11

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Priority active

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1A

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IV

- (f) IV

1V2 2V2! 1 2V3

1M 1

1M2 2M 1 2M2 3M1

3A

3V

23 © Festo Didactic 8034662

Table of contents

1 General requirements for operating the devices 25

2 Pictograms 26

3 Use for intended purpose 26

4 For your safety 27 4.1 Important information 27 4.2 Obligations of the operating company 27 4.3 Obligations of the trainees 27 4.4 Dangers associated with the modular production system 27 4.5 Working safely 28

5 Technical data 31 5.1 General data 31 5.2 Pin allocation table 32

6 Transport, unpacking, scope of delivery 33 6.1 Transport 33 6.2 Unpacking 33 6.3 Scope of delivery 33

7 Layout 34 7.1 The Distributing/conveyor station 34 7.2 The Stacking magazine module 35 7.3 The Conveyor module 36

8 Function 37

9 Sequence description 37

10 Commissioning 38 10.1 Workstation 38 10.2 Mounting the profile plate and the control console 39 10.3 Cable connections 39 10.4 Power supply 40 10.5 Loading the PLC program 40 10.6 Starting the sequence 40

11 Maintenance and care 41

12 Further information and updates 41


Table of contents

Distributing/conveyor station


1 General requirements for operating the devices

General requirements for safe operation of the devices: • National regulations for operating electrical systems and equipment must be observed in commercial

facilities. • The laboratory or classroom must be overseen by a supervisor.

– A supervisor is a qualified electrician or a person who has been trained in electrical engineering, knows the respective safety requirements and safety regulations, and whose training has been documented accordingly.

• Maximum permissible current loads for cables and devices must not be exceeded. – Always compare the current ratings of the device, the cable and the fuse. – In the event that these are not the same, use a separate upstream fuse in order to

provide appropriate overcurrent protection. • Devices with an earth terminal must always be grounded.

– If an earth connection (green-yellow laboratory socket) is available, it must always be connected to protective earth. Protective earth must always be connected first (before voltage), and must always be disconnected last (after voltage).

• If not otherwise specified in the technical data, the device is not equipped with an integrated fuse.

The laboratory or the classroom must be equipped with the following devices: • An emergency-off device must be provided.

– At least one emergency-off device must be located within, and one outside the laboratory or the classroom.

• The laboratory or classroom must be secured so that the operating voltage and compressed air supply cannot be activated by any unauthorised persons, for example by means of: – A key switch – A lockable on-off valve

• The laboratory or classroom must be protected by residual current devices (RCDs). – Type B residual current circuit breakers with a residual current rating of ≤ 30 mA

• The laboratory or classroom must be protected by overcurrent protection devices. – Fuses or circuit breakers

• The laboratory or classroom must be overseen by a supervisor. – A supervisor is a qualified electrician or a person who has received appropriate instruction,

has knowledge of the respective safety requirements and safety regulations and whose training has been documented accordingly.

• No damaged or defective devices may be used. – Damaged devices must be barred from further use and removed from the laboratory or classroom. – Damaged connecting cables, pneumatic tubing, and hydraulic hoses represent a safety

risk and must be removed from the laboratory or classroom.



Warning Non-observance of this pictogram may result in serious personal injury or damage to property.

2 Pictograms

This document and the hardware described include warnings concerning possible hazards which may arise if the system is used incorrectly. The following pictograms are used:

3 Use for intended purpose

The stations of the Modular Production System may only be used: • For their intended purpose in teaching and training applications • When their safety functions are in flawless condition

The stations are designed in accordance with the latest technology as well as recognised safety rules. However, life and limb of the user and third parties may be endangered, and the components may be impaired if they are used incorrectly.

The learning system from Festo Didactic has been developed and produced exclusively for training and continuing vocational education in the field of automation technology. The training company and/or trainers must ensure that all trainees observe the safety precautions described in this workbook.

Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company and/or any third parties, which occur during use of the equipment sets in situations which serve any purpose other than training and/or vocational education, unless such damages have been caused by Festo Didactic due to malicious intent or gross negligence.



4 For your safety

4.1 Important information

Fundamental prerequisites for safe use and trouble-free operation of the MPS include knowledge of basic safety precautions and safety regulations. This manual includes the most important instructions for safe use of the MPS.

In particular, the safety precautions must be adhered to by all persons who work with the MPS. Beyond this, all pertinent accident prevention rules and regulations, which are applicable at the respective location of use, must be adhered to.

4.2 Obligations of the operating company

The operating company undertakes to allow only those persons to work with the MPS who: • Are familiar with the basic regulations regarding work safety and accident prevention and have been

instructed in the use of the MPS • Have read and understood the chapter concerning safety and the warnings in this manual

Personnel should be tested at regular intervals for safety-conscious work habits.

4.3 Obligations of the trainees

All persons who have been entrusted to work with the MPS undertake to complete the following steps before beginning work: • Read the chapter concerning safety and the warnings in this manual • Familiarise themselves with the basic regulations regarding work safety and accident prevention

4.4 Dangers associated with the modular production system

The MPS is laid out in accordance with the latest technology, as well as recognised safety rules. Nevertheless, life and limb of the user and third parties may be endangered, and the machine or other property may be damaged during its use.



Malfunctions which may impair safety must be eliminated immediately!

The MPS may only be used: • For its intended purpose • When its safety functions are in flawless condition

4.5 Working safely

General information • Trainees may only work with the circuits under the supervision of a trainer. • Electrical devices (e.g. power supply units, compressors and hydraulic power units) may only be

operated in training rooms which are equipped with residual current devices (RCDs). • Observe the specifications included in the technical data for the individual components, and in

particular all safety instructions! • Malfunctions which may impair safety must not be generated in the training environment, and must be

eliminated immediately. • Wear personal protective equipment (safety goggles, safety shoes) when working on circuits.

Mechanical safety • Switch off the power supply!

– Switch off the working as well as the control power before working on the circuit. – Only reach into the setup when it’s at a complete standstill. – Observe possible overruning of the drives.

• Mount all of the components securely onto the slotted profile plate. • Make sure that limit switches are not actuated from the front. • Risk of injury during troubleshooting!

Use a tool to actuate the limit switches, for example a screwdriver. • Set all components up so that activation of switches and disconnectors is not made difficult. • Follow to the instructions regarding positioning of the components.



Electrical safety • Disconnect from all sources of electrical power!

– Switch off the power supply before working on the circuit. – Please note that electrical energy may be stored in individual components.

Further information on this issue is available in the data sheets and operating instructions included with the respective components.

• Use extra-low voltage only: max. 24 V DC. • Establishing and disconnecting electrical connections

– Electrical connections may only be established in the absence of voltage. – Electrical connections may only be disconnected in the absence of voltage.

• Maximum permissible current loads for cables and devices must not be exceeded. – Always compare the current ratings of the device, the cable and the fuse. – In the event that these are not the same, use a separate upstream fuse in order to

provide appropriate overcurrent protection. • Use only connecting cables with safety plugs for electrical connections. • When laying connecting cables, make sure they are not kinked or pinched. • Do not lay cables over hot surfaces.

– Hot surfaces are identified with a corresponding warning symbol. • Make sure that connecting cables are not subjected to continuous tensile loads. • Devices with an earth terminal must always be grounded.

– If an earth connection (green-yellow laboratory socket) is available, it must always be connected to protective earth. Protective earth must always be connected first (before voltage), and must always be disconnected last (after voltage).

– Some devices have a high leakage current. These devices must be additionally grounded with a protective earth conductor.

• The device is not equipped with an integrated fuse unless specified otherwise in the technical data. • Always pull on the plug when disconnecting connecting cables; never pull the cable.



Pneumatic safety • Depressurise the system!

– Switch off the compressed air supply before working on the circuit. – Check the system with pressure measuring instruments to make sure that the entire circuit

is pressure-free. – Please note that energy may be stored in pressure reservoirs.

Further information on this issue is available in the data sheets and operating instructions included with the respective components.

• Do not exceed the maximum permissible pressure of 600 kPa (6 bar). • Do not switch on the compressed air until all tubing connections have been completed and secured. • Do not disconnect tubing while under pressure. • Do not attempt to connect tubing or push-in connectors with your hands or fingers. • Risk of injury when switching compressed air on!

Cylinders may advance and retract automatically. • Risk of accident due to advancing cylinders!

– Always position pneumatic cylinders so that the piston’s working space is unobstructed over the entire stroke range.

– Make sure that the piston rod cannot collide with any rigid components of the setup. • Risk of accident due to tubing slipping off!

– Use shortest possible tubing connections. – In the event that tubing slips off:

Switch off the compressed air supply immediately. • Pneumatic circuit setup:

Connect the devices with plastic tubing with an outside diameter of 4 or 6 mm. Push the tubing into the push-in connector as far as it will go.

• Switch off the compressed air supply before dismantling the circuit. • Dismantling the pneumatic circuit

Press the blue release ring down so that the tubing can be pulled out. • Noise due to escaping compressed air

– Noise caused by escaping compressed air may damage your hearing. Reduce noise by using silencers, or wear hearing protection if noise cannot be avoided.

– All of the exhaust ports of the components included in the equipment set are equipped with silencers. Do not remove these silencers.



5 Technical data

5.1 General data

Parameter Value

Operating pressure 600 kPa (6 bar)

Operating voltage 24 V DC, 4.5 A

Digital inputs/outputs Inputs: 6 Outputs: 4

Max. 24 V DC Max. 2 A per output Max. 4 A total

Electrical connection 24-pin IEEE 488 socket (SysLink)

Pneumatic connection Plastic tubing with 6 mm outside diameter

Compressed air consumption at 600 kPa (continuous cycling) 3 l/min

Dimensions 350 x 700 x 230 mm

Subject to change



Note Cable jumpers are connected from emergency off to bit 1.5 on all PLC variants.

5.2 Pin allocation table

Digital

Function SysLink Colour Designation

I0 13 Grey-pink Workpiece at beginning of conveyor

I1 14 Red-blue Workpiece in middle of conveyor

I2 15 White-green No workpiece at end of conveyor

I3 16 Brown-green

I4 17 White-yellow Slide retracted

I5 18 Brown-yellow Slide advanced

I6 19 White-grey Magazine empty

I7 20 Grey-brown

Q0 1 White Conveyor forward

Q1 2 Brown Conveyor reverse

Q2 3 Green Advance feed separator

Q3 4 Yellow

Q4 5 Grey Advance slide

Q5 6 Pink

Q6 7 Blue

Q7 8 Red

24 V A 9+10 Black 24 V power supply for outputs

24 V B 21+22 White-pink 24 V power supply for inputs

GND A 11 Brown-pink 0 V power supply for outputs

GND A 12 Purple 0 V power supply for outputs

GND B 23+24 White-blue 0 V power supply for inputs



6 Transport, unpacking, scope of delivery

6.1 Transport

MPS stations are delivered in a crate on a pallet. The crate may only be transported with a suitable pallet jack or forklift. The crate must be secured against tipping over and falling. The freight forwarder and Festo Didactic must be notified of any transport damage without delay.

6.2 Unpacking

Carefully remove the padding material from the crate when unpacking the station. When unpacking the station, make sure that none of its assemblies have been damaged. Examine the station for possible damage after unpacking. The freight forwarder and Festo Didactic must be notified of any damage without delay.

6.3 Scope of delivery

Check delivered items against the delivery note and the purchase order. Festo Didactic must be notified of any discrepancies without delay.



7 Layout

7.1 The Distributing/conveyor station

The Distributing/conveyor station is a feeder unit. Feeder units fulfil the function of holding, sorting and feeding workpieces. In addition, feeder units also enable workpieces to be sorted according to several characteristics (workpiece shape, weight etc.).

Feeder units include: • Magazines with separator function • Vibratory hopper conveyors • Inclined conveyors • Hoppers with feed separators

Workpieces which can be handled by feeder units include: • Electroplated parts • Moulded plastic parts • Stamped parts • Turned parts



7.2 The Stacking magazine module

The Stacking magazine module separates workpieces from a magazine. Up to 7 workpieces can be stacked in the magazine tube in any order. Up to 17 workpiece caps can be separated by turning the tube.

A light barrier underneath the magazine tube checks to determine whether or not the magazine is empty. An opto-electronic sensor can optionally be screwed into the base, which detects the caps and the workpieces. The position of the ejector cylinder is scanned electrically by proximity sensors.

The speed at which the ejector cylinder advances and retracts can be infinitely adjusted via one-way flow control valves.

A double-acting cylinder pushes the workpiece at the bottom out of the gravity-fed magazine against an external stop and positions it in the fixture. An opto-electronic sensor can be mounted on this fixture and used to detect the caps or the workpieces. This position is the transfer point to the next module.

By supplementing the module with a base, its height can be adjusted so that it can be attached directly to, for example, a conveyor module.



7.3 The Conveyor module

The Conveyor module can be mounted on a profile plate, a profile foot or a slotted mounting frame. The DC motor is freely positionable. The Conveyor module is suitable for transporting and separating workpieces with a diameter of 40 mm (e.g. “Body” or “Cylinder for assembly” workpiece sets).

The module is supplied completely assembled. The attached motor controller permits clockwise and anticlockwise rotation.

The Conveyor module is used to transport and buffer workpieces. Optical proximity switches with fibre-optic cables are used to check that workpieces are present upstream from the feed separator and at the end of the conveyor.

The conveyor belt is driven by a DC gear motor.

The workpieces can be stopped and separated by an attached electromagnet (solenoid) with separator. The end positions are monitored by inductive proximity switches.



8 Function

The Distributing/conveyor station separates workpieces stored in the magazine tube of the stacking magazine. A double-acting cylinder pushes the workpieces out one at a time. The conveyor module transports the workpiece to the right or left. If required, the workpiece can be stopped and separated on the conveyor.

9 Sequence description

Start-up prerequisites • No workpiece at the beginning of the conveyor • Magazine filled with workpieces

Initial position • Ejector cylinder retracted • Conveyor motor off

Sequence 1. When the start key is pressed, the ejector cylinder is advanced and pushes a workpiece out of the

magazine. 2. When the ejector cylinder once again reaches its retracted end-position, the conveyor motor is

switched on. 3. The workpiece is transported to the end of the conveyor. 4. The presence of the workpiece is checked at the end of the conveyor and the conveyor motor is

switched off.



Note When stations are combined, the mechanical setup as well as sensor positions and settings may have to be changed.

10 Commissioning

MPS stations are generally shipped: • Fully assembled • Individually adjusted and ready for use • Pre-commissioned • Tested

Commissioning is normally limited to visual inspection in order to ensure correct tubing connections, wiring and operating voltage supply.

All components, tubing connections and cabling are clearly identified so that all of the connections can be readily restored as required.

10.1 Workstation

You’ll need the following in order to commission the MPS station with the sample programs: • The assembled and adjusted MPS® station • A control console • A PLC board with 16 digital inputs and outputs • A power supply unit: 24 V DC, 4.5 A • Compressed air supply: 600 kPa (6 bar) • A PC with installed PLC programming software • Two I/O cables (SysLink)



10.2 Mounting the profile plate and the control console

10.3 Cable connections

1 Profile plate 2 Hammer head nut, M6-32 (4 ea.) 3 Trolley 4 Socket head screw, M6x10 (4 ea.) 5 Sheet metal screw, 3.5x9 (2 ea.) 6 Control console

1. PLC board to station If the SysLink 19" system plug module is used: connect socket A to the SysLink socket on the C interface using a SysLink cable or the SysLink socket at the station’s digital I/O terminal.

2. PLC board to control console If the SysLink 19" system plug module is used: connect socket B to the SysLink socket on the control console using a SysLink cable.

3. PLC board to power supply unit Insert the 4 mm safety plug into the socket on the power supply unit.

4. PC to PLC Connect your PC to the PLC via a programming cable.



Notes • The sequence can be stopped at any time by pressing the emergency stop button or

the STOP key. • You can select either automatic operation (AUTO) or a manual operation (MAN) of the station

with the help of the AUTO/MAN key switch. • The following applies when several stations are combined:

The individual stations are aligned against the direction of the material flow. • If there aren’t any workpieces in the stacking magazine, the MAG. EMPTY indicator lamp

lights up. Load workpieces in this case. Acknowledge by pressing the START key.

10.4 Power supply

• The stations are supplied with electrical power from a power supply unit with an output voltage of 24 V DC (max. 5 A).

• The entire station is supplied with electrical power from the rack PLC.

10.5 Loading the PLC program

Proceed as described in the user’s manuals for the programming software used in order to load the PLC program.

Current PLC programs for various controllers can be found on the Internet at the following website:

www.festo-didactic.com > Services > MPS® The Modular Production System > Stations

10.6 Starting the sequence

1. Check power supply and compressed air supply. 2. Before aligning, manually remove the workpieces from the module and station transfer points. 3. Carry out the adjustment procedure. The alignment procedure is prompted by the blinking ALIGN key

and is carried out after the key has been pressed. 4. Place a workpiece on the beginning of the conveyor. 5. Start the station’s sequence. Start-up is prompted by the illuminated START key and is executed after

the key has been pressed.

http://www.festo-didactic.com/

Note Do not use aggressive or abrasive cleaning agents.

11 Maintenance and care

The MPS® stations are largely maintenance-free. The following components should be cleaned at regular intervals with a soft, lint-free cloth or brush: • The lenses on the optical sensors, the fibre optics and the reflectors • The active surface of the proximity switch • The entire station

12 Further information and updates

Further information and updates of the technical documentation for the MPS stations is available on the following website:

www.festo-didactic.com > Services > MPS® The Modular Production System

http://www.festo-didactic.com/

SkillsUSA Mechatronics Virtual ProjectScope of the ContestKnowledge PerformanceCircuit diagramsMPS RStation Verteilen - Band Distributing - Converyor stationTitelblatt

distributing - conveyor stationVerteilen +Inhaltsverzeichnis

distributing - conveyor stationVerteilen +Aufbauplan

distributing - conveyor stationVerteilen +Mini E/A-Terminal

distributing - conveyor stationmini I/O-terminal DPJVerteilen +C-Interface

distributing - conveyor stationVerteilen +MModul Band digital

distributing - conveyor stationconveyor module digital DPJVerteilen +Modul Stapelmagazin

distributing - conveyor stationStacking Magazine module DPJVerteilen +MPS® Station Verteilen - Band

distributing - conveyor stationMPS® Distributing - Converyor station DPJVerteilen +EXERCISE OBJECTIVEDISCUSSIONProcedure SummaryEQUIPMENT REQUIREDPROCEDUREBasic setupReversing starter with jogging circuit using push buttons and a control relayADDITIONAL EXERCISECONCLUSIONREVIEW QUESTIONS

Distribution/Belt Station Pneumatic Diagram1A1V21M 12M 1Table of contents1 General requirements for operating the devices 253 Use for intended purpose 265 Technical data 316 Transport, unpacking, scope of delivery 337 Layout 348 Function 3710 Commissioning 3811 Maintenance and care 41

1 General requirements for operating the devices2 Pictograms3 Use for intended purpose4 For your safety4.1 Important information4.2 Obligations of the operating company4.3 Obligations of the trainees4.4 Dangers associated with the modular production system4.5 Working safelyMechanical safetyElectrical safetyPneumatic safety

5 Technical data5.1 General data

6 Transport, unpacking, scope of delivery6.1 Transport6.2 Unpacking6.3 Scope of delivery

7 Layout7.1 The Distributing/conveyor station7.2 The Stacking magazine module7.3 The Conveyor module

8 Function9 Sequence descriptionStart-up prerequisitesInitial positionSequence

10 Commissioning10.1 Workstation10.2 Mounting the profile plate and the control console1. PLC board to station2. PLC board to control console4. PC to PLC10.4 Power supply10.5 Loading the PLC program10.6 Starting the sequence

11 Maintenance and care12 Further information and updates

Documents

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