Festo MecLab Getting Started

F

esto Learning Systems

Getting Star

MecLab

ted

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

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

Festo Corporation 395 Moreland Rd. Hauppauge, NY, USA 11788

Table of Contents

I

ntroduction

4

C

ourse Objectives

5

S

afety

6

raining Systems Operations 7

T

verview 9

O

ommissioning 14

C

Sample Programs 15

S

afety and Maintenance 16

Stac

k Magazine Station 18

onveyor Station 40

C

andling Station 56

H

esson Planning 77

L

P

rojects 86

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 industrial automation. It also provides exercises for developing pneumatic and electrical schematics using FluidSim-P software. Overall the topics are intended to prepare the student to study more advanced systems.

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.

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.

All information in this workbook is intended for educational use only. It has

been carefully compiled and checked, and we beli

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.

eve the material to be accu-

*See also page 7, “Operation of the Festo Training System,” for additional safety considerations.

Operation of the Festo Training System

Festo training systems have been designed for ease of use by both the student and the instructor.

Compressed air should be handled with respect. Care should be taken to ensure that compressed 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 service 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 connected to these fittings should be cut squarely. Tubing is pushed into the fitting until a resistance 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 secured 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 automated systems.

Getting Started with Festo MecLab Overview

Automation technology has become increasingly important in engineering. It helps to improve 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, mechanical 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” exactly 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 components 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.

Getting Started with Festo MecLab 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 components. For every theory related to engineering sciences, there is a corresponding application.

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 MecLab®, 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 sensor 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 fundamentals than on applying them.

Getting Started with Festo MecLab Overview

The MecLab® learning system consists of three stations that carry out the following functions:

− 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 machining station (7) (handling and separating functions).

Figure 2.1: Automated manufacture of bent sheet metal parts

Getting Started with Festo MecLab 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 example 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 actuate 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 programming. 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 stations. The stations can be used independently or joined together to form a production line.

Getting Started with Festo MecLab 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-

tems , relevant technologies and project planning

− PowerPoint presentation

Getting Started with Festo MecLab 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 distributor (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

at the top of the screen.

Figure 3.1: Connecting the EasyPort

Getting Started with Festo MecLab 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 software and the hardware operate.

CAUTION: Any changes to the sample circuits, if saved, will change the sample program. Save the file under a different name.

Program Station Function

1-4.ct

1-5.ct

1-7.ct

2-5a.ct

2-7.ct Conveyor Activate conveyor by means of a through-beam sensor.

2-8.ct

DC MOTOR RELAY. ct

3-4.ct Handling Manually advance “z” axis

Stack magazine

Manually activate single-acting cylinders

Stack magazine

Manually activate double-acting cylinders

Stack

Separate and press lids onto containers (automatic)

magazine

Conveyor Activate conveyor by means of a through-beam sensor

Sort metal work pieces and de-activate the conveyor after 5 seconds.

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.

Conveyor Manually activate/deactivate conveyor. Reverse conveyor di-

rection.

3-6.ct Handling Automatically advance “z” axis in continuous operation. 3-7.ct

Handling Automatically reposition work piece from rear to the front

storage plate.

Getting Started with Festo MecLab Safety and Maintenance

MecLab® has been designed in compliance with all relevant safety guidelines. As with all technical systems, there is additional safety information that must be observed.

General

Students must be supervised at all times when working on the stations. Read Data sheets and note individual station safety information.

Electrical components

Electrical power must be disconnected before making or breaking electrical connections. Use only extra low voltages (max. 24 V DC).

Pneumatic components

− Do not exceed 60 psi (4 bar).

− Do not turn on compressed air until all tubing connections have been established and se-

cured.

− Do not uncouple tubing under pressure.

− Be alert for “pinch points” when switching on compressed air as cylinders can automati-

cally extend or retract.

− Loose tubing can “whip” rapidly causing serious eye injury. Ensure that “main air” is turned off before disconnecting or connecting tubing.

− Always wear safety goggles when working on or near the system.

− Select tubing length that will provide the shortest connection between two ports.

Pneumatic circuit assembly:

− Connect devices using plastic tubing with an outside diameter of either 4 or 6 mm (whichever is appropriate)

− Push the tubing as far as possible into the push-in connector.

Getting Started with Festo MecLab Safety and Maintenance

Pneumatic circuit disassembly:

− Switch off the compressed air supply before disassembling the circuit.

− Press down on the blue release ring to pull out the tubing.

Compressor

Air pressure can be regulated at the compressor:

− Pull out the rotary knob on the pressure regulator and turn until pressure gauge shows the required pressure.

− Push rotary knob back in (this locks the regulator).

− Do not touch the compressor once started as it can become extremely hot during opera-

tion.

− After switching off the compressor, release the pressure from the compressor tank.

− Do not leave the compressor running uninterrupted for more than one hour.

Mechanical components

− Install all components securely on the plate.

− Do not place your hand in the station while it is running.

Maintenance information

MecLab® is essentially maintenance-free. Wipe occasionally with a dry, lint free rag.

Water must be drained from the compressor tank or water separator (at the regulator) at regular intervals.

Inspect compressor tank regularly for damage.

Getting Started with Festo MecLab Stack Magazine Station

Virtually all automated production requires the temporary storage of raw material, semifinished product or finished product. Often the material is kept on pallets or in warehouses. At some point the material (or parts) will be brought to the production line. It is here that the work pieces must be organized in such a way that they can be fed into the production process as quickly and efficiently as possible.

Many small parts such as screws, nuts or springs are supplied in bulk and have to be arranged before they can be processed. Vibration feeders (Figure 4.1) are often used for this. The high-speed vibrations move the small parts into either a “gate” or a vision system that only let correctly aligned parts through and then on to the production process.

Figure 4.1: Vibration feeder for storing and sorting screws

Getting Started with Festo MecLab Stack Magazine Station

Delicate work pieces are generally supplied in an organized manner. Smaller work pieces are often stored on tape while larger work pieces are stored on pallets (Figure 4.2 shows integrated circuits (ICs) on a pallet, normally called a tray in the electronics industry).

Figure 4.2: ICs on a pallet

The stack magazine is one of the simplest ways to store work pieces in an organized manner. In production systems, the components are delivered in tube magazines. This means the stack magazines can be filled quickly.

Besides storing and separating, the stack magazine station also contains a "pressing” function: when a container is placed on the deposit table, a lid can be pushed out from the stack magazine and then pressed closed by the second pneumatic cylinder.

In addition to the electro mechanical content, the stack magazine station can also be used as an introduction to "pneumatics".

As with the conveyor and the handling system, the FluidSIM® software is used to control the stack magazine. Students can learn about the structure and function of programs used to control automated production sequences.

Getting Started with Festo MecLab Stack Magazine Station

Although not necessary, a basic knowledge of CAD/CAM programs is helpful when using the FluidSIM software. The software, in turn, can be useful in learning:

− The function of simple electro-pneumatic circuits.

− The operation of common application programs.

− The sequence of production processes.

− The basics of pneumatics.

Stack Magazine Station Components

The stack magazine station consists of components that can be used on their own or combined, depending on the task. The system was designed for flexibility in order to meet varying requirements. All necessary tools are provided with the system.

Figure 4.3: Complete structure of the Stack magazine station

Getting Started with Festo MecLab Stack Magazine Station

The following table lists the most important components of the Stack magazine station together with their circuit symbol.

Component Symbol Function

Mounting kit for proximity

sensors

Magnetic proximity sensor for detecting the position of the cylinder piston

3/2-way stop valve used for shutting off the compressed air and exhausting system.

T-connector for distributing the compressed air

Single-acting cylinder with 50 mm stroke and 10 mm piston diameter

Double-acting cylinder with 50 mm stroke and 10 mm piston diameter

One-way flow control valve, used to regulate the speed of pneumatic actuators

Getting Started with Festo MecLab Stack Magazine Station

Component Symbol Function

4/2-way solenoid valve, with pneumatic spring

4/2-wa

Multi-pin plug distributor for connecting the electrical components

return

y double solenoid valve

Getting Started with Festo MecLab Stack Magazine Station

Assembly and Wiring

Several lessons require the student to disassemble and then reassemble the system. Follow the instructions in this section.

An aluminum profile plate is used as a base in order to mount the components of the stack magazine. T-nuts are used to secure the components to the plate. The tool used for assembling and disassembling are an adjustable wrench and a hex head, or Allen key.

Use the screwdriver to adjust the one-way flow control valves. Pneumatic tubing can be cut to the correct length using the tubing cutter. Do not use scissors or knives to cut the tubing as this can result in leaks.

The station contains a single-acting cylinder (press), a double-acting cylinder (ejector) and a 4/2-way single solenoid valve that are plumbed and wired. There is a second valve (double solenoid) as well as a “reed” switch (magnetic proximity sensor) that must be plumbed and wired. The instructions are listed on page 22.

Figure 4.4: Stack magazine station

Getting Started with Festo MecLab Stack Magazine Station

Assembling the 4/2-way double solenoid valve

1. Shut off compressed air supply and electrical power.

2. Loosen the retaining screws that connect the valve to the valve retainer.

3. Remove the two short screws and replace with the longer screws.

4. Screw down the two valves using the longer screws.

5. Install tubing between outputs 2 and 4 of the valve and the corresponding ports on the double-acting cylinder. Use the tube cutter to cut the tubing.

5a. Port 2 is connected to the front cylinder chamber. 5b. Port 4 is connected to the rear cylinder chamber.

6. Connect the valve to the multi-pin plug distributor.

6a. Connect valve solenoid 1M1 to slot # 3. 6b. Connect valve solenoid 1M2 to slot # 5.

Figure 4.5: Assembling the second valve

Getting Started with Festo MecLab Stack Magazine Station

It is also possible to install a sensor for checking the end position of the double acting cylinder. This ensures that the overall sequence is monitored and enables the next step in the sequence.

The sensor is installed by placing the mounting kit for proximity sensors around the cylinder body and securing it using the screw provided. The sensor is then inserted in the retainer and carefully secured by turning the socket head screw half a rotation.

Figure 4.6: Proximity sensor on the cylinder

In order to establish a connection between the computer and the individual components, the sensor must be connected to the multi-pin plug distributor.

The cables for the valves are connected to the row labeled with uneven numbers on the multipin distributor. These are “inputs” from the “control system” which is the FluidSIM software. The cables for the sensors are connected to the row labeled with even numbers. These are “outputs” to the “control system”.

Getting Started with Festo MecLab Stack Magazine Station

Converting the 4/2-way solenoid valve

This shows normal use of a 4/2 directional control to contr cylinder. All (1,2,3 and 4).

ol a double acting

ports are used

valve

This shows a 4/2 directional control valve to function a tional contr (normall port 2 is plugged.

reconfigured

s a 3/2 direc-

ol valve

y closed). Note that

Figure 4.7: Converting a 4/2-way single solenoid valve

This shows a 4/2 directional control valve to function a tional contr (normall port 4 is plugged.

reconfigured

s a 3/2 direc-

ol valve

y open). Note that

Getting Started with Festo MecLab Stack Magazine Station

a) 4/2-way solenoid valve (normal use in combination with a double-acting cylinder)

b) 3/2-way solenoid valve normally closed (in combination with a single-acting cylinder; port 2 is “plugged”)

c) 3/2-way solenoid valve, normally open (in combination with a single-acting cylinder; port 4 is “plugged”, the cylinder is advanced in the switching position shown)

The station contains two valves they are both 4/2-way directional control valves. This means that they each have 4 ports and 2 positions. The difference is in how the valves are actuated. One valve is actuated by means of single solenoid the other is actuated by means of two solenoids.

The 4/2-way valve can be converted to a 3/2-way valve by sealing one of the two outputs.

The decision to seal one of the two output ports should be made after deciding which type of valve is desired, normally closed or normally open.

The 4/2-way single solenoid valve is supplied with output 4 sealed, producing a 3/2-way normally closed valve. In this configuration the valve can be used to activate the single-acting cylinder (stamping cylinder).

Opening output 4 produces a 4/2-way valve for actuating the double-acting cylinder.

Sealing output 2 produces a 3/2-way normally open valve. If this valve is used, the single acting cylinder will extend when the valve is not actuated and retract when the valve is actuated.

Festo MecLab Getting Started

Specifications and Main Features

Frequently Asked Questions

User Manual