Mechatronics
For
Production Engineering & Industrial Systems
General System Description:
The Modular Production System stations should allow simulation of real industrial production equipment of
varying complexity. The system should be universal, industry based, modular and open to further
expansion (e.g. up-grade with industrial communication, new technologies etc).
The system should promote teamwork oriented training activities (project oriented) and develop
independence and organisational abilities of students by providing training schemes in Mechatronics.
Each station should be adaptable to suit the extent of knowledge of each student by enabling training on
simple operations and automated sequences expandable step by step to build complex automated
processes.
The system should allow use of different PLC’s by using standardised interfacing concept.
Each station should be used as a stand alone (for training of two students) or together with other station(s)
within a given configuration.
The system consists of the following stations. Sub-systems out of this must be possible.
Item
No.
Description
Qty
1
Distributing station
1
2
Testing station
1
3
Processing station
1
4
Sorting station
1
5
Training media
9
6
Accessories
22
7
Installation Commissioning and Training
1
1
SYKA
Mechatronics - Technical Specifications
Item
No.
Description
Qty
1
Distributing station
Function
The Distributing station separates workpieces. Up to 8 workpieces are stored in the
magazine tube of the stack magazine. A double-acting cylinder pushes the workpieces out
individually. The Changer module grips the separated workpiece with a vacuum gripper.
Driven by a rotary cylinder, the swivel arm of the changer moves the workpiece to the
transfer point of the downstream station.
Consisting of the following items:
1.1
Distributing station
Complete station fully assembled and tested, including the following:
- comprehensive technical documentation
- profile panel
- electrical mounting system
- stack magazine module
- changer module
- Pressure switch (differential)
- Compact valve terminal
- Start up valve with fine filter
- Station link receiver
- Light sensor
- Input/output terminals
- Fittings and accessories – profile panel connectors, tubing, cable holders, binders and
cable end sleeves
1
1.2
Trolley
The trolley is used to make the control station a compact and mobile unit. It is supplied
with lockable castors.
- Height (including castors, to bottom edge of profile plate): 750 mm
- Width: 350 mm
- Depth: 700 mm
1
1.3
Control console (with membrane keypad)
The control console is fully assembled with operating panel, communication panels,
spare panel and support frame Syslink connector.
1
Membrane keypad
- Start pushbutton with LED
- Stop pushbutton
- Reset pushbutton with LED
- Auto/Man switch (with key)
- 2 user assigned control lamps
4mm safety sockets with LED status display for simple I/O connection. Syslink and SubD sockets for connection to PLC of choice are available on the rear panel.
Expandable
If additional control or display elements are required for customized design of
information flow, ready-to-use terminal strips on the rear of the control console allow
quick and easy expansion.
2
SYKA
Mechatronics - Technical Specifications
Item
No.
1.4
Description
Qty
PLC control board with S7-300 system
- To allow separation of MPS station control and operations, an independent PLC is
used on each station
- Can be mounted or suspended directly in the trolley – easily removed from trolley and
placed on any table when working on the PLC board or for demonstration purposes
1
Supplied with
- 24v DC power supply
- PLC already assembled on control board
- Cable for connection to station
- Cable for connection to console
- Strap for connection to EMERGENCY STOP
System
- 32KB RAM for program and data
- 24 digital inputs, 24V DC maximum 400mA
- 4 analogue outputs, 11 bit, 20ms (± 10V, 0-10V, ± 20mA, 0/4-20mA)
- 1 Pt100 input
- 2 analogue outputs (± 10V, 0-10V, ± 20mA, 0/4-20mA)
Interfaces
- MPI
2
Testing station
Function
The Testing station detects the various properties of the workpieces inserted. It
differentiates workpieces with the aid of an optical and a capacitive sensor. A retroreflective sensor monitors whether the operating space is free before the workpiece is
raised with a linear cylinder. An analog sensor measures the height of the workpiece. A
linear cylinder guides correct workpieces via the upper air slide to the neighboring station.
Incorrect workpieces are rejected via the lower air slide.
Consisting of the following items:
2.1
Testing station
Complete station fully assembled and tested, including the following:
- Comprehensive technical documentation
- Profile panel
- Electrical mounting system
- Recognition module
- Raising module
- Measuring module
- Slide module
- Air slide module
- Compact valve terminal
- Start up valve with fine filter
- Station link receiver
- Light sensor
- Input/output terminals
- Fittings and accessories – profile panel connectors, tubing, cable holders, binders and
cable end sleeves
1
3
SYKA
Mechatronics - Technical Specifications
Item
No.
Description
Qty
2.2
Trolley
The trolley is used to make the control station a compact and mobile unit. It is supplied
with lockable castors.
- Height (including castors, to bottom edge of profile plate): 750 mm
- Width: 350 mm
- Depth: 700 mm
1
2.3
Control console (with membrane keypad)
The control console is fully assembled with operating panel, communication panels,
spare panel and support frame Syslink connector.
1
Membrane keypad
- Start pushbutton with LED
- Stop pushbutton
- Reset pushbutton with LED
- Auto/Man switch (with key)
- 2 user assigned control lamps
4mm safety sockets with LED status display for simple I/O connection. Syslink and SubD sockets for connection to PLC of choice are available on the rear panel.
Expandable
If additional control or display elements are required for customized design of
information flow, ready-to-use terminal strips on the rear of the control console allow
quick and easy expansion.
2.4
PLC control board with S7-300 System
- To allow separation of MPS station control and operations, an independent PLC is
used on each station
- Can be mounted or suspended directly in the trolley – easily removed from trolley and
placed on any table when working on the PLC board or for demonstration purposes
1
Supplied with
- 24v DC power supply
- PLC already assembled on control board
- Cable for connection to station
- Cable for connection to console
- Strap for connection to EMERGENCY STOP
System
- 32KB RAM for program and data
- 24 digital inputs, 24V DC maximum 400mA
- 4 analogue outputs, 11 bit, 20ms (± 10V, 0-10V, ± 20mA, 0/4-20mA)
- 1 Pt100 input
- 2 analogue outputs (± 10V, 0-10V, ± 20mA, 0/4-20mA)
Interfaces
- MPI
4
SYKA
Mechatronics - Technical Specifications
Item
No.
Description
Qty
-
3
Handling station
Function
The Handling station is equipped with a flexible two-axis handling device. Workpieces
inserted into the holder are detected by an optical diffuse sensor. The handling device
picks up the workpieces from there with the aid of a pneumatic gripper. The gripper is
equipped with an optical sensor which differentiates between “black” and “non-black”
workpieces. The workpieces can be placed on different slides according to this criterion.
Other sorting criteria can be defined if the station is combined with other stations.
Workpieces can also be transferred to a down-stream station.
Consisting of the following items:
3.1
Handling station
Complete station fully assembled and tested, including the following:
- Comprehensive technical documentation
- Profile panel
- Electrical mounting system
- Holder module
- PicAlfa module
- Slide module
- Compact valve terminal
- Start up valve with fine filter
- Station link receiver
- Light sensor
- Input/output terminals
- Fittings and accessories – profile panel connectors, tubing, cable holders, binders and
cable end sleeves
1
3.2
Trolley
The trolley is used to make the control station a compact and mobile unit. It is supplied
with lockable castors.
- Height (including castors, to bottom edge of profile plate): 750 mm
- Width: 350 mm
- Depth: 700 mm
1
3.3
Control console (with membrane keypad)
The control console is fully assembled with operating panel, communication panels,
spare panel and support frame Syslink connector.
1
Membrane keypad
- Start pushbutton with LED
- Stop pushbutton
- Reset pushbutton with LED
- Auto/Man switch (with key)
- 2 user assigned control lamps
4mm safety sockets with LED status display for simple I/O connection. Syslink and SubD sockets for connection to PLC of choice are available on the rear panel.
Expandable
If additional control or display elements are required for customized design of
information flow, ready-to-use terminal strips on the rear of the control console allow
quick and easy expansion.
5
SYKA
Mechatronics - Technical Specifications
Item
No.
3.4
Description
Qty
PLC control board with S7-313C
- To allow separation of MPS station control and operations, an independent PLC is
used on each station
- Can be mounted or suspended directly in the trolley – easily removed from trolley and
placed on any table when working on the PLC board or for demonstration purposes
1
Supplied with
- 24v DC power supply
- PLC already assembled on control board
- Cable for connection to station
- Cable for connection to console
- Strap for connection to EMERGENCY STOP
System
- 32KB RAM for program and data
- 24 digital inputs, 24V DC maximum 400mA
- 4 analogue outputs, 11 bit, 20ms (± 10V, 0-10V, ± 20mA, 0/4-20mA)
- 1 Pt100 input
- 2 analogue outputs (± 10V, 0-10V, ± 20mA, 0/4-20mA)
Interfaces
- MPI
4
Sorting station
Function
The Sorting station sorts workpieces onto three slides. Workpieces placed on the start of
the conveyor are detected by a diffuse sensor. Sensors upstream of the stopper detect the
workpiece properties (black, red, metal). Branches, which are actuated by short-stroke
cylinders via a deflector, allow sorting of workpieces onto the appropriate slides. A retroreflective sensor monitors the level of the slides.
Consisting of the following items:
6
SYKA
Mechatronics - Technical Specifications
Item
No.
Description
Qty
4.1
Sorting station
Complete station fully assembled and tested, including the following:
- Comprehensive technical documentation
- Profile panel
- Electrical mounting system
- Conveyor module
- Guide rails, sorting
- Starting current limiter
- Branch module, pneumatic
- Slide module
- Stopper module
- Diffuse sensor
- Retro-reflective sensor
- Sensor, inductive
- Compact valve terminal
- Start up valve with fine filter
- Station link receiver
- Light sensor
- Input/output terminals
- Fittings and accessories – profile panel connectors, tubing, cable holders, binders and
cable end sleeves
1
4.2
Trolley
The trolley is used to make the control station a compact and mobile unit. It is supplied
with lockable castors.
- Height (including castors, to bottom edge of profile plate): 750 mm
- Width: 350 mm
- Depth: 700 mm
1
4.3
Control console (with membrane keypad)
The control console is fully assembled with operating panel, communication panels,
spare panel and support frame Syslink connector.
1
Membrane keypad
- Start pushbutton with LED
- Stop pushbutton
- Reset pushbutton with LED
- Auto/Man switch (with key)
- 2 user assigned control lamps
4mm safety sockets with LED status display for simple I/O connection. Syslink and SubD sockets for connection to PLC of choice are available on the rear panel.
Expandable
If additional control or display elements are required for customized design of
information flow, ready-to-use terminal strips on the rear of the control console allow
quick and easy expansion.
7
SYKA
Mechatronics - Technical Specifications
Item
No.
4.4
Description
Qty
PLC control board with S7-300 System
- To allow separation of MPS station control and operations, an independent PLC is
used on each station
- Can be mounted or suspended directly in the trolley – easily removed from trolley and
placed on any table when working on the PLC board or for demonstration purposes
1
Supplied with
- 24v DC power supply
- PLC already assembled on control board
- Cable for connection to station
- Cable for connection to console
- Strap for connection to EMERGENCY STOP
System
- 32KB RAM for program and data
- 24 digital inputs, 24V DC maximum 400mA
- 4 analogue outputs, 11 bit, 20ms (± 10V, 0-10V, ± 20mA, 0/4-20mA)
- 1 Pt100 input
- 2 analogue outputs (± 10V, 0-10V, ± 20mA, 0/4-20mA)
Interfaces
- MPI
5
Training media
Consisting of the following items:
5.1
Mechatronics Training software
2
A Mechatronics Training software which should be syllabus-oriented, with structured
archive on CD-ROM in which one can easily find the documentation for the classes –
any time:
- Practice- and subject-oriented book of exercises with solutions, including for all MPS
stations
- Drawings, circuit diagrams and graphics
- Video sequences
- Presentations
- Technical documentation, operating instructions and safety notes
- Manuals and other aids
8
SYKA
Mechatronics - Technical Specifications
Item
No.
5.2
Description
Qty
4
PLC Simulation software, single licence
Professional 3D Software for simulation and programming of PLC-controlled stations of
the Modular Production System. The simulation includes
- 3D process models of all stations
- a simulation of the dynamic behaviour of pneumatic and electric actors
- realistic sensor and error simulation
- collision detection
- one virtual PLC to control the Mechatronics application
The 3D representation of the stations has 3D-CAD quality such that the student can
identify all components of the station. By mouse click notation of the electric and
pneumatic components will be displayed.
There exists a teach-modus enabling you to set single step actor movements. So you
can create a sequence of actor movements without programming.
Programming of the virtual PLC can be done by standard programming tools for Step7 .
Virtual PLC provides a powerful tool for trouble shooting your PLC program:
- Online display of single steps
- Online display of I/O status
- Setting of breakpoints
Sample programs for all process models are available.
The simulation environment should allow to define error scenarios including non
correctly adjusted sensors. This provides a very realistic training scenario for systematic
trouble-shooting and commissioning of mechatronic systems.
Online documentation about functions, learning outcomes and hints for programming
the application are provided for each station .
Using the integrated OPC server to control the model stations by the PLCSim – a SoftPLC of Siemens – or by any hardware PLC via Easyport connected to the serial port of
the PC.
5.3
PLC programming and visualization software for 12 users
contains the programming languages Statement List (STL), Function Chart (FCH) and
Ladder Diagram (LDR) (basic package) as well as STEP 7-SCL, STEP 7-HiGraph and
STEP 7-Graph. It facilitates the realisation of networked solutions with SIMATIC S7300/-400, SIMATIC C7. The trainer package also contains the S7-PLCSIM simulation
software. Using the simulation software S7-PLCSIM it is possible to carry out the
functional test of the SIMATIC S7 user blocks on PG/PC regardless of the availability of
the target hardware. Detection and elimination of program errors are therefore possible
at a much earlier stage in development. The trainer package contains 48 copies of the
STEP 7 Software for Students (120-day license). S7-PLCSIM can be used for all user
blocks and a selection of existing system functions which have been created in one of
the following programming languages: STL, LDR, FCH, STEP 7-GRAPH, STEP 7HiGraph, STEP 7-SCL. The software and documentation are supplied on CD-ROM
whilst the floating licence is supplied on disk (DE/EN/FR/ES/IT). Intended for nonindustrial users only.
5.4
Proximity sensors – Textbook (English)
1
1
9
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Mechatronics - Technical Specifications
Item
No.
Description
Qty
5.5
PLC – Baslc level Textbook (English)
1
-
6
Accessories
Consisting of the following items:
6.1
Tabletop power supply unit 24 V DC with mains cable ( local standard socket).
- Input voltage: 230/115 V AC (47 - 63 Hz)
- Output voltage: 24 V DC, short-circuit proof
- Output current: max. 4.5 A
- Connection cable: 1.3 m
- Dimensions: 115 x 155 x 200 mm
4
6.2
Workpiece set “Bodies”
- Number of workpieces: 12 (4 black, 4 red, 4 aluminium)
Dimensions as required by the offered system.
4
6.3
Simulation box, digital
The simulation box allows simulation of the input and output signals of an MPS station
or a PLC. Two types of applications are possible:
- Simulation of inputs for testing of a PLC program (need cable 034031 – order
separately)
- Setting of outputs (with separate 24v power supply) in order to operate an MPS
station (need cable 167106 – included in scope of delivery)
Simulation box contains SysLink socket
4
6.4
Simulation box, digital/analog
- Allows simulation of the input and output signals from an MPS or a PLC
- Allows simulation and display of analog signals 0 – 10 V
1
6.5
Workpiece set “Reject bodies”
- Number of workpieces: 6 (different types)
Dimensions as required by the offered system.
1
6.6
PC programming adapter
Cable for the connection of the PLC with the PC for programming with PLC
programming software SIMATIC Step 7
4
6.7
Classroom compressor - extremely quite (noise level 40 dB)
- Pressure: max. 800 kPa (8 bar)
- Free air delivery: 50 l/min
- Reservoir capacity: 25 litre
- Electric motor: 240 V/ 50 Hz; 0.34 kW
1
6.8
Compressor accessories - quick coupling socket, quick coupling plug and tubing
1
6.9
Tool set with screw drivers, allen keys and more. At least 15 different tools must be
provided.
2
7
Installation , Commissioning and Training on site at Birzeit University , for 3 days, for
training 3 persons. Including all costs, like accommodation, Flight ticket and other
related cost.
1
10
SYKA