Mechatronic Compact System for PLC: Material control with quality inspection

E6.7.2.8
Mechatronic Compact System for PLC:  Material control with quality inspection

System
The MCS (Mechatronic Compact System) is comprised of   four individual systems, each with a basic mechatronic function. Connecting the systems determines the interaction of mechanics, pneumatics, electronics, and SPC programming.

Educational objectives

• Recognition of different materials (sensors)
• Mechanical construction of a testing station
• Programming a test procedure   
• Mechanical construction of a  swivelling object-transfer device
• Programming of a  swivelling object-transfer device
• Mechanical construction of a  measurement process
• Programming of a  measurement process with analog sensor 
• Mechanical construction of a sorting station with 3 tracks
• Programming of a sorting station with 3 tracks  

Design
The setup includes five models:

• gravitiy feed magazin with testing unit:  Workpieces are provided seperatly by a gravity feed magazine. The filling level and the workingpiece in tray is supervised with photo sensors and micro switches.The material property of workpieces is checked with optical and inductiv sensors.
• Swivelling Object-Transfer Device : Transfers workpieces between two modules with defined material transfer points. A pneumatic swivel drive, infinitely adjustable up to 180°, conveys the workpieces with a vacuum gripper.
• Height measurement: Measures the height of the workpieces and processes the analog value so that workpieces with unacceptable height are sorted out.
• Sorting Station with three tracks: Workpieces are guided past three chutes by a linear system with speed controller. A traveling pneumatic output unit conveys the workpieces to the chutes according to material type. The filling level of the chutes is monitored by a light barrier.

Method
The device is designed for student experiments. Practical exercises require that the learner resolve the controller or system problem with their own programming and using mechanical configurations. The basics of SPC programming and a understanding of production processes are required prior knowledge.

Target Group
Trainees studying industrial business and students of automation engineering are the target group being addressed. The course offers experiments for intermediate learners for trade school and bachelor training.

Topics

• Programs for process control
• Creation of sequential controls
• Differentiation of manual and automatic functions in programs.
• Plans for driving pneumatic valves.
• Collision-proof provision on a tray
• Micro switch for position recognition
• One-way photoelectric barrier
• Optical sensor
• Inductive sensor
• Positioning of the micro switch
• Electric drives
• Limit switch with micro switch
• Reversing contact control
• Analog sensor
• Analog values in PLC