DC-R/Copyright Festo Didactic GmbHCo. KG Principles of Mechatronics Technology Professional Development Instructor Workshop

DC-R/ Copyright Festo Didactic GmbH&Co. KG

Principles of Mechatronics TechnologyProfessional Development Instructor Workshop

www.festo-didactic.comwww.labvolt.comwww.aetlabs.com

Presented by David KempskieSenior Technology Consultant

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

http://www.labvolt.com/

http://www.aetlabs.com/


What is Mechatronics?

Mechatronics is a multidisciplinary field of

engineering that includes a combination of

mechanical engineering, electrical engineering,

telecommunications engineering, control

engineering and computer engineering.

- Wikipedia


Mechatronics is...

3

Vending Machines 3D printers

Industrial Automation

ATM Machines

Medical Devices


Manufacturing of Cars at Ford

4

x

y


Production of Cars with Industrial Robots

5

x

y

z


Automated Assembly Line

6


MecLab®

7


Air Compressor

8

Industrial Compressor ISO Symbol


4/2-Way Solenoid Valve

9

4/2-Way-Valve Monostable 4/2-Way-Valve Bistable


Single and Double Acting Cylinder

10


Proximity Switches for Pneumatical Cylinders

11

Piston with MagnetBarrel


Programmable Logic Controllers

12

0V Q1 Q2 Q3 Q4 Q5 Q6

24V I1 I2 I3 I4 I5 I6


MecLab® Station Stack Magazine

13


MecLab® Station Conveyor

14


MecLab® Station Handling

15


ACTUATORS

16


Profile Cylinder

17


Mechanical Grippers - Types

18

20°

90°90°

20°

a)

c) d)

b)


Mechanical Grippers – Working Principle

19

Housing

Gripper jaws

slider

Piston

Bearings


Vacuum Grippers – Working Principle

20

1 3

21 Supply port2 Vacuum port3 Exhaust port

Vacuum generator

Suction Cup


Inline-Type Vacuum Generator

21

P Supply portV Vacuum portR Exhaust port

P

R

V


DC-Motor – Picture and Symbol

22


Solenoid

23

+

-

+

-


CONTROL VALVES

24


One Way Flow Control Valve

25


Flow Control

26


3/2 and 4/2 Way Valve – Working Principle

27


4/2-Way-Valve - Cut-Away Drawing

28


4/2-Way-Valve – Cut Away Drawing (II)

29


CONTROLS & SENSORS

30


Electrical Switches

31

3

4

1

23

1

2

1

32

42

1

1

34

2

Normally open contact toggle switch

Normally closed contact


Relays

32

14 2412 22

11 21

124A1 A2

A1

A24

5

1

6

2 3


Pressure Switch

33

p

241

X

42

1


Optical Proximity Switches (Thru Beam)

34

Transmitter

Receiver

Transmitter Receiver

Without Object

With Object


Thru Beam Sensor - Applications

35

Standstill control in feeding units Parts detection in handling devices and transfer presses


Thru Beam Sensor – Applications (II)

36

Object detection in harsh environmentsObject detection at long distances


Optical Proximity Switches – Retro Reflective Sensor

37

S

E

S

E

Without Object

With Object

MirrorRetro-Reflective SensorTransmitter + Receiver


Retro Reflective Sensor - Applications

38

Position control of small objects IC-pins control


Optical Proximity Switches – Diffuse Sensor

39

S

E

S

E

Without Object

With Object

ObjectDiffuse SensorTransmitter + Receiver


Diffuse Sensor - Applications

40

IC-Pin inspectionRecognition of objects with different contrasts


Inductive Proximity Switches

41

core coilOscillator Magnetic Field

Without Object With Object


Inductive Sensors - Applications

42

Object Detection


Open and Closed Loop Control

43

x yProcess

ProcessControllerx y


Industry 4.0

44


Industry 4.0

45


THE AUTOMATION PYRAMID

COMMUNICATION

COMMUNICATION


AUTOMATION TECHNOLOGY by LEVELS

LEVEL 1: Field Level

• SENSORS/TRANSDUCERS• ELECTRICAL ACTUATORS• MECHANICS• PNEUMATICS• HYDRAULICS• ROBOTICS• ARTIFICIAL VISION• IDENTIFICATION SYSTEMS• COMMUNICATIONS


LEVEL 2: Control Level

• PROGRAMMABLE LOGICAL CONTROLLER (PLC)• P.I.Ds• PERSONAL COMPUTERS• FREQUENCY CONVERTER• COMMUNICATIONS



LEVEL 3: Supervision Level

• SUPERVISION , CONTROL & DATA ACQUISITION (SCADA).

• COMMUNICATIONS



LEVEL 4: Planning Level

• MANUFACTURING EXECUTION SYSTEM (M.E.S)

“To link both planning and control levels, giving answers to questions such as what information must be provided, when it is needed to provide that information, etc. With the purpose of improving and optimizing the production parameters ”

• COMMUNICATIONS



LEVEL 5: Management Level

• E. R. P. (ENTERPRISE RESOURCE PLANNING)

Integral system of handling of resources of the company (accounting, purchasing, invoicing, stocks, personnel, etc...)

• COMMUNICATIONS



The Factory – Critical Elements to Production

Manufacturing Engineering

• Design and conceive new production tools

• Develop and implement new manufacturing concepts for increased productivity

Production

• Utilize field, control and supervisor level automation methods for manufacturing of finished goods

• Implement quality assurance processes

Shipping

• Orders are grouped according to customers and/or batches

Maintenance Management

• Implement preventive maintenance on equipment

• Diagnose and repair system failures

• Sales – Orders received and processed

• Purchasing/Planning – Raw materials purchased based on anticipated orders

• Production Management – In charge of all manufacturing operations

Production Supervisor

• Dispatches orders

• Relays all critical information to upper management


Factory Network CommunicationsCOMMUNICATION

COMMUNICATION



COMMUNICATION



COMMUNICATION



COMMUNICATION



COMMUNICATION



COMMUNICATION



COMMUNICATION



COMMUNICATION


LEVEL 1: Field Level Factory Operations

• Independent, manual-operated work cells

• Field level technology devices

• Manual start/stop/selection processes

• Human intervention

• Orders processed manually

• No communications


LEVEL 1: Field Level Factory Operations

• Independent, manual-operated work cells

• Field level technology devices

• Manual start/stop/selection processes



• No communications


LEVEL 2: Control Level Factory Operations

• Independent PLC-operated work cells

• Control level technology devices

• Semi-Autonomous start/stop/selection processes



• Device layer communication


LEVEL 2: Control Level Factory Operations

• Independent PLC-operated work cells

• Control level technology devices

• Semi-Autonomous start/stop/selection processes



• Device layer communication


LEVEL 3: Supervisor Level Factory Operations

• Synchronized autonomous work cells

• Supervisory level technology devices

• Fully-Autonomous start/stop/selection processes

• Human intervention unnecessary

• Orders launched by SCADA system

• Control layer communication


LEVEL 3: Supervisor Level Factory Operations

• Synchronized autonomous work cells

• Supervisory level technology devices



• Orders launched by SCADA system

• Control layer communication


LEVEL 4 & 5: Integrated “Smart Factory” Operations

• MES and ERP integration



• Orders processed, scheduled and prioritized by Production, Sales and Purchasing management

• Information layer communications


LEVEL 4 & 5: Integrated “Smart Factory” Operations

• MES and ERP integration



• Orders processed, scheduled and prioritized by Production, Sales and Purchasing management

• Information layer communications

Documents

DC-R/Copyright Festo Didactic GmbHCo. KG Principles of Mechatronics Technology Professional Development Instructor Workshop