Conveyor station. Ruggeveldlaan Deurne tel

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1 Conveyor station

2 Introduction and didactic background In the age of knowledge, automation technology is gaining increasing importance as a key division of engineering sciences. As a technical/scientific achievement, it is an expression of creative thoughts and actions of engineers and natural scientists. Automation technology brings about lasting changes to the working and living conditions of people by ensuring high productivity and consistent product quality while at the same time satisfying people's ever- growing need for technological know- how. This applies as much to people s professional as to their private lives. As a technical area of science, automation technology combines knowledge from virtually all other technical sciences. Such an intensely interdisciplinary field of study could scarcely have developed to the extent it has without scientific fundamentals from electrical engineering, mechanical engineering, process engineering and information technology to name just a few. People of all age groups come face- to- face with automated technical systems every day. They use escalators, wait for automatic doors to open, see their groceries move along conveyors at the supermarket and operate automated teller machines. Automation technology, in this sense, is everywhere. Everyone, in every aspect of their lives, is regularly confronted, either directly or indirectly, with the purposeful selection and use as well as the evaluation and assessment of automated systems. The objectives of future- oriented, general technical education must therefore be more strongly geared towards this technology than in the past. Specific objectives are: - Promoting implicit and explicit knowledge of automated systems, - - developing skills and promoting abilities in the use of automated systems, Consolidating abilities with regard to appropriate selection, operational commissioning and careful maintenance of automated technical systems. It is precisely the complexity of automation technology that makes determining the educational content for general pre- vocational technology education difficult yet important. Innovations, essential to every economy, first and foremost require the creativity of technically educated people who have a flexible and above all positive approach to constantly evolving technology. This gives rise to special requirements for general education in technology. It must consist of and provide the content that helps students to understand and deal with technology. People are expected to adapt quickly to the constantly changing conditions of the professional and working world and to acquire the appropriate competencies. For most people, this is only addressed during vocational training. Basic attitudes, however, are created and acquired much earlier. Consequently, general technical studies as well as technological education as part of work studies or interdisciplinary projects is particularly important. Modern didactics always start from the students' current stage of development and ensure they progress from there. Automation technology is one of the most challenging academically since it forms a very complex subject matter within the technology curriculum of a general school system. It can't be taught and learned solely through lectures by a teacher and multimedia lesson units. Involving experts in class work or going on factory tours as a "bridge to practice" is also insufficient. Instead, students must be offered the opportunity to get hands- on practice with automated technical systems, to observe and understand how subsystems and components interact and to be able to assemble and disassemble them. It's all about learning through experience with all the senses. Complex models can be used in the lesson to

3 this end as enactive, i.e. realistic, media. They convey information, represent reality, are communication tools and enable active autonomous and co- operative learning. Models bring every day practice into the classroom. The MecLab is a learning system developed by Festo Didactic, with its stacking magazine, conveyor and handling subsystems, simulates automation practice; its aim is to familiarise students with automated technical systems. Its focus on learning objectives means it can be called a learning media system. Its three subsystems (stacking magazine, conveyor, handling) are separate but can also be used in combination and can thus be seen as an example of learning media complexes. They combine reproductive learning about a disassembly object with productive learning about a production object. The modules can be used to design models, where the focus is on synthesis. Models that can be dismantled and adapted to different requirements by the students through conversion and modification, as is the case in the MecLab system, can be used for both analysing the component parts of a technical system and re- integrating those parts and trace them back to a coherent unit. Linking of theory and practice is an essential aspect of MecLab and its components. Students learn about the practical applications of theories and learn their value as individual statements and statement systems, hypotheses, theses, premises, principles, rules and laws, and therefore will be able to appreciate why they are important. For every theory related to engineering sciences, there is a corresponding application. Generally speaking, practice is the application of technology. Links between theory and practice can, on the one hand, lead students to practise what they have learned by studying the theory and, on the other, to analyse practical applications to prove the theoretical fundamentals on which they are based. These links can be methodically constructed in a number of ways. What's important is that students don't learn about practice just through descriptions or pictures, but internalise and experience it as genuine practice or its equivalent and in so doing exercise their problem- solving skills.

4 Technical significance Conveyor station Conveyors are technical systems that are used in the professional and working world for, among others, the production of material goods in industry, in construction and in agriculture. Conveyors are also hugely important in day- to- day life. Retailers not only use conveyors for merchandise, for example at cash tills in supermarkets, but also in the form of escalators for effortless conveyance of their customers. In stations and airports, they carry passengers through the ever expanding terminals. Their development went hand in hand with industrialisation. In the beginning, animal or human muscle power was used to drive conveyors. Later electric motors were used, and are still used to this day thanks to their many advantages. The introduction of conveyors revolutionised industrial production. It's impossible in this context not to mention Henry Ford, who, in 1913, pioneered an entirely new method of labour organisation with the development of the assembly line and its use in automobile production. The technology of the assembly line as created by Henry Ford has long since been overhauled to become what it is today. Where at one time manual labour required the continuous presence of workers, these days computer- controlled systems are taking over this role. Digital technology is constantly opening up new perspectives for automation. Automated systems are being used more and more for sometimes heavy and also monotonous manual labour. Despite its clearness and transparency, from a technical point of view the conveyor station is a challenging electromechanical lesson medium that can be flexibility adapted to a range of requirements. Complete structure of the conveyor station

5 Components of the conveyor station The following table lists the most important components of the conveyor station together with their circuit symbol.

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7 Assembly and wiring MecLab is already assembled. The purpose is to connect MecLab to a PLC or LOGO via a Multi- pin plug connection DB15. See attachments for technical data concerning the Multi- pin connection. The station can be converted in order to fulfil different tasks. The function is primarily determined by the position of the sensors and the solenoid: - The solenoid can act as a stopper or deflector (which rejects workpieces onto the slide, for example) depending on which side of the conveyor it is mounted. - The through- beam sensor reacts to all workpieces, while the inductive sensor only reacts to metal workpieces. This enables specific actions to be triggered all the time or only with metal workpieces or only with non- metal workpieces (e.g. starting or stopping the belt motor, triggering the solenoid). Preparation The assignment starts by trying to find out which in- and outputs are connected to the Multi- plug in connection. Once these links are found, we are able to generate connections based upon the technical data of the Multi- plug in connection (see attachment) and a custom made addressing table. Correct wiring of the actuators and sensors must be ensured in order for the process to work correctly. Aids FluidSIM Conveyor station LogoSoft Learning objectives Upon completing this exercise, you should - be able to select the components of an electropneumatic circuit - be able to design electropneumatic circuits - be able to control a single- acting cylinder using LogoSoft - be able to interpret schematic diagrams, allocation lists and circuit diagrams - be able to control a double- acting cylinder using LogoSoft - be familiar with the function of one- way flow control valves - be familiar with the mode of operation and fields of application of relays - be able to create simple control systems using LogoSoft - be able to realise logic operations using LogoSoft - be able to realise circuits using time LogoSoft - be familiar with the function of inductive and opto sensors - be able to realise control circuits using sensors - be able to realise simple control systems using LogoSoft

8 Problem description 1 Generally speaking, the DC motor is one of the most important drives. It is used in many electronic entertainment devices, household devices, toys and industrial machines. This exercise involves developing an actuator for this motor type. Task 1 In LogoSoft, create a circuit that can be used to switch the DC motor on and off manually as well as change the direction of motion. Extend your program to include the multi- pin plug symbol, set all necessary labels and connect the PC and conveyor station to the the multi- pin plug distributor. Test your program using the station. Problem description 2 Logic operations are an important basis of control technology. LogoSoft, inputs and outputs are linked using logic operations. This exercise deals with the most important logic operations. Task2 Transfer the following logic circuits to LogoSoft and study the circuit's behaviour by setting the input channels I1 through I3 to the status 'high' by clicking on them. Complete the truth table. In each case specify an example of a control task that can be solved using this logic operation. Create the logic circuit shown below in LogoSoft, test its behaviour and describe it. Create the circuit shown below in LogoSoft. Create a program with the following characteristics: Lamp P1 should light up when the two pushbuttons T1 and T2 are pressed (and stay on after pushbuttons T1 and T2 have been released). The lamp should switch off when pushbuttons T3 or T4 are actuated. Extend the circuit from the previous exercise so that an electric motor is switched on and off instead of the lamp.

9 Transfer the following logic circuits to LogoSoft and study the circuit's behaviour by setting the input channels I1 through I3 to the status 'high' by clicking on them. Complete the truth table. In each case specify an example of a control task that can be solved using this logic operation. I1 I2 I3 Q Example of a control task: I1 I2 I3 Q Example of a control task:

10 I1 Q1 0 1 Example of a control task: I1 I2 Q Example of a control task:

11 Create the logic circuit shown below in LogoSoft, test its behaviour and describe it. What control tasks can this so- called latching element be used for? Create the circuit shown below in LogoSoft. Open the logic module and create a program with the following characteristics: Lamp P1 should light up when the two pushbuttons T1 and T2 are pressed (and stay on

12 after pushbuttons T1 and T2 have been released). The lamp should switch off when pushbuttons T3 or T4 are actuated. Extend the circuit so that an electric motor is switched on and off instead of the lamp.

13 Problem description 3 Conveying of workpieces is a requisite in all automated assembly systems. MecLab provides a conveyor for this. To save energy, the conveyor should not run continuously. The conveyor should therefore switch on whenever a workpiece is placed at the start of the conveyor and stop once the conveying task has been completed. The workpieces can be any colour. Task 3 How can you arrange it so that the conveyor only functions when a workpiece is placed on it? What components are needed and how must they be arranged? Create a schematic diagram of the setup. Create the accompanying circuit diagram for the schematic diagram in LogoSoft and the allocation list for the pins on the multi- pin plug distributor. Use the logic module. Next, plan the control program. What logic components can be used to arrange it so that the motor keeps running until the workpiece is conveyed to the end of the conveyor? Test your solution using the conveyor station. Do this by setting up the station as per the schematic diagram, connect all components as per the allocation list and connect your PC to the station via the multi- pin plug distributor. Create the accompanying circuit diagram for the schematic diagram in LogoSoft and the allocation list for the pins on the multi- pin plug distributor. Use the logic module. Slot Designation Explanation 0 1 Next, plan the control program. What logic components can be used to arrange it so that the motor keeps running until the workpiece is conveyed to the end of the

14 conveyor? Test your solution using the conveyor station. Do this by setting up the station as per the schematic diagram, connect all components as per the allocation list and connect your PC to the station via the multi- pin plug distributor.

15 Problem description 4 Conveying and sorting tasks are important functions in all production. This exercise consists of designing a conveyor and an accompanying control program with the following characteristics: the workpieces (containers and lids in red or black) are to be conveyed from the start to the end of the conveyor. Conveying should start when a workpiece is placed at the start of the conveyor and stop once the workpiece has left the conveyor at the other end. Silver workpieces should be rejected onto the slide. Task 4 What conveyor setup is needed to realise the specified functions? Create a schematic diagram of the setup showing the arrangement of each component and specify meaningful designations for the components. Create an allocation list that shows which slot on the multi- pin plug distributor the electrical components are plugged into. Set up the conveyor as per the schematic diagram and wire in accordance with the allocation list. Develop a control program using LogoSoft monitor the specified functions. Provide an ON/OFF switch. Test the program via simulation. Extend the Logosoft program to include the multi- pin plug distributor, set the labels as per the allocation list and test your program using the conveyor station.

16 What conveyor setup is needed to realise the specified functions? Create a schematic diagram of the setup showing the arrangement of each component and specify meaningful designations for the components. Create an allocation list that shows which slot on the multi- pin plug distributor the electrical components are plugged into. Slot Designation Explanation