HRA-1007A Modular Flexible Automated Production Line Training System (6 stations)

Equipment Overview

HRA-1007A modular flexible automation production line training system consists of six sets of independent but closely connected workstations, such as loading inspection station, handling station, processing station, installation station, installation and handling station and sorting station, which has good flexibility. The communication between each station adopts the network communication mode (PROFIBUS), i.e., the master station adopts S7-300-313C 2DP to achieve mutual communication with S7-200 PLC through the communication module EM277. The master station uses S7-300-313C 2DP to communicate with S7-200 PLC through the communication module EM277.

The system includes mechatronics professional learning involved in such as motor drive, pneumatic, programmable controllers, sensors and other control technologies, to provide students with a typical integrated training environment, so that students have learnt a number of professional knowledge of a single subject here to get a comprehensive understanding of the comprehensive training and mutual enhancement.

Functional characteristics

This equipment adopts aluminium alloy rail type practical training platform, using the standard unit structure and drawer type mesh plate installation, interchangeability is strong; between the module uniformly by the wire connection discharge slot in the line, the overall structure is simple and practical, according to the principle of productive function and integration of the learning function of the determination of the unit content, suitable for targeted teaching and learning to use.

This device modular combination of production lines, in six stations can be carried out on a variety of different types of sensor technology, pneumatic technology, stepper motors and drives and PLC hardware and soft technology, PLC network communication technology and other aspects of the practical training, this training device has a training and demonstration functions, all interfaces are open according to their own training requirements for their own wiring.

1, the system should be controlled by network control. Among them, the feeding station is designated as the master station, the rest of the workstations for the slave station. The system master command work signal is provided by the button/indicator connected to the feeding station, and the warning light installed in the feeding unit should be able to display the main work status of the whole system, including power-on reset, start, stop, alarm, and so on.

2, the number of sensors used in the system amounted to more than forty, optical fibre type, inductive, photoelectric and magnetic sensors, each sensor has its own role, according to the nature of the detected objects play a role in making the system can work reliably. Students can understand the system of various types of sensors to strengthen the working characteristics of these sensors to the perceptual understanding, combined with the teacher's analysis of the working principle of the sensor and the characteristics of the demonstration, which allows students to quickly master the knowledge gained. And the use of a large number of pneumatic components, including a variety of electronically controlled pneumatic valves, a variety of cylinders, pneumatic hand claw, vacuum suction cups, vacuum generators, filtering and reducing valves. In the study of these pneumatic components, we can not only learn each kind of pneumatic components alone, but also in the study of a variety of pneumatic components to understand how to work with each other.

3, this training device provides six workstations have a set of PLC controller, which makes the equipment can be divided into six completely independent work units, so that more than two dozen students can study at the same time, and each student has the opportunity to do it. In the device students can not only learn PLC hardware and software technology, but also to learn the communication technology between PLC. For the mastery of all aspects of learning PLC knowledge to provide the conditions. The electrical control parts of the six workstations are all designed in accordance with industrial standards and customs, and all design drawings and manuals are provided in the form of attachments. Students can learn circuit schematic analysis, PLC I/O address checking and new equipment circuit connection analysis methods on this equipment. Six workstations including a variety of mechanical systems, such as rotary table, material sorting device, etc., the students can be a single station of the workstation training, but also reassembled the station, and then debugged to the normal state of operation, the entire system for on-line practical training. This is to improve the hands-on ability of school students has greatly helped.

4, each unit of the whole system are divided into stand-alone and online two modes, through the switch to make the present stand-alone and online switching, when selecting the stand-alone mode, disconnect the online only the implementation of the unit's programme every time you press the start-up, the implementation of the unit during the same period of time in the step so that students are more aware of the movement of each unit of the process. With other units without any connection, and we mentioned the motion process are in the online mode of the motion process and must require each unit are in the online state, otherwise there will be communication alarm.

5, each unit is equipped with a learning board, through the button switch for conversion. Students can switch to make the host and set up independent of the switch can be used for other practical training.

6. Description of the system's working tasks. 

(1) When the system is powered up, it first performs a reset operation to return each unit to the initial position set by the system. At this time, the green warning light flashes at a frequency of 1Hz. After each unit returns to the initial position, the reset is completed and the green warning light is always on, indicating that the system is allowed to start. Pressing the start button starts the system and both the green and yellow warning lights are permanently illuminated. After the system is started, the feeding station rotates and pushes the workpiece to be processed onto the material table and raises the table to signal the completion of the feeding operation to the system. If the feeding station does not detect the material within the set time, it will send an alarm or warning signal to the system. After the workpiece on the material table is taken out by the handling station robot, if the system start signal is still ON, then the next rotary push out the workpiece operation.

(2) After the handling station receives the handling signal, the handling manipulator will grasp the workpiece and carry it to the processing unit according to the sequence of action. After discharging the workpiece, it returns to the initial position in sequence and waits for the next cycle.

(3) processing unit in receiving the handling unit to carry over the material, according to the sequence of rotation to the processing area and the order of the completion of the milling groove, stamping processing, processing unit processing is completed after the classification of detection and send test results to the system. One point to note here is that: when the finished workpiece has not been taken by the handling unit when the system to lock the handling unit of the discharge.

(4) handling and installation unit receives the signal of the system processing is complete, handling and installation unit of the robot into the material, through the stepping motor to drive the screw, the workpiece is carried to the assembly table, and to the system to send the signal to carry in place. Waiting for the system to send out the signal of completion of assembly, and then from the assembly table is to grab also assembled workpieces, moving to the conveyor unit, to the system to send out the signal of completion of transport.

(5) assembly unit receives the system signal, according to the system feedback signal on the bin selection, the launch of the corresponding assembly materials, industrial suction cups on the workpiece sucked, through the mechanical arm of the mechanical transmission of the assembly materials loaded into the finished workpiece to complete the assembly, back to the initial position and to the system to send out a signal for the completion of the assembly.

(6) The diffuse reflection photoelectric sensor beside the material table of the sorting unit detects that a workpiece arrives at the material table, and inputs the signal to the PLC host, and the PLC host combines the total feedback signals of the various units of the system to discriminate the workpiece, and then controls the corresponding solenoid valves to push the cylinders, and pushes the workpieces into the corresponding material tanks to make the current shunting process.

(7) If the material does not have enough pre-warning signal, the red light in the warning lamp flashes at a frequency of 1Hz, the green and yellow lights remain on. If there is no material alarm signal, the red light in the warning light flashes at a frequency of 1Hz, the yellow light goes out, and the green and yellow lights remain on.

Practical training projects

1.Automatic testing technology use of practical training

2.Pneumatic technology application training

3.Programmable controller programming training

4.PLC network formation training

5.Electrical control circuit training

6. Stepping motor drive and position control training

7.Automatic control technology teaching and training

8.Mechanical system installation and debugging training

9.System maintenance and fault detection training