HRA-105A automatic production line training and examination equipment

Equipment Overview

HRA-105A automatic production line training and assessment equipment consists of five units, namely, feeding unit, processing unit, assembly unit, conveying unit and sorting unit, which are installed on the aluminium alloy rail-type training platform. The electrical layout of the double drawer type, all of its electrical controllers are installed in the mesh plate type drawer, this electromechanical separation of the format with the industrial reality.

Among them, each work unit can be an independent system, but also a mechatronic system. Each unit of the actuator is basically pneumatic actuators, but the conveyor unit of the overall movement of the robot device to take the servo motor drive, precision positioning position control, the drive system has a long stroke, multi-positioning point characteristics, is a typical one-dimensional position control system. The conveyor drive of the sorting unit adopts the AC drive of three-phase asynchronous motor driven by general-purpose frequency converter. Position control and frequency converter technology is the most widely used electrical control technology in modern industrial enterprises.

Various types of sensors are applied to the HRA-105A equipment, which are used to judge the movement position of the object, the state of the object passing through, the colour and the material of the object and so on. Sensor technology is one of the key technologies in mechatronics technology and is one of the prerequisites for achieving a high degree of automation in modern industry.

In terms of control, the standard configuration of HRA-105A adopts a PLC network control scheme based on RS485 serial communication, i.e. each work unit is controlled by one PLC to undertake its control task, and the PLCs are interconnected by RS485 serial communication to achieve a distributed control method. Users can choose PLCs of different manufacturers and their supported RS485 communication modes according to their needs to form a small PLC network. Small PLC network with its simple structure and low price in small automatic production line still has a wide range of applications, in the modern industrial network communication still occupies a considerable share. On the other hand, mastering the PLC network technology based on RS485 serial communication will lay a good foundation for further study of fieldbus technology, industrial Ethernet technology and so on.

Functional characteristics

HRA-105A automatic production line training and assessment equipment has the following more prominent advantages:

1, HRA-105A basically contains the core knowledge points of automation class.

2, has a high degree of flexibility and easy scalability, especially suitable for skills assessment and competition.

It is easy to upgrade the 485 communication mode to fieldbus, remote I/O mode and so on.

It is easy to follow the position control servo motor and stepping motor of the conveyor station.

It is also very easy to upgrade the workstation.

3, the workflow from shallow to deep, in line with the law of teaching.

The basic functions of each unit are as follows:

1、Feeding unit

The basic function of the feeding unit:

Feeding unit is the starting unit in HRA-105A, in the whole system, plays the role of providing raw materials to other units in the system.

Specific Functions of the Feed Unit:

Automatically push out the workpieces to be processed (raw materials) placed in the silo onto the material table as required, so that the robot of the conveying unit can grab them and convey them to other units.

Main components of the feeding unit:

Mainly includes vertical cylinder, top material cylinder, push material cylinder, material detection sensor parts, mounting bracket platform, material detection device parts, with protection terminal unit and other components.

The working process of the feeding unit is as follows:

After the system starts, the top material cylinder extends to hold the penultimate workpiece; the push material cylinder pushes out and pushes the bottom workpiece in the material chute to the workpiece gripping position on the material table. After the workpiece in place sensor detects the workpiece in place, the push out cylinder and the top material cylinder retract one by one, and the penultimate workpiece falls to the lowest level, waiting to be pushed out. The handling station robot extends and grabs the workpiece and transports it to the processing station.

2、Processing unit

The basic function of the processing unit:

Processing unit is one of the workpiece processing units in HRA-105A, in the whole system, it plays a role in simulating punching or stamping of workpieces sent from the conveying station.

Specific functions of the processing unit:

(1) The workpieces on the material table of the unit (the workpieces are fed and sent by the gripping robot device of the conveying unit) are sent to the bottom of the stamping mechanism to complete a stamping process, and then sent back to the material table to be taken out by the gripping robot device of the conveying unit.

(2) The workpieces on the material table of the unit (the workpieces are sent from the assembly station by the gripping robot device of the conveying unit) are sent to the bottom of the stamping mechanism to complete the process of pressing the small workpieces into the large workpieces, and then sent back to the material table to be removed by the gripping robot device of the conveying unit.

The main components of the processing unit:

Mainly includes sliding material table, analogue punch and punch press, tight manipulator, material table extending/retracting cylinder, with protection terminal unit and corresponding sensors, solenoid valve structure and other components.

The function of this station is to complete a workpiece stamping process, the process is as follows:

The robot at the handling station transports the workpiece to the material table → the material detection sensor detects the workpiece → the mechanical finger clamps the workpiece → the material table returns to the processing area under the stamping cylinder → the stamping cylinder extends downwards to stamp the workpiece → after completing the stamping action, it retracts upwards → the stamping cylinder retracts to its place → the material table extends back to its position → the mechanical finger is loosened after the position is put into place → the manipulator at the handling station extends and clips the workpiece, and transports it to the assembling station. Assembly Unit

3. Assembly unit

The basic function of the assembly unit:

The assembly unit is a force unit for workpiece processing in HRA-105A, and in the whole system, it plays the role of assembling the workpieces sent from the conveying station and feeding small workpieces.

Specific functions of the assembly unit:

The unit will feed and lift up small black or white cylindrical workpieces in the bin.

(1) The large workpieces that have been processed from the processing unit are assembled (small workpieces are assembled into the large workpieces by robots) and then moved to the disassembly unit by the handling robots of the conveying unit.

(2) The large workpieces from the feeding unit are assembled (the small workpieces are assembled into the large workpieces by robots), and then moved to the processing unit by the handling robot of the conveying unit to carry out the stamping process.

The main components of the assembly unit:

It mainly includes feeding mechanism, rotary feeding unit, robotic assembly unit, unloading table, and terminal unit with protection.

The working process of the assembly unit is as follows:

When the handling station of the robot to transport the workpiece to the assembly station on the material table, the top material cylinder extends the top of the feeding unit penultimate workpiece; blocking cylinder retracted, so that the material groove in the lowest level of small cylindrical workpiece falls to the rotary feeding table, and then rotate the feeding unit rotates clockwise 180 degrees (right-handed), in place after the assembly of the manipulator according to the descending pneumatic hand hand claw → grasp the small cylindrical → hand claw to lift the → arm outstretched → claw descent → hand claw release action sequence, the small garden column workpiece smoothly loaded into the large workpiece, robot assembly unit reset at the same time, the rotary feeding unit counterclockwise rotation of 180 degrees (left-handed) back to the original position, the handling station manipulator to extend and grasp the workpiece, and transport it to the material disintegration station.

4、Sorting unit

The basic function of the sorting unit:

Completion of the last unit sent by the processed, assembled workpieces for sorting, so that different colours of workpieces from different troughs shunt, respectively, for the combination of functions.

The main components of the sorting unit:

Mainly includes conveyor belt mechanism, three-phase motor power unit, sorting pneumatic components, sensor detection unit, high progress feedback and positioning mechanism, with protection terminal unit and other components.

Sorting unit work process is as follows:

The function of this station is to complete the sorting of assembled workpieces sent from the assembly station. When the handling station sends the workpiece to the conveyor belt and for the inlet photoelectric sensor detected, that is, start the frequency converter, the workpiece began to be sent to the sorting area, if the workpiece into the sorting area for the white, the fibre optic sensor detects the white material action, as the No. 1 slot pushes the material cylinder to start the signal to push the white material to the No. 1 slot, if the workpiece into the sorting area for the black, the fibre optic sensor detects the black material as the No. 2 slot If the workpiece entering the sorting area is black, the fibre-optic sensor detecting black will be used as the starting signal for the pushing cylinder of No.2 slot to push black material into No.2 slot. The processing of the automatic production line is finished.

5、Conveying unit

The basic function of the conveying unit:

The unit by going to the designated unit of the material table to accurately locate, and in the material table to grab the workpiece, the grabbed workpiece transported to the designated location and then put down the function.

The main components of the conveying unit:

It mainly includes four degrees of freedom manipulator, linear conveyor unit, proportional transmission mechanism, multi-function mounting bracket, synchronous wheel, synchronous belt, with protection terminal unit and other components.

The working process of the conveyor unit is as follows

The function of this station is to complete the delivery of workpieces to the various work units, the system is divided into four degrees of freedom gripping manipulator unit and linear displacement position precision control unit in two parts, the system is powered on, the first implementation of the operation back to the origin, when it reaches the origin position, if the system is activated, the material station material table detection sensor detects a workpiece, the manipulator as a whole first lifted into place after the claw extends into place after the claw clamping, claw clamping in place! The claws will start to shrink the robot as a whole will be down in place, the servo motor began to work according to the set amount of pulses to the processing station. Processing station in place after the overall lifting of the robot, lifting in place after the hand claw extended out in place after the overall decline of the robot, down in place after the workpiece has been put into the processing station material table, and then the hand claw loosened, loosened in place after the robot retracted, and so on the processing station processing is completed and then the workpiece will be sent to the assembly station and the sorting station to complete the entire automatic production line processing process.

Practical training projects

1、Organic integration of mechanical technology (including pneumatic technology), sensor technology, AC motor frequency control and stepping motor drive control, touch screen technology, PLC control and communication networks and other technologies, reflecting the characteristics of the production process of modern manufacturing.

★ Practical training on the installation and debugging of the feeding unit;

★Practical training for the installation and debugging of processing unit;

★Practical training for the installation and debugging of assembly units;

★Practical training for installation and commissioning of sorting units;

★Practical training for the installation and commissioning of conveying units;

★Automatic production line control of the installation and commissioning of practical training;

2, the overall structure of the open and disassembled, can easily replace the module, according to the principle of productive function and integration of learning functions to determine the module content, so that the teaching or competition can be convenient to select the required module. The expandability and upgradability of the equipment is strong, such as:

★ Such as replacement or expansion of the work unit;

★Electrical upgrade to fieldbus;

★Positioning module to control servo motors, etc.;

3, for teaching, you can plan teaching activities according to the work process-oriented, engineering-learning mode, to complete the following work tasks:

In line with the law of teaching step by step

(1) pneumatic system installation and commissioning project:

Select the equipment configuration of the single out of the rod cylinder, single out of the double rod cylinder, rotary cylinder and other pneumatic actuating elements and single-control solenoid directional valve, dual-control solenoid directional valves and magnetic switches and other pneumatic control elements, you can complete the following work tasks of pneumatic technology:

★ Installation of pneumatic direction control circuits;

★Installation of pneumatic speed control circuits;

★Installation of swing control circuits;

★Installation of pneumatic sequence control circuits;

★Installation of pneumatic manipulator devices;

★Installation and commissioning of pneumatic systems;

★Design and installation of pneumatic integrated system;

(2) Installation of electrical control circuits and PLC programme writing project:

Select the device configuration of the PLC module, inverter module and servo drive module, sensors, etc., can complete the following PLC application technology work tasks:

★Three-phase motor forward and reverse control circuit connection and control programme writing;

★Connection and control programme writing for three-phase motor control circuit;

★Connection and control programme writing for motor speed control circuit;

★Connection and control programming of inverter analogue control;

★Connection and parameter setting of servo motor control circuit;

★PLC control network control technology;

★Pneumatic direction control programme writing;

★Pneumatic sequential action control programme writing;

★Pneumatic manipulator control programme writing;

★Belt conveyor control programme writing;

★Mechatronics equipment control programme writing;

★Automatic production line control programme writing.

3) PLC communication network installation, programming and debugging:

★PLC control technology - 485 communication technology programming and debugging

4）Electromechanical equipment installation and debugging project

Select the device configuration of electromechanical integration equipment components, PLC modules, inverter modules and command switches, sensors, etc., can complete the following electromechanical equipment installation and electromechanical integration technology tasks:

★Adjustment of the coaxiality of the transmission unit;

★Mechanical installation and adjustment of the feeding unit;

★Mechanical installation and adjustment of processing units;

★Mechanical installation and adjustment of assembly units;

★Mechanical installation and adjustment of the sorting unit;

★Mechanical installation and adjustment of conveying units;

★Automatic production line equipment installation and commissioning.

4、This equipment is used for assessment or skills competition, can examine the vocational ability:

★Ability of assembly and adjustment of mechanical components;

★Installation and debugging ability of electromechanical equipment;

★Circuit installation ability;

★Installation and debugging ability of pneumatic system;

★Ability to use frequency converters in automatic production lines;

★Servo motor in the automatic production line ability to use;

★Ability to use PLC analogue control in automatic production lines;

★Ability to write control programmes for mechatronics equipment;

★Ability of installation and debugging of automatic control systems.

★PLC network installation, programming and debugging ability.

★Programming and debugging ability of human-machine interface and configuration technology.