Compact Mechatronics Training System
(MR109)

1.Pneumatic cylinder 2.Magazine tube 3.Light barrier sensor 4.Pneumatic solenoid valves 5.Pneumatic rotary actuator 6.Vacuum valve 7.Limit switch 8.Swivel arm 9.Capacitive sensor 10.Suction valve

1.Swivel arm 2.Pneumatic cylinder 3.Limit switch 4.Vacuum cup 5.Vacuum valve 6.Pneumatic solenoid valves 7.Rotary Pneumatic cylinder 8.Limit switch

1.Light barrier sensor 2.Belt conveyor 3.Inductive sensor 4.Pneumatic cylinder 5.Capacitive sensor 6.DC motor 7.Atlas color sensor 8.Pneumatic solenoid valve

1.Stepper motors 2.Driller 3.Pneumatic cylinder 4.Capacitive sensor 5.Inductive sensor 6.Gear box 7.Photo electric sensor 8.Optical fiber amplifier sensor

1.Pneumatic cylinder 2.Light barrier sensor 3.First belt conveyor 4.Second belt conveyor 5.Test parts 6.DC motor 7.Vacuum valve 8.Pneumatic solenoid valves 9.Capacitive sensor

1.Part receiving area 2.Pneumatic rotary actuator 3.Pneumatic solenoid valves 4.Guided pneumatic cylinder 5.Photo electric sensor for the storage box 6.Stepper motor 7.Containers 8.Photo electric sensor 9.Pneumatic gripper 10.Inductive sensor

  • Main objectives of the mechatronics training system:
    • Introduction to mechatronics
    • Introduction in PLC programming
    • Introduction to the basics of pneumatics
    • Introduction to sensor technology
    • Operation and testing of control functions
    • Profinet communication.
    • Introduction to industrial robotics operation and handling
  • Loading station (MR109.01)
    • Investigate the structure of stacking magazine
    • Introduction to pneumatic systems
    • Learning how actuators and sensors work
    • Preparation and commissioning of a mechatronic system
    • Carrying out the loading process using PLC
  • Transporting station (MR109.02)
    • Investigate the working principles of pneumatic Rotary actuator.
    • Investigate the working principles of pneumatic suction grippers
    • Pass on the workpieces to a subsequent station
    • Carrying out the handling process using PLC
  • Measuring station (MR109.03)
    • Learn the concepts of analog sensor operation with PLC controller
    • Positioning & parameter adjustment of sensors
    • Systematic search of errors and their elimination in a mechatronic system
    • Carrying out the Measuring process using PLC
  • Processing station (MR109.04)
    • Understand the role of proximity sensors sensors and roller lever limit switches in automatic production
    • Program several functions on a rotary indexing table
    • Familiarization with Stepper motors and stepper motor control using PLC
    • Carrying out the processing operation using PLC
  • Assembly station (MR109.05)
    • Familiarization with Assembly process in industrial automation system
    • learn the concept of 2 axis linear pneumatic mechanism
    • Carrying out the Assembly process using PLC
  • Buffering station (MR109.06)
    • Set-up and adjustment of sensors
    • Introduction to electrical and pneumatic function stations
    • Buffering Station Sequencing
    • Carrying out the buffering process using PLC
  • Sorting station (MR109.07)
    • Carrying out the DC motor position control using PLC
    • Learning the control mechanism of DC motor
    • Carrying out the sorting process using PLC
  • Robot Arm station (MR109.08)
    • Mechanical structure of a robot station
    • Terminology in robot technology
    • Areas of application of industrial robots
    • Teaching robots in different coordinate systems
    • Carrying out the robot integration process with PLC
  • Storage station (MR109.09)
    • Differentiate amongst workpieces
    • Store workpieces
    • Learn the concepts of rotary, stroke, and linear movement
    • Analyzing the storage space and flow of the existing facility
    • Carrying out the storage process using PLC
  • Loading station (MR109.01)
    • Reed switch
    • Photo electric sensor
    • Proximity sensor
    • pneumatic valves
    • Rotary actuator
    • Limit switches
    • PLC Unit
  • Transporting station (MR109.02)
    • Reed switch
    • Pneumatic valves
    • Double acting cylinder
    • Rotary actuator
    • Vacuum valve
    • PLC Unit
  • Measuring station (MR109.03)
    • Analog transmitter
    • Pneumatic valves
    • Double acting cylinder
    • Reed switch
    • Pneumatic guided cylinder
    • PLC unit
  • Processing station (MR109.04)
    • Photo electric sensor
    • Proximity sensor
    • Encoder
    • Limit switch
    • Fiber sensor
    • DC Motor
    • Double acting cylinder
    • Pneumatic valves
    • PLC unit
  • Assembly station (MR109.05)
    • 2 axis pneumatic mechanism
    • Photo electric sensor
    • Pneumatic valves
    • Double acting cylinder
    • Reed switch
    • Vacuum valve
    • Suction cup
    • Belt conveyor system
    • PLC unit
  • Buffering station (MR109.06)
    • Photo electric sensors
    • Proximity sensor
    • Pneumatic valve
    • Double acting cylinder
    • Color sensor
    • Belt conveyor system
    • PLC unit
  • Sorting station (MR109.07)
    • Belt conveyor system
    • Pneumatic valves
    • Double acting cylinders
    • Photo electric sensors
    • PLC unit
  • Robot Arm station (MR109.08)
    • Number of axes: 6 axes
    • Payload: 3kg max
    • Running radius: 700 mm
    • Robot controller
    • End effector
  • Storage station (MR109.09)
    • Pneumatic valves
    • Double acting cylinder
    • Reed switch
    • Stepper motor
    • Proximity sensor
    • Pneumatic gripper
    • PLC Unit
  • Compact Mechatronics Training System (MR109)
    • Loading station (MR109.01)
    • Transporting station (MR109.02)
    • Measuring station (MR109.03)
    • Processing station (MR109.04)
    • Assembly station (MR109.05)
    • Buffering station (MR109.06)
    • Sorting station (MR109.07)
    • Robot Arm station (MR109.08)
    • Storage station (MR109.09)
  • Hard copy user manual
  • Set of Workpieces
  • Laboratory PC
  • Compressor
  • Tia Portal v17 license.

Compact mechatronics training system is a fully-integrated system that provides automation training, combining mechanics, pneumatics, electrical engineering, PLC control, communication interfaces, and more technologies principles. Various individual stations are available in this system to represent the most common types of manufacturing production processes in the industrial system and address further subject areas, including robot station, storage, distributing, buffering, testing, assembling, processing, sorting, and handling stations, each Station can be operated separately or linked as a system to simulate real production processes. The system is based on the programmable logic controller (PLC) that plays a vital role in manufacturing and act as a central processor for all real time decisions. Trainees can perform real-time experiments on the system stations and learn how PLC can be used in managing complex, simultaneous, multi-stage operations.

  • Mechatronics training system is designed to represent a variety of technology fundamentals that are highly used in many production processes such as, pneumatics, robotics, sensors, and PLC controller.
  • The system is based on the programmable logic controller (PLC) that is used to control a wide variety of systems to support the automation requirements. It monitors inputs and changes outputs as controlled in the system program.
  • A number of (9) experimental stations are provided to allow trainees to enhance their skills on the operation and testing of different types of manufacturing production processes, sensors and actuators similar to those found in real industrial applications.
  • System stations provide inclusive and flexible systems to handle, and include all the required components of each system so trainees have absolute freedom to use any one based on the type of the experiments to be carried out.
  • System stations can also be arranged in various sequences as desired so that trainees can recreate a fully functional automated line such as processing - testing– sorting line, assembly-handling-storage line, and more.
  • Industrial stations provided in the training system are:
    • Loading station (MR109.01)
    • Transporting station (MR109.02)
    • Measuring station (MR109.03)
    • Processing station (MR109.04)
    • Assembly station (MR109.05)
    • Buffering station (MR109.06)
    • Sorting station (MR109.07)
    • Robot station (MR109.08)
    • Storage station (MR109.09)
  • Each station is designed with three main parts, technology station, control unit (panel), and underframe. All of them are provided with software to adjust the settings of the PLC or demonstrate the process carried out.
  • The horizontal part of each station includes the technology station which is the process area that demonstrates a real-life manufacturing production process system.
  • The control panel accommodates PLC control panel and all components needed to power and control the system experiments. It incorporates power sources, switches, and indication LEDs.
  • Additionally, the control panel is equipped with ON/OFF main power switch as well as, emergency switch, which guarantee the required protection to produce a safeworking environment.
  • Every station station can be operated separately or linked to another Station or more.
  • The system provides different ways for connecting the stations.
  • An adapter plate is supplied to allow two stations without a common hole pattern to be attached together.
  • Loading station demonstrates the feeding system that is responsible of the sequential flow of the products which are designed and linked to facilitate and monitor the movement.
  • The process begins with the stacking magazine of the station, where the work pieces are stored in the magazine tube.
  • Work pieces of different sizes are provided so trainees can examine how the system stores and provides various types of pieces to the overall system
  • This station composes of a wide variety of contact-less sensors and actuators such as photo electric sensors, proximity sensors and contact-less sensors
  • Double acting cylinder is used to push the work pieces out of the magazine tube one at a time.
  • The end position of the pneumatic cylinder is fixed by contactless sensor.
  • A proximity sensor is being used to detect the presence of the sample
  • The system is driven by a rotary actuator used for the motion-control system that moves the work pieces to the desired position.
  • Transporting station is primarily concentrates on pneumatic rotary axis and how to control it, in addition to a pneumatic linear axis for sample transfer is being used to transfer the sample.
  • This system Station consists of a wide variety of components including: pneumatic Rotary Actuator, contact-less sensors and more Industrial handling components.
  • A vacuum gripper is used to hold the work piece during the operation of the rotary actuator.
  • The measuring station is designed to determine the height of the workpiece sample using an analog transmitter sensor.
  • A PLC with analog input can analyse an analog tension from 0 to 10V
  • The work piece can be transported to the next station by using an inclined mechanism
  • Pneumatic linear cylinder is used to reject the workpiece according to the classification process
  • The cylinders end positions are checked using contact-less sensors
  • The processing station is designed to demonstrate the processing operation programmed using PLC controller. it tests and processes the sample characteristics by the use of sensor fusion and integration
  • It consists of a rotary plate which is used to implement two processes
  • The rotary indexing plate is driven by a DC motor which is supplied with encoder to send feedback for the motor’s position
  • A simulation of drilling process & inspection process are being done by using drilling station and inspection station
  • The drilling station simulate the drilling by using drill, proximity sensor & Travelling mechanism.
  • The inspection station is used to inspect the work piece after drilling to make sure it has been done correctly
  • A pneumatic cylinder with a proximity sensor checks whether the workpieces are inserted in the correct positions as well as, a pneumatic cylinder clamps the workpiece for each process
  • The assembly station is designed to practice experiments on assembly processes that are fully automated.
  • Through related experiments, trainees can learn how to identify and design a smooth assembly process.
  • The station consists of transfer push cylinder, & press cylinder
  • The end position of the pneumatic cylinder is fixed by contact-less sensor.
  • Two contact-less sensors are used to detect the sample at the start of the conveyor system and the end of the conveyor system.
  • The station consists of transfer push cylinder, & press cylinder
  • The end position of the pneumatic cylinder is fixed by contact-less sensor.
  • Two contact-less sensors are used to detect the sample at the start of the conveyor system and the end of the conveyor system.
  • The buffering station is designed to help trainees to understand how the buffering system is used in manufacturing to adjust variations in the production process.
  • The station is designed to hold and buffer the work piece in order to state the flow of the process according to the workpiece characteristics by using a color sensor & inductive sensor.
  • The material characteristic of the work piece is determined.
  • Two contact-less sensors are used to detect the sample at the start of the conveyor system and the end of the conveyor system.
  • The sorting station is designed to demonstrate sorting methods of products which used in real-life industrial plants.
  • Sorting system sorts the workpieces and moves them via an electrical conveyor belt.
  • This station includes optical sensors to detect falling parts at each pocket
  • The sorting station is used to sort the samples according to the analysis of the work piece characteristic.
  • The station is being used to sort the sample in different pockets according to each sample characteristics.
  • Two contact-less sensors are used to detect the sample at the start of the conveyor system and the end of the conveyor system.
  • This station provides one of the most popular robot types in the industrial space which is the 6-axis Robot arm.
  • It is equipped with a 6-axis articulated arm by robot controller, and multifunction gripper.
  • The 6-axis allow a robot to move in the x, y, and z planes, as well as position itself using roll, pitch, and yaw movements. This functionality is suitable for complex movements that simulate a human arm.
  • This station demonstrates how to use robot arm in the handling operation in industrial process
  • The workpieces are transferred by the robot from a running process to another process.
  • This station is provided to teach trainees how the storage system can differentiate amongst workpieces based on their characteristics and store a variety of workpieces over many levels and rows. It creates a space-saving storage for products and this is importantly required in any industry system.
  • It includes rotary movement performed by pneumatic rotary actuator, traveling movement executed using electrical linear axis with separate controller, and linear movement executed using a cylinder.
  • Trainees can understand the function and application used for storing workpieces of different forms and structures.
  • A contact-less sensor is being used to determine if the storage unit is full or not.