Compact Mechatronics Training System
(RM -016)
  • Main objectives of the mechatronic training system:
    • Introduction to mechatronics
    • Introduction in PLC programming (digital inputs, outputs, flag, timing element)
    • Introduction to the basics of pneumatics
    • Introduction to sensor technology
    • Operation and testing of control functions
    • Introduction to field bus communication
  • Loading Station Module
    • Investigate the structure of stacking magazine and conveyor modules
    • Introduction to pneumatic systems
    • Learning how actuators and sensors work
    • Controlling a DC motor using a micro controller
    • Preparation and commissioning of a mechatronic system
    • Gaining insight into common separation and distribution processes
    • Carrying out the distribution process using PLC
  • Transport Station Module
    • Determine the material characteristics of a workpiece
    • Investigate the working principles of pneumatic linear axes
    • Remove workpieces from a receptacle
    • Pass on the workpieces to a subsequent station
    • Carrying out the handling process using PLC
  • Storage Station Module
    • Differentiate amongst workpieces according to color
    • Store workpieces
    • Rotary, stroke, and linear movement
    • Analyzing the storage space and flow of the existing facility
    • Carrying out the storage process using PLC
  • Measuring Station Module
    • Learn installation of unit
    • Learn the correct assembly of the workpiece
    • Positioning and parameter rising of sensors
    • Testing different ways of operation
    • Systematic search of errors and their elimination in a mechatronic system
    • Carrying out the testing process using PLC
  • Sorting Station Module
    • Carrying out the sorting process using PLC
    • Carrying out the sorting process using manual control mode
  • Robots Station Module
    • Mechanical structure of a robot station
    • Terminology in robot technology
    • Moving robots in object coordinate system
    • Use of safety switches
    • Mode of operation and applications of optical sensors
    • Areas of application of industrial robots
    • Teaching robots in different coordinate systems
    • Carrying out the robot control process using PLC
  • Processing Station Module
    • Understand the role of capacitive sensors and roller lever limit switches in automatic production
    • Control DC motors using a number of methods, including relays
    • Control solenoid probes
    • Understand how relay circuits are used
    • Program several functions on a rotary indexing table
    • Carrying out the processing operation using PLC
  • Assembly Station Module
    • Familiarization with the most common components of the assembly station
    • Learn how to design a smooth assembly process
    • High-Speed Assembly
    • Small Parts Assembly
    • Cylinder types: push cylinder and press cylinder
    • Carrying out the assembly process using PLC
  • Buffering Station Module
    • Set-up and adjustment of sensors
    • Introduction to electrical and pneumatic function modules
    • Buffering module Sequencing
    • Carrying out the buffering process using PLC
  • Loading Module
    • » Sensors: 2 reed switch
    • 1 Oneway light barriere
    • 1 Micro switch
    • 1 Optic sensor
    • 1 Inductive sensor
    • Actors: 1 5/2 directional valve, bistable
    • Installation: 25-pol D-SUB plug
  • transport Station Module
    • Sensor: 2 Reed switch
    • Actors:1x5/2 directional valve, monostable
    • 1x5/3 directional valve
    • Swivel gripper
  • Storage Station Module
    • Electrical servo drive
    • Integrated controller
    • Electrical linear axis with separate controller
    • Cylinder
    • PLC unit (LS OR Siemens)
  • Measuring Station Module
    • Sensors: 4 Reed switch
    • 1xAnalog transmitter
    • Actors: 1 5/2 directional valve, monostable
    • 2x5/3 directional valve
  • Sorting Station Module
    • Sensors: 2 Micro switch
    • 1x One-way light barrier
    • 1x Reed switch
    • Actors: 1 5/2 directional valve, monostable Dc motor 24V + encoder
  • Robots Station Module
    • Sensors
    • Actuators
    • Robot controller
    • Safety housing
    • Pneumatic multifunction gripper.
    • PLC unit (LS OR Siemens)
  • Processing Station Module
    • Rotary plate
    • Proximity sensors
    • Sensors
    • DC motor
    • PLC unit (LS OR Siemens)
  • Assembly Station Module
    • Transfer push cylinder
    • Press cylinder
    • Mating parts feed cylinder
    • Proximity sensors
    • Actuators
    • PLC unit (LS OR Siemens)
  • Buffering Station Module
    • Diffuse sensors
    • Short-stroke cylinder
    • Actuators
    • Pistons
    • PLC unit (LS OR Siemens)
  • Industrial mechatronics system trainer (RM - 016)
    • Loading Module (RM-016.1)
    • transport station Module (RM-016.2)
    • Storage Station Module (RM-016.3)
    • Measuring station Module (RM-016.4)
    • Sorting Station Module (RM-016.5)
    • Robot Station Module (RM-016.6)
    • Processing Station Module (RM-016.7)
    • Assembly Station Module (RM-016.8)
    • Buffering Station Module (RM-016.9)
  • Set of Workpieces
  • Hard copy user manual
  • Laboratory PC
  • Compressor

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 modules 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 module 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 modules 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 modules are provided to allow trainees to enhance their skills on the operation and testing of different types of manufacturing production processes similar to those found in real industrial applications.
  • System modules 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 modules 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 handling – assembly- storage line, and more.
  • Industrial modules provided in the training system are :
    • Loading Station Module
    • transport Station Module
    • Testing Station Module
    • Measuring Station Module
    • Storage (Storing) Station Module
    • Sorting Station Module
    • Robot Station Module
    • Assembly Station Module
    • Buffering Station Module
  • Each module 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 system module 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 safe working environment.
  • All modules are supplied with metal and non-metal test parts (workpieces) made out of different widths and colors to simulate the products in the industrial plants and enable performing the most common processes using a PLC system.
  • The station modules in this training system are delivered completely assembled, wired and tested.
  • Every station module can be operated separately or linked to another module or more.
  • The system provides different ways for connecting the modules.
  • An adapter plate is supplied to allow two modules without a common hole pattern to be attached together.
  • This module demonstrates the distribution system that is responsible of the sequential flow of the products which are designed and linked to facilitate and monitor the movement.
  • This system module composes of a wide variety of components including: optical, proximity and contact sensors, double acting cylinder, clockwise / counter-clockwise rotation, linear actuators, semi rotary actuators and more.
  • Work pieces of different shape and size are provided so trainees can examine how the distribution system separates, stores, and distributes various types of pieces.
  • This module demonstrates the distribution process begins with the stacking magazine of the station, where the work pieces are stored in the magazine tube.
  • Double acting cylinder is used to push the work pieces out of the magazine tube one at a time.
  • Material characteristics of the work piece are determined using an optical and inductive sensor.
  • The end positions of the cylinder piston are fixed by contactless sensors.
  • The system is driven by a rotary actuator used for the motion-control system that moves the work pieces to the desired position.
  • This module focuses mainly on pneumatic linear axes and how to control them. The pneumatically actuated station is equipped with a flexible two-axis handling device.
  • This system module consists of a wide variety of components including: pneumatic linear axis, pneumatic gripper, limit switches, optical sensor, and more Industrial handling components.
  • The handling system uses input criteria to sort work pieces or transfer them to a station downstream.
  • Work pieces that are inserted into the holder are detected by an optical diffuse sensor and the handling device then picks up each work piece with the aid of pneumatic gripp
  • This system module is provided to teach trainees how the storage system can differentiate amongst workpieces based on their color 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 electrical servo drive and integrated controller, stroke 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.
  • Through relevant experiments in this system, trainees will learn that by analyzing the storage space and flow of the existing facility, it is possible to minimize moving manufacturing equipment, which keeps costs low and reduces manufacturing downtime.
  • A hoisting device transports workpieces to a measuring system.
  • A PLC with analogue input can analyze an analogue tension from 0 to 10V. (material thickness measuring).
  • The work item can be transported to the next station via a gripper while in an inclined position.
  • The cylinder›s end positions are checked using contactless sensors.
  • The station is fully constructed, wired, and tested when it is delivered.
    • Material thickness measuring
    • lock out of defined parts
    • Reed switch
    • Double-acting pneumatic cylinder
    • Cylinder without piston rod
    • Remove parts in position and lock out
    • 5/2 directional valve, monostable
    • 5/3 directional valve, ventilated
    • Positioning by means of 5/3 directional valve
  • This system module is designed to demonstrate sorting methods of products which used in real-life industrial plants.
  • Sorting system sorts the workpieces by color and moves them via an electrical conveyor belt.
  • This module includes proximity sensors, sensor array to distinguish colors, optical sensors to monitor number of parts in each slide.
  • As well, it consists of belt conveyor, hopper, arm, rotary cylinder, DC motor, pistons, and more.
  • The hopper is where the test parts are located, and it is supplied with a proximity sensor at its bottom to sense the existence of the parts within it.
  • Hopper is also supplied with a pneumatic piston to move the test parts depending on signals received from the proximity sensor.
  • The belt conveyor represents a real-life one used in industries. The conveyor speed could be adjusted easily using PLC.
  • The arm is moved by using a rotary cylinder attached to it. A pneumatic suction cup is attached to the arm in order to transport the parts from the hopper to the conveyor.
  • The conveyor is driven using a DC motor which is supplied with encoder to send feedback for the motor’s speed.
  • This system module provides one of the most popular robot types in the industrial space which is the 6-axis robot.
  • It is equipped with a 6-axis articulated arm by robot controller, pneumatic gripper, safety housing, and pneumatic 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 module demonstrates how to use optical sensors, mechanical structure, and safety switches in industrial robotics applications.
  • The workpieces are transferred by the robot from a running process to another position.
  • Trainees can learn how the 6-axis articulated robots reflect the great flexibility that 6-degrees of freedom permit and learn how they have substantial reach with certain models.
  • This system module is designed to demonstrate the processing operation programmed using PLC controller. it tests and processes workpieces and uses electric actuator technology.
  • It consists of a rotary plate which is used to implement two parallel processes in the same time.
  • The system uses proximity sensors located on the rotary table and sensors located at the pickup and processing points to apply different applications such as machining and quality control.
  • The rotary indexing plate is driven by a DC motor which is supplied with encoder to send feedback for the motor’s speed.
  • A solenoid probe with an inductive sensor checks whether the workpieces are inserted in the correct positions as well as, a solenoid probe clamps the workpiece for the drilling procedure.
  • This system module is designed to practice experiments on assembly processes that are manual or partially automated. This guarantees optimum synchronization between the operators and the assembly line.
  • With configurable work instructions at the machine level, trainees have a clear visual indication of each step of an assembly process minimizing necessary training.
  • Through related experiments, trainees can learn how to identify and design a smooth assembly process.
  • The system module consists of transfer push cylinder, press cylinder, and the mating parts feed cylinder.
  • Both types of cylinders are used to generate motion and force from air pressure through an influx of pressurized gas, the specific role of a pneumatic cylinder will depend on the product's application.
  • This system module is designed to help trainees to understand how the buffering system is used in manufacturing to adjust variations in the production process. the buffer is a way to ensure that the production line continues to run smoothly despite unforeseen factors coming into play.
  • The system is mainly used to buffer and separate many workpieces. This process begins with diffuse sensors that are located at the beginning of the conveyor that detected inserted workpieces.
  • Light barriers located upstream and downstream of the separator control process, so that if the transfer point is free, the separator passes on the workpiece.
  • The separator is actuated by a short-stroke cylinder that fitted with a deflected mechanism and the end positions of the cylinder are detected by means of end position sensors.