Principles of Mechatronics Technology Professional Development Instructor Workshop

Principles of Mechatronics Technology Professional Development Instructor Workshop Presented by David Kempskie Senior Technology Consultant www. festo-didactic. com www. labvolt. com www. aetlabs. com DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

What is Mechatronics? Mechatronics is a multidisciplinary field of engineering that includes a combination of mechanical engineering, electrical engineering, telecommunications engineering, control engineering and computer engineering. - Wikipedia DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

Mechatronics is. . . Medical Devices Industrial Automation ATM Machines DC-R/ Vending Machines Copyright Festo Didactic Gmb. H&Co. KG 3 D printers 3

Manufacturing of Cars at Ford x y DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 4

Production of Cars with Industrial Robots x y z DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 5

Automated Assembly Line DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 6

Mec. Lab® DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 7

Air Compressor Industrial Compressor DC-R/ Copyright Festo Didactic Gmb. H&Co. KG ISO Symbol 8

4/2 -Way Solenoid Valve 4/2 -Way-Valve Monostable DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 4/2 -Way-Valve Bistable 9

Single and Double Acting Cylinder DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 10

Proximity Switches for Pneumatical Cylinders Barrel DC-R/ Piston with Magnet Copyright Festo Didactic Gmb. H&Co. KG 11

Programmable Logic Controllers DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 12

Mec. Lab® Station Stack Magazine DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 13

Mec. Lab® Station Conveyor DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 14

Mec. Lab® Station Handling DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 15

ACTUATORS DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 16

Profile Cylinder DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 17

Mechanical Grippers - Types DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 18

Mechanical Grippers – Working Principle Housing Gripper jaws Bearings slider Piston DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 19

Vacuum Grippers – Working Principle Vacuum generator Suction Cup 1 Supply port 2 Vacuum port 3 Exhaust port DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 20

Inline-Type Vacuum Generator P V R P Supply port V Vacuum port R Exhaust port DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 21

DC-Motor – Picture and Symbol DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 22

Solenoid DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 23

CONTROL VALVES DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 24

One Way Flow Control Valve DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 25

Flow Control DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 26

3/2 and 4/2 Way Valve – Working Principle DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 27

4/2 -Way-Valve - Cut-Away Drawing DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 28

4/2 -Way-Valve – Cut Away Drawing (II) DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 29

CONTROLS & SENSORS DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 30

Electrical Switches Normally open contact toggle switch Normally closed contact DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 31

Relays DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 32

Pressure Switch DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 33

Optical Proximity Switches (Thru Beam) Transmitter Without Object Receiver With Object Transmitter DC-R/ Receiver Copyright Festo Didactic Gmb. H&Co. KG 34

Thru Beam Sensor - Applications Standstill control in feeding units DC-R/ Copyright Festo Didactic Gmb. H&Co. KG Parts detection in handling devices and transfer presses 35

Thru Beam Sensor – Applications (II) Object detection at long distances DC-R/ Copyright Festo Didactic Gmb. H&Co. KG Object detection in harsh environments 36

Optical Proximity Switches – Retro Reflective Sensor E S Without Object E S With Object Retro-Reflective Sensor Transmitter + Receiver DC-R/ Mirror Copyright Festo Didactic Gmb. H&Co. KG 37

Retro Reflective Sensor - Applications Position control of small objects DC-R/ Copyright Festo Didactic Gmb. H&Co. KG IC-pins control 38

Optical Proximity Switches – Diffuse Sensor E S Without Object E S With Object Diffuse Sensor Transmitter + Receiver DC-R/ Object Copyright Festo Didactic Gmb. H&Co. KG 39

Diffuse Sensor - Applications Recognition of objects with different contrasts DC-R/ Copyright Festo Didactic Gmb. H&Co. KG IC-Pin inspection 40

Inductive Proximity Switches With Object Without Object Oscillator DC-R/ core coil Magnetic Field Copyright Festo Didactic Gmb. H&Co. KG 41

Inductive Sensors - Applications Object Detection DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 42

Open and Closed Loop Control x x DC-R/ Process Controller Copyright Festo Didactic Gmb. H&Co. KG y Process y 43

Industry 4. 0 DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 44

Industry 4. 0 DC-R/ Copyright Festo Didactic Gmb. H&Co. KG 45

THE AUTOMATION PYRAMID IC UN M M CO N O I AT M COM DC-R/ Copyright Festo Didactic Gmb. H&Co. KG ION T A C UNI

AUTOMATION TECHNOLOGY by LEVELS LEVEL 1: Field Level DC-R/ • SENSORS/TRANSDUCERS • ELECTRICAL ACTUATORS • MECHANICS • PNEUMATICS • HYDRAULICS • ROBOTICS • ARTIFICIAL VISION • IDENTIFICATION SYSTEMS • COMMUNICATIONS Copyright Festo Didactic Gmb. H&Co. KG

AUTOMATION TECHNOLOGY by LEVELS LEVEL 2: Control Level DC-R/ • PROGRAMMABLE LOGICAL CONTROLLER (PLC) • P. I. Ds • PERSONAL COMPUTERS • FREQUENCY CONVERTER • COMMUNICATIONS Copyright Festo Didactic Gmb. H&Co. KG

AUTOMATION TECHNOLOGY by LEVELS LEVEL 3: Supervision Level DC-R/ • SUPERVISION , CONTROL & DATA ACQUISITION (SCADA). • COMMUNICATIONS Copyright Festo Didactic Gmb. H&Co. KG

AUTOMATION TECHNOLOGY by LEVELS LEVEL 4: Planning Level • MANUFACTURING EXECUTION SYSTEM (M. E. S) “To link both planning and control levels, giving answers to questions such as what information must be provided, when it is needed to provide that information, etc. With the purpose of improving and optimizing the production parameters” • DC-R/ COMMUNICATIONS Copyright Festo Didactic Gmb. H&Co. KG

AUTOMATION TECHNOLOGY by LEVELS LEVEL 5: Management Level • E. R. P. (ENTERPRISE RESOURCE PLANNING) Integral system of handling of resources of the company (accounting, purchasing, invoicing, stocks, personnel, etc. . . ) • DC-R/ COMMUNICATIONS Copyright Festo Didactic Gmb. H&Co. KG

The Factory – Critical Elements to Production • Sales – Orders received and processed • Purchasing/Planning – Raw materials purchased based on anticipated orders • Production Management – In charge of all manufacturing operations Manufacturing Engineering • Design and conceive new production tools • Develop and implement new manufacturing concepts for increased productivity Production Supervisor • Dispatches orders • Relays all critical information to upper management Maintenance Management • Implement preventive maintenance on equipment • Diagnose and repair system failures Production • Utilize field, control and supervisor level automation methods for manufacturing of finished goods • Implement quality assurance processes Shipping • Orders are grouped according to customers and/or batches DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

Factory Network Communications N IO AT IC UN M M CO TION NICA MMU CO DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

Factory Network Communications N IO AT IC UN M M CO TION NICA MMU CO DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

Factory Network Communications N IO AT IC UN M M CO TION NICA MMU CO DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

Factory Network Communications N IO AT IC UN M M CO TION NICA MMU CO DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

Factory Network Communications N IO AT IC UN M M CO TION NICA MMU CO DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

Factory Network Communications N IO AT IC UN M M CO TION NICA MMU CO DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

Factory Network Communications N IO AT IC UN M M CO TION NICA MMU CO DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

Factory Network Communications N IO AT IC UN M M CO TION NICA MMU CO DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

LEVEL 1: Field Level Factory Operations • Independent, manual-operated work cells • Field level technology devices • Manual start/stop/selection processes • Human intervention • Orders processed manually • No communications DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

LEVEL 1: Field Level Factory Operations • Independent, manual-operated work cells • Field level technology devices • Manual start/stop/selection processes • Human intervention • Orders processed manually • No communications DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

LEVEL 2: Control Level Factory Operations • Independent PLC-operated work cells • Control level technology devices • Semi-Autonomous start/stop/selection processes • Human intervention • Orders processed manually • Device layer communication DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

LEVEL 2: Control Level Factory Operations • Independent PLC-operated work cells • Control level technology devices • Semi-Autonomous start/stop/selection processes • Human intervention • Orders processed manually • Device layer communication DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

LEVEL 3: Supervisor Level Factory Operations • Synchronized autonomous work cells • Supervisory level technology devices • Fully-Autonomous start/stop/selection processes • Human intervention unnecessary • Orders launched by SCADA system • Control layer communication DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

LEVEL 3: Supervisor Level Factory Operations • Synchronized autonomous work cells • Supervisory level technology devices • Fully-Autonomous start/stop/selection processes • Human intervention unnecessary • Orders launched by SCADA system • Control layer communication DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

LEVEL 4 & 5: Integrated “Smart Factory” Operations • MES and ERP integration • Fully-Autonomous start/stop/selection processes • Human intervention unnecessary • Orders processed, scheduled and prioritized by Production, Sales and Purchasing management • Information layer communications DC-R/ Copyright Festo Didactic Gmb. H&Co. KG

LEVEL 4 & 5: Integrated “Smart Factory” Operations • MES and ERP integration • Fully-Autonomous start/stop/selection processes • Human intervention unnecessary • Orders processed, scheduled and prioritized by Production, Sales and Purchasing management • Information layer communications DC-R/ Copyright Festo Didactic Gmb. H&Co. KG