Stacking magazine station

INTRODUCTION

Temporary storage of raw materials, semi-finished products or finished products is a requisite for all production. This is frequently done on pallets or in (automated) warehouses. In the vicinity of the production line, however, the workpieces need be stored in such a way that they can be fed into the actual production process as effectively as possible.

The stacking magazine is one of the simplest ways of storing workpieces in an organised manner. In actual production systems, the components are then supplied already in tube magazines. This means the stacking magazines can be filled quickly.

Apart from the magazining and separating function, the stacking magazine station also offers a "pressing in" function: if a container is placed on the deposit table, a lid can be pushed out from the stacking magazine and then pressed in by the second pneumatic cylinder.

In addition to the electrotechnical content, the stacking magazine station also offers a way of introducing the theme of "pneumatics" into the lesson. Simple exercises on the fundamentals of the function or manual control of a valve can be realised as part of this, as can more complex automated controllers with several pneumatic cylinders using different valves.

The stacking magazine station can be put to flexible use during the lesson. Whether used in the featured lesson or used by the students for individual or team learning, the individual MecLab® stations provide a means of bringing the modern professional and working world into the classroom and of explaining its requirements to future "producers".

As with the conveyor and the handling system, the FluidSIM® software is used to automatically actuate the stacking magazine. Students get the opportunity to learn about the structure and function of programs for the automation of production sequences. For this they only need the most basic knowledge of dealing with CAD/CAM programs. It is an advantage to have a basic knowledge of:

• the function of simple circuits
• the operation of common application programs
• the sequence of production processes
• the fundamentals of pneumatics. 

Components of the stacking magazine station

 The stacking magazine station consists of several individual components that can be used on their own or combined, depending on the task. It has been deliberately designed so it can be flexibly adapted to different technical requirements. All that is needed for this is the enclosed tool

CIRCUIT DIAGRAM CREATION AND PROGRAMMING USING FluidSIM®  

Step 1:Launch the FluidSIM® program

Open the FluidSIM® program by double-clicking on the program icon

 

Call up a new workspace 
Click on the blank white page on the left in the second menu bar. A new empty workspace for a controller appears.

Save the new controller 
To do this, select "File > Save As ..." in the menu bar and save the file to the desired location on a data storage medium under a user-defined name.

Step 2: Create the pneumatic circuit diagram 

The components needed to create the pneumatic circuit diagram are located in the toolbar on the left side of the screen. They are inserted in the circuit diagram by:

• clicking on the appropriate symbol, 
• keeping the left mouse button pressed, 
• dragging the symbol to the required location in the circuit diagram and then releasing the mouse button.

The pneumatic system consists of a double - acting cylinder, a 4/2 - way double solenoid valve, two one - way flow control valves and the compressed air supply. Figure 4.9 shows the components on the workspace

The one - way flow control valves should be rotated to produce a clear circuit diagram. To do this, right - click on the symbol for the one - way flow control valve on the workspace; in the context menu that opens, select the menu item "Rotate" followed by " 270°".

The components then need to be connected via tubing. To do this, mouse over a node point of the symbol until a crosshair is displayed. With the left mouse button pressed, move to the required node point of the next symbol. Release the left mouse button as soon as the crosshair symbol confirms the connection

To be able to link the valve solenoids with the electrical circuit and the station, the ports of the valve solenoids must be labelled appropriately.

To do this, right - click on the node of a valve solenoid. A context menu opens in which the menu item "Properties" is selected. The designation is entered in the "Label" field. The left - hand valve solenoid is called 1M1 and the right - hand 1M2 as per the connection table

Step 3: Simulate the pneumatic circuit diagram

FluidSIM ® facilitates the simulation and thus the testing of this pneumatic circuit. To this end, the simula tion is started by clicking on the Start button.

Left - clicking on the left or right of the respective valve manual override advances or retracts the cylinder.

Step 4: Create the electrical circuit diagram 

The components required must first be inserted. To do this, select the symbols in the subcategory Electrical controls in the column on the left. Then drag them to the right side of the program window using the left mouse button.

The following components are required: power supply (24 V and 0 V), 2 pushbuttons (N/O contact) and 2 valve solenoids.

The components are wired in the same way as the pneumatic components by clicking on the contacts and dragging the connecting cable to the next contact

An important step is setting labels for the valve solenoids to guarantee the link between the electrical and pneumatic circuits.

This is done in the same way as for the pneumatic components. Right - click on the symbol for the valve solenoid to open the context menu. Select the menu item "Properties". Enter the label in the dialog box. The valve solenoids must have the same labels as the ports in the pneumatic circuit diagram, i.e. 1M1 and 1 M2 in this case

Step 5: Simulate the entire circuit 

Pressing the Start button starts the simulation in FluidSIM ® . This is an easy and safe way of testing the functions of the electrical and pneumatic circuits.

To execute the individual program steps, the pushbuttons must be actuated in simulation mode by clicking on them with the mouse. Actuating the left push button closes the circuit, the solenoid valve reverses, the valve opens the path for the compressed air and the pneumatic cylinder advances. Actuating the right pushbutton retracts the cylinder piston to its initial position.

The following is shown in Flu idSIM ® :

• Pneumatic circuit 

 The lines shown in light blue represent the lines not supplied with compressed air, the line shown in dark blue is the line currently under pressure.

• Electrical circuit 

The line shown in red represents the part of the circuit that is currently closed (conducting current).

Step 6: Test with the stacking magazine station 

The actual cylinder will also advance if the symbol for the multi - pin plug distributor is inserted in the FluidSIM ® program (provided the station is connected via the EasyPort). An error message will appear if the EasyPort is not connected. Simulation is still possible if this happens 

HANDLING STATION

INTRODUCTION

  The stacking magazine know as "pick & place devices". It is one of the simplest ways of storing work-pieces in an organized manner. In actual production systems, the components are then supplied already in tube magazines. This means the stacking magazines can be filled quickly. Apart from the magazine and separating function, the stacking magazine station also offers a "pressing-in" function: if a container is placed on the deposit table, a lid can be pushed out from the stacking magazine and then pressed in by the second pneumatic cylinder.

 In addition to the electronically content, the stacking magazine station also offers a way of introducing the theme of "pneumatic" into the lesson. Simple exercises on the fundamentals of the function or manual control of a valve can be realized as part of this, as can more complex automated controllers with several pneumatic cylinders using different valves.

The stacking magazine station can be put to flexible use during the lesson. Whether used in the featured lesson or used by the students for individual or team learning, the individual MecLab® stations provide a means of bringing the modern professional and working world into the classroom and of explaining its requirements to future producers

COMPONENT OF HANDLING STATION


The handling station consists of: :

1) two pneumatic linear axes,
2) one pneumatic gripper,
3) three valves for controlling the pneumatic actuators,
4) four magnetic proximity sensors for detecting the position of the axes and further components.

 

One of the most important components in a handling device are the grippers used to establish contact with the workpiece. There are many different designs of grippers:

1) Mechanical grippers with two or three gripper jaws grip work pieces like a hand. Since these grippers' fingers are not as flexible as the fingers on an actual hand, however, it means that the gripper jaws generally have to be adapted to the work piece to be gripped.
2) Vacuum grippers hold the workpieces by means of vacuum. They are especially suitable for flat workpieces but less suitable for porous ones because no vacuum can be built up.
3) Magnetic grippers for magnetisable workpieces.
4) Adhesive grippers where the workpieces are held using an adhesive film. These are used less frequently because they are very sensitive to soiling.

Since two-axis automated handling machines are most frequently used to remove (pick) work pieces from a magazine and then deposit or assemble (place) them somewhere else, they are also called pick and place devices.

CIRCUIT DIAGRAM CREATION AND PROGRAMMING USING FluidSIM® 

The supplied FluidSIM® software is used for programming. This enables the circuit to be simulated first on the computer. If the simulation does not reveal any errors, then the station can be directly activated and operated.

Since the test setup consists of electrical and pneumatic components, a circuit plan must be created in the FluidSIM® program for both system components. It is recommended to create the pneumatic circuit diagram first, followed by the electrical circuit diagram.

Step 1: Opening FluidSIM®

In preparation for creating the circuit diagram, it is first necessary to create a new page to get an active workspace. To this end, FluidSIM® must be opened by double-clicking on the program icon:

–Call up a new workspace Click on the blank white page on the left in the second menu bar (or on "File > New"). A new empty workspace for a controller appears.

-Save the new controller
To do this select "File > Save As ..." in the menu bar and save the file to the desired location on a data storage medium under a user-defined name.

Step 2: Inserting the components

The components needed to create the pneumatic circuit diagram are located in the toolbar on the left side of the screen. They are inserted in the circuit diagram by: - clicking on the appropriate symbol, - keeping the left mouse button pressed, - dragging the symbol to the required location in the circuit diagram and then releasing the mouse button. The pneumatic system consists of a double-acting cylinder, a 4/2-way double-solenoid valve, two one-way flow control valves and the compressed air supply. Figure below shows the components in the workspace

Step 3: Rotate the one-way flow control valves

The one-way flow control valves should be rotated to produce a clear circuit diagram. To do this, right-click on the symbol for the one-way flow control valve in the workspace in the context menu that opens, select the menu item "Rotate" followed by "270°".

Step 4: Install tubing between the components 

Next, the tubing between the components must then be installed. This is done by dragging the mouse over a node point of the symbol until a crosshair is displayed. With the left mouse button pressed, move to the required node point of the next symbol. Release the left mouse button as soon as the crosshair symbol confirms the connection.

The pneumatic circuit diagram then looks as follows:

Step 5:Set labels and insert proximity sensors 

Labels need to be set so that the link with the electrical circuit diagram and the actual hardware can be established later. These labels are needed for all electrical components, i.e. valve solenoids and proximity sensors.

To label the valve solenoids, right-click on the valve solenoid and select the menu item "Properties". Enter the valve solenoid designation in the "Label" field, in this case 1M1 and 1M2 (for the first or second valve solenoid respectively of the first valve).

To mount the proximity sensors on the cylinder, right-click on the cylinder. A window opens where you can enter the proximity sensors mounted on the cylinder and their position.

There are two proximity sensors on the cylinder; one in the retracted end position and one in the forward end position. The position of one of the proximity sensors is therefore 0 mm, the position of the other 100 mm. The proximity sensors are labelled 1S1 and 1S2 (for the first and second proximity sensors of the first cylinder).

Clicking on "OK" closes the input window again.

Step 6:Test the pneumatic circuit

The simulation is started by clicking on the Start button. If one of the two manual overrides is clicked on, the valve reverses and the cylinder retracts or advances

Step 7: Components and wiring of the electrical circuit 

The components of the electrical circuit are inserted and connected in the same way as the pneumatic components.

The workspace should look as follows after the components are inserted and wired

Step 8: Assign labels 

To connect the electrical and the pneumatic components, the electrical components must also be labelled.

This is done in the same way as for the pneumatic components, i.e. by right-clicking on the component and entering the labels in an input window. Labels are needed for the valve solenoids and the sensors.

In addition, the two pushbuttons are labelled with S1 and S2.

Step 9:Create the control program 

To be able to enter the control program in the digital module, the digital module must be opened by double-clicking on it. A new window containing the digital module's input and output channels is displayed

On the left side are the inputs marked I1 to I6, on the right side the outputs marked Q1 to Q6. You now link the inputs and outputs using logic modules. These are in the toolbar on the left side of the screen and are dragged to the workspace like all other components.

The task demands that the cylinder retract or advance when the respective pushbutton is actuated and the cylinder has reached the relevant end position:

1) Valve solenoid 1M1 is switched on when pushbutton S1 and proximity sensor 1S1 are actuated.
2)Valve solenoid 1M2 is switched on when pushbutton S2 and proximity sensor 1S2 are actuated.

This means that two AND gates are needed in the program. Since the AND gate in FluidSIM® has three inputs, two high gates are used so that the third, redundant one can always be set to high. Otherwise FluidSIM® would issue an error message that there is one unassigned input.

The logic gates are now connected and the logic program therefore created (cf. Figure below). Closing the input window stores the program in the digital module (or PLC). The simulation can be started after the window closes.

Testing the solution via simulation 

The simulation is started by clicking on the Start button. If pushbutton S1 is then actuated, the cylinder advances in the simulation, pushbutton S2 retracts it again.

Testing the solution on the actual handling station

To connect the handling station to FluidSIM®, the EasyPort must be plugged into the multi-pin plug distributor on the station and this must be connected to the PC (using the USB cable) and to thepower supply.The symbol for the multi-pin plug distributor is then dragged into the workspace in the FluidSIM® program.

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