AT-205 Industrial Automation Training System

By: Mechatechs  09-12-2011
Keywords: Plc, Filling Station, Proximity Sensor


The AT-205 system has been designed based on the training requirements in industries with a medium to high level of automation.

Its skillfulness and attractive design allows the simulation of the operation of a real factory, thus allowing the study of different scenarios.

The state-of-the-art technologies used in productive processes are integrated in this didactic system, which responds to the need of the most diverse sectors (automotive, semiconductors, food, pharmaceutical etc.). Technologies included and the situations reproduced have been designed in accordance with the requirements of these industries.  AT-205 covers field, controller, operator and management levels in the automation pyramid.

With this system, the student will use an integrating and motivating context to become familiar with technologies such as electro-pneumatics, sensors, motors and PLCs in an enjoyable and intuitive way, using completely industrial components.

The AT-205 allows the user to manufacture different products. The raw material includes containers which can be filled by two types of raw material, P.V.C. color granules, and metallic balls. Production line can be programmed at managing level to fill container with different volume and weight of raw materials. ASRS warehouse which is designed to be final station stores container based on their cap material (P.V.C. or metallic) and/or  color (red or blue).

Stations Specification:

Function:

The feeding station investigates and feeds empty containers to production line. Up to 20 containers placed on the rotary feeding disk simulates one most usual methods of feeding scenarios in industry. This functional module feeds containers to the line at constant speed. In an investigation module which is located immediately after the disk, all feed containers inspect for proper positioning on the line. If there is any bottom up condition detected, the container will removed from the line.

Special Technology:

· Stepper Motor drive and control technology.

The most important components:

1x2-Phase Stepper Motor

1xStepper Motor Drive

1xSIMATIC S7-300 PLC (CPU 314C-2DP) – with Profi-bus connection

1xSIMATIC S7-300 Stabilized Power Supply

2xPneumatic Jack

1xAir treatment and pressure regulator

2x3/2 Electro-Pneumatic Valve

1xCapacitive Proximity Sensor

Filling Station 1

Function:

Time-based filling is one of most methods that used in industries. The "filling station 1" simulates such scenario with a storage tank filled with PCV granules and equipped with special funnel that open and close by a pneumatic linear actuator. Opening time of funnel can be programmed and control by PLC. So, students may learn principles and applications of this filling method.

Special Technology:

· Innovative handling system

The most important components:

1xRetro-reflective Optical Sensor

1x5/2 Electro-Pneumatic Valve

1xSIMATIC S7-300 PLC (CPU 314C-2DP) – with Profi-bus connection

1xSIMATIC S7-300 Stabilized Power Supply

3xPneumatic Jack

1xAir treatment and pressure regulator

2x3/2 Electro-Pneumatic Valve

1xCapacitive Proximity Sensor

Filling Station 2


Function:

The "Filling Station 2" teaches principles of weight measurement and its application in industrial automation with properly installed load cell under belt conveyor. Containers which filled up in "Filling station 1" are carried to weighting location, then conveyor stops to be filled with metallic balls and let noise-less measurement in parallel with filling process.

Special Technology:

· Load cell transducer with display and analog interface to PLC

The most important components:

1xRetro-reflective Optical Sensor

1xLoad Cell Sensor

1xSIMATIC S7-300 PLC (CPU 314C-2DP) – with Profi-bus connection

1xSIMATIC S7-300 Stabilized Power Supply

2xPneumatic Jack

1xAir treatment and pressure regulator

2x3/2 Electro-Pneumatic Valve

1xCapacitive Proximity Sensor

1xInductive Proximity Sensor

1xLoad Cell Transducer with 0.10V Analog output

Capping Station

Function:

Containers' cap will place and close in two stages in the "Capping Station". Four types of caps with different color and material are placed in the magazine. An indexing table takes container from belt conveyor, places the cap, close the cap by a pushing mechanism and finally deliver it to next station.

Special Technology:

· 3 phase AC motor drive technology

The most important components:

1x3-Phase AC Motor

1xMotor Inverter

1xOptical Photo-Gate Sensor

1x5/2 Electro-Pneumatic Valve

1xSIMATIC S7-300 PLC (CPU 314C-2DP) – with Profi-bus connection

1xSIMATIC S7-300 Stabilized Power Supply

2xPneumatic Jack

1xAir treatment and pressure regulator

1x3/2 Electro-Pneumatic Valve

1xIncremental Rotary Encoder

Sort/Storage Station

Function:

The "Sort/Storage Station" is designed to sort containers based on their cap material and color. At first stage, material and color of receiving containers recognized by two sensors: inductive proximity sensor and industrial color marking sensor. Based on output of these sensors, containers are sorted into 4 categories and then an elevator picks up container and places it in appropriate section of the warehouse.

Special Technology:

· DC motor drive

· Color sensing technology

The most important components:

1xPermanent Magnet DC Motor

1xIndustrial Color-Marking Sensor

1xInductive Proximity Sensor

1x5/2 Electro-Pneumatic Valve

1xSIMATIC S7-300 PLC (CPU 314C-2DP) – with Profi-bus connection

1xSIMATIC S7-300 Stabilized Power Supply

4xPneumatic Jack

1xAir treatment and pressure regulator

2x3/2 Electro-Pneumatic Valve

1xCapacitive Proximity Sensor

Monitoring Station

Function:

All new and modern automated factories are equipped with properly designed HMI and Monitoring units. The "Monitoring Station" displays manufacturing line schematically and enables operators to check status of sensors and actuators of each station. This station will connect to all other stations via a Profi-Bus industrial network link.

Special Technology:

· Field-Bus industrial network technology

· HMI programming

The most important components:

1xDesktop PC

1xSIMATIC CP-5611 Profi-Bus PCI card

1xSIMATIC Step7 Professional Edition

1xWinCC Flex 2008

1xSIMATIC S7-300 PLC (CPU 314C-2DP) – with Profi-bus connection

1xSIMATIC S7-300 Stabilized Power Supply

Keywords: Electro-pneumatic Valve, Filling Station, Plc, Proximity Sensor,

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