Assembly Station With PLC AND HMI
Hytech Didactic Assembly Station is a mechatronics based training system designed to carry out automated assembly of 4 different parts with pneumatically and electrically actuated process. Automated bearing dispensing station is also provided in the system. Entire station is programmed and operated with SIEMENS PLC and HMI.
Users can have hands on experience on the remote commissioning as well through Siemens Mechatronics Concept Designer Software. Assembly station is an individual station which can be integrated with Hytech Computer Integrated Manufacturing System. When integrated with Computer Integrated Manufacturing system, raw jobs are loaded in the assembly station by gantry mounted robot whereas in an individual system, these raw jobs are loaded manually.
User can change the process as well as the PLC ladder and HMI screens depending on training requirements. This station is designed to provide students with real time industrial automation process and integration of various automation components such as PLC, HMI, Servo motors, Auto feeders, pneumatic press process etc
Assembly Station Experiments:
Assembly Station can be used individually as well as in integration with the entire CIM Setup. Assembly Station is equipped with PLC as well as HMI and relevant software necessary for the PLC and HMI programming.
Even in integration setup with CIM, Assembly cell will initiate the process once it receives the signal from Central Control Unit. It will complete entire task of assembly and pass on the signal of process completion to CCU (Master PLC) for further process.
For experimentation, user is expected to carry out all process cycles or experiments on assembly station in individual mode. In ideal scenario, assembly station is programmed individually and then integrated with the CIM setup.
There are 3 jobs which are to be assembled together on assembly station along with bearing assembly. Bearings are fed into the assembly station automatically. Three manufactured jobs which are to be assembled in assembly station are as follows:
1. Mill Job 1 – Pocket Job
2. Mill Job 2 – Male Job
3. Turning job – Shaft
All three jobs are to be placed on the assembly pallet for experimentation to start.
Technical Details of Assembly Station:
| Servo Slides | |
|---|---|
| Servo Slide 1 | Servo Slide with ball screw and LM Block |
| Minimum stroke of 500mm | |
| Servo Motor (AC Digital Servo) with minimum capacity of 400 Watt | |
| Servo Motor amplifier with PT Logic | |
| Drag Chain for Servo Slide 1 | |
| Servo Slide 2 | Servo Slide with ball screw and LM Block |
| Minimum stroke of 200mm | |
| Servo Motor (AC Digital Servo) with minimum capacity of 200 Watt | |
| Servo Motor amplifier with PT Logic | |
| Press Module | |
| Slide Cylinder 1 | Servo Slide with ball screw and LM Block |
| Slide Cylinder 2 | Pneumatic Guided cylinder with minimum stroke of 150mm and with FCV |
| Press Cylinder | Pneumatic Guided Cylinder with minimum bore of 25mm and stroke of of 100mm with FCV |
| Vertical Lift Cylinder | Square cylinder with guides and with minimum stroke of 25mm |
| Assembly Pallet | |
| Assembly Pallet | Cell 1 to store Mill Job 1 |
| Cell 2 to store Mill Job 2 | |
| Cell 3 to store Turning Job | |
| Cell 4 to store assembled job | |
| Inductive proximity sensor (Qty: 04) for digital feedback of all cells | |
| Controller | |
| PLC | Siemens S7 1200 |
| HMI | Siemens KTP 700 HMI (Basic) |
| Switch | 5 Port unmanaged switch |
| I/O Link Infrastructure | |
| Master | i/o link based master with minimum 8 ports - M12 |
| Hub | i/o link based hub with minimum 8 ports - M12 (Suitable for 16 inputs / outputs) |
| Smart Light | i/o link based smart light with minimum 7 colours |
| Pneumatics | |
| Pneumatic Valve Bank | 5/2 Way double acting solenoid based valve bank with 4 valves |
| Pressure Switch | Digital Pressure Switch with analog output |
| Rotary Vane motor | Rotary vane motor with minimum bore of 25 mm and FCV |
| Auto Feeder Station Bearing Auto Feeder | Pneumatic Guided Cylinder |
| Inductive Proximity sensor to sense metallic objects | |
| Pneumatic Gripper | Parallel gripper with minimum stroke of 10mm for each finger |
| Structure | |
| Total Dimensions | 2000mm x 720mm x 1670mm (HT) |
| Approximate Weight | 150 KG |
| Worksurface | Made in aluminum extrusions with minimum dimensions of 1000mm x 720mm |
| Operation Surface | Made in MDF of minimum 25mm thickness with minimum dimensions of 800mm x 720mm |
| Mobility | 4 Qty castor wheels with brakes |
| Workstation | |
| CPU | Intel i5 Processor, 256 GB Hard Disk, 8 GB RAM |
| Operating System | Windows 10 Professional - Licensed Copy |
| Monitor 1 | 21 inch LED Monitor |
| Monitor mounting stand | Dual monitor mounting stand |
| Software | |
| PLC | Siemens TIA Basic - Perpetual |
Utility Sheet for Assembly Station:
| Description | Electrical Supply | Power Requirement |
| Assembly Station (CIM) | Single Phase, 230 V | 2 kVA |
| Description | Foot Print | Box Dimensions | Electrical Supply | Power Requirement | |||||
| Length | Width | Height | Length | Width | Height | Approx Weight | |||
| mm | mm | mm | mm | mm | mm | KG | |||
| Assembly Station for CIM | 2000 | 800 | 1700 | 2200 | 1000 | 1900 | 220 | Single Phase, 230 V | 2 kVA |