Principles of Mechatronics Presentation

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 GmbH&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

Mechatronics is...
Medical Devices
Industrial Automation
ATM Machines Vending Machines 3D printers

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Manufacturing of Cars at Ford

Production of Cars with Industrial Robots

Automated Assembly Line

MecLab®

Air Compressor
Industrial Compressor ISO Symbol

4/2-Way Solenoid Valve
4/2-Way-Valve Monostable 4/2-Way-Valve Bistable

Single and Double Acting Cylinder

Proximity Switches for Pneumatical Cylinders
Barrel Piston with Magnet

Programmable Logic Controllers
24V I1 I2 I3 I4 I5 I6
0V Q1 Q2 Q3 Q4 Q5 Q6

MecLab® Station Stack Magazine

MecLab® Station Conveyor

MecLab® Station Handling

ACTUATORS

Profile Cylinder

Mechanical Grippers - Types
a) b)
20° 20°
c) d)
90° 90°

Mechanical Grippers – Working Principle
Housing
Gripper jaws
Bearings
slider
Piston

Vacuum Grippers – Working Principle
1 3
Vacuum generator
Suction Cup
2
1 Supply port
2 Vacuum port
3 Exhaust port

Inline-Type Vacuum Generator
P V
P Supply port
V Vacuum port
R Exhaust port

DC-Motor – Picture and Symbol

Solenoid
+ +
- -

CONTROL VALVES

One Way Flow Control Valve

Flow Control

3/2 and 4/2 Way Valve – Working Principle

4/2-Way-Valve - Cut-Away Drawing

4/2-Way-Valve – Cut Away Drawing (II)

CONTROLS & SENSORS

Electrical Switches
1 1 2 4
3
1
2
2 3
3 4
Normally open contact toggle switch
1 1
2
3
Normally closed contact

Relays
2 3
12 14 22 24
A1
A2
4 11 21
A1 A2 4 2 1

Pressure Switch
2 4
p
1
1
4
2

Optical Proximity Switches (Thru Beam)
Transmitter
Without Object
Receiver
With Object
Transmitter Receiver

Thru Beam Sensor - Applications
Standstill control in feeding units Parts detection in handling devices and transfer presses

Thru Beam Sensor – Applications (II)
Object detection at long distances Object detection in harsh environments

Optical Proximity Switches – Retro Reflective Sensor
S
Without Object
With Object
Retro-Reflective Sensor Mirror

Transmitter + Receiver
Retro Reflective Sensor - Applications
Position control of small objects IC-pins control

Optical Proximity Switches – Diffuse Sensor
S
Without Object
With Object
Diffuse Sensor Object

Transmitter + Receiver
Diffuse Sensor - Applications
Recognition of objects with different contrasts IC-Pin inspection

Inductive Proximity Switches
Without Object With Object
Oscillator core coil Magnetic Field

Inductive Sensors - Applications
Object Detection

Open and Closed Loop Control
x y
Process
x y
Controller Process

Industry 4.0

Industry 4.0

THE AUTOMATION PYRAMID

AUTOMATION
TECHNOLOGY by LEVELS
LEVEL 1: Field Level
• SENSORS/TRANSDUCERS
• ELECTRICAL ACTUATORS
• MECHANICS
• PNEUMATICS
• HYDRAULICS
• ROBOTICS
• ARTIFICIAL VISION
• IDENTIFICATION SYSTEMS
• COMMUNICATIONS

AUTOMATION
LEVEL 2: Control Level
• PROGRAMMABLE LOGICAL CONTROLLER (PLC)

• P.I.Ds
• PERSONAL COMPUTERS
• FREQUENCY CONVERTER
• COMMUNICATIONS

AUTOMATION
LEVEL 3: Supervision Level
• SUPERVISION , CONTROL & DATA ACQUISITION

(SCADA).
• COMMUNICATIONS

AUTOMATION
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”
• COMMUNICATIONS

AUTOMATION
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...)
• COMMUNICATIONS

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 Maintenance Management

Production Supervisor
Engineering
• Implement preventive
• Dispatches orders
• Design and conceive new maintenance on equipment
production tools • Relays all critical
• Diagnose and repair system
information to upper
• Develop and implement failures
management
new manufacturing
concepts for increased
productivity
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

Factory Network Communications








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

LEVEL 1: Field Level Factory Operations
• Independent, manual-operated work cells

• Field level technology devices
• Manual start/stop/selection processes
• No communications

LEVEL 2: Control Level Factory Operations
• Independent PLC-operated work cells

• Control level technology devices
• Semi-Autonomous start/stop/selection
processes
• Device layer communication

LEVEL 2: Control Level Factory Operations
• Independent PLC-operated work cells

• Control level technology devices
• Semi-Autonomous start/stop/selection
processes
• Device layer communication

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

LEVEL 3: Supervisor Level Factory Operations
• Synchronized autonomous work cells

• Supervisory level technology devices
processes
• Orders launched by SCADA system
• Control layer communication

LEVEL 4 & 5: Integrated “Smart Factory” Operations
• MES and ERP integration

processes
• Orders processed, scheduled and prioritized by
Production, Sales and Purchasing management
• Information layer communications

LEVEL 4 & 5: Integrated “Smart Factory” Operations
• MES and ERP integration

processes
• Orders processed, scheduled and prioritized by
Production, Sales and Purchasing management
• Information layer communications

Principles of Mechatronics Presentation

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Principles of Mechatronics Technology

Professional Development Instructor Workshop

Presented by David Kempskie

DC-R/ Copyright Festo Didactic GmbH&Co. KG

Mechatronics is a multidisciplinary field of

engineering that includes a combination of

mechanical engineering, electrical engineering,

telecommunications engineering, control

engineering and computer engineering.

DC-R/ Copyright Festo Didactic GmbH&Co. KG

ATM Machines Vending Machines 3D printers

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Industrial Compressor ISO Symbol

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4/2-Way-Valve Monostable 4/2-Way-Valve Bistable

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Barrel Piston with Magnet

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Normally open contact toggle switch

Normally closed contact

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Object detection at long distances Object detection in harsh environments

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Retro-Reflective Sensor Mirror

Position control of small objects IC-pins control

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Diffuse Sensor Object

Recognition of objects with different contrasts IC-Pin inspection

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Without Object With Object

Oscillator core coil Magnetic Field

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LEVEL 1: Field Level