Course Outline and Daily Schedule

INDUSTRY REVOLUTION 4.0 WITH MODULAR MECHATRONIC SYSTEM (mMS4.0)

The study topics will be done with three single stations, which can be combined to a complete system. The complete system
displays a cube-assembly, which puts together various halves of the cubes. Each single station provides the opportunity to
process specified learn topics.

Station 1 supplies the halves of the cubes on a conveyor belt, position and material will be detected via sensors and halves of the
cubes get transferred or sorted out.
Station 2 assembles the cubes, operated by a pinning unit and a pneumatic press.
Course Overview: The material is transferred from the conveyor belt to the press and back by a pneumatic vacuum gripper.
Station 3 provides a warehouse system. The assembled cubes are moved by a Cartesian robot with pneumatic gripper into a high
rack warehouse.
Each station of the modular mechatronic system has a separate controller. The used industrial PLC's have some specialties:
- PLC programming using the international standard IEC61131-3. Programming with the following languages is possible:
Instruction list, ladder diagram, function block diagram, sequential function chart, structured text.
Open Core Engineering (OCE) is integrated. This ensures a lot of possibilities and features for the new Connected Industry
(Industry 4.0)

Engineers, Technicians, Technical Managers, Production Managers, Academia with relevant background.
Target Audience:
The objectives of training programme is to provide knowledge and skills for Mms4.0

1. Perform to commissioning of the system.

2. Perform to programming PLC according IEC 61131-3.
3. Perform to programming PLC via high level language.
Course Objectives: 4. Perform to troubleshooting.
5. Handle material transport with pneumatic system
6. Program and solve sequential projects.
7. Apply advanced commands in program.
8. Be able understand our machine & process capabilities
9. Apply method using MES and OEE.
Hardware:

1. Computer / Laptop
2. Modular Mechatronic System (mMS 4.0)

Course Resources: Software:

1. IndraWork
2. Node-Red
3. Open Core Engineering
DAILY LESSON PLAN MODULE / TOPICS

INTRODUCTION INDUSTRY 4.0

Project 01: mMS4.0 – Magazine station Configuration

Hardware configuration for the magazine station 1

Configuration of the PLC

FRIDAY
Configuration of the inline I/Os

Configuration of the VAM machine control desk

Configuration of the bus coupler

Project execution Exercise 1

Project 01: mMS4.0 – Magazine station

Exercise 2 :

Extension of the project by the following functions:

- Rest key flashes when the emergency stop relay is not active.

- Start key flashes when the automatic sequence can be started.

- Start key is illuminated while the automatic sequence is running.

Exercise 3 :

Extension of the project by the following functions:

Test capacitive sensor

- The test cylinder extends for 500 ms

- The test cylinder retracts for 500 ms.

- The belt starts running again.

Exercise 4 :

-Extension of the project by the following functions:

- Magazine 2 is to be added to magazine 1 in the alternative branch.

- The two magazines are to work alternately in the automatic sequence.

LUNCH BREAK

Exercise 5 :
SATURDAY
Extension of the project by the following functions:

- Visualization for the Start and Reset keys.

-The LED display of the two push buttons

Exercise 6 :

Extension of the project by the following functions:

- The properties of the cube half (contour on top open/closed, metal/non-metal,
bright/dark) are to be saved during the process.

- The properties are to be analyzed at the end of the process and are to be provided in the form of a numerical value (integer).
See the following table for clarification

Exercise 7 :

Display of the workpiece properties in plain text in the visualization

Display of the workpiece properties in plain text on the PLC display

Embed via Library Manager – Add library – IndraLogic – Base

Exercise 8 :

Display of the active step in the visualization

Reset of the step chain

Operating mode has to be selected

Perform the single step, the SINGLE STEP key

Filling level of the magazines

Project 01: I 4.0 – Converting an industrial system to 4.0 – Station 1 mMS 4.0

How does the mMS 4.0 training system work

Where could industry 4.0 components be attached

What are industry 4.0 components

Preventative maintenance (service alarm, intelligent sensor technology,monitoring)

Cloud connection (cloud computing, big data, Internet of things)

SUNDAY
Workpiece-controlled production (RFID)

Analysis of the assemblies.

Setup of the assemblies.
Test of the assemblies.
RFID connection Station 1
Installation RFID at mMS4.0 Station
The communication module
Connection of the PROFIBUS circuit
Networking all components and connection to other networks
Project 02: mMS4.0, St. 2 - Observation, analysis and documentation
Hardware configuration for the magazine station 2
Configuration of the PLC

FRIDAY
 Configuration of the inline I/Os
Configuration of the VAM machine control desk
Configuration of the bus coupler
Executing Station 2
FRIDAY Creation of a sequence table of station 2:
Project 03: Basic technologies of station 2
Executing
Identification of the mMS 4.0 system in the documentation
mMS 4.0 circuit diagram of the removing cylinder of the press
mMS 4.0 PN distributor and maintenance unit
mMS 4.0 electric circuit diagram 24 V DC motor; relay control
mMS 4.0 electric circuit diagram 24 V DC motor; power supply
Project 04: Design of the PLC project mMS 4.0 –
Station 2
The PLC inputs and outputs
Executing
Create a new project named “Station 2” in IndraWorks.
Assigned to the I/Os according to the list of variables
Project 05: PLC program to reset the emergency stop circuit
Executing
View the electric circuit diagrams and understand the emergency stop circuit
Participants of local emergency stop circuit
Participants of global emergency stop circuit
Create the program.
SATURDAY
LD program of the emergency stop functionality
LUNCH BREAK
Project 06: PLC program for the pinning unit
Executing
Creating a sequence table of the pinning unit
Creating a GRAFCET for the pinning unit:
Programming the pinning unit in Ladder Diagram (LD)
Project 07: PLC program for portal – load press
Executing
Creating a sequence table of the loading process of the portal
Creating a GRAFCET for the loading process of the portal:
Programming the loading process of the portal in sequential function chart (SFC)
Project 08: PLC program - Press with two-hand activation
Executing
Creating a sequence table of the loading process of the press:
Creating a GRAFCET for the loading process of the portal:
Programming the pressing process in sequential function chart (SFC)
Project 09: PLC program for portal – unload press
Executing
SUNDAY Creating a sequence table of the loading process of the press:
Creating a GRAFCET for the loading process of the portal:
Programming the pressing process in sequential function chart (SFC)
Project 10: Programming the entire sequence of station 2
Executing
Creating a sequence table of the loading process of the press:
Creating a GRAFCET for the loading process of the portal:
Programming the pressing process in sequential function chart (SFC)
Project 11: Design of the PLC project mMS 4.0 –Station 3
Hardware configuration for the magazine station 1
Configuration of the PLC
THURSDAY Configuration of the inline I/Os
Configuration of the VAM machine control desk
Configuration of the bus coupler
PLC configuration
Project 12: Commissioning of drives mMS 4.0 -Station 3
Executing
Loading the basic parameters
Phase switch-over and acknowledging errors
Scaling / Units
Mechanical transmission
Project 13: Setting and moving the axes - Station 3
Executing
To commissioning a system
Control system is in the “STOP” operating state
Phase switch-over and acknowledging errors
Jogging the axis
Zero point / reference point of station 3
Setting the absolute position 1/2
Setting the absolute position 2/2
Project 14: Monitoring and controlling drive controllers using the PLC – Connecting power
FRIDAY Executing
Creating program modules
Power modules for both axes
Reset modules for both axes
Program call main program PlcProg
Project 15: Monitoring and controlling drive controllers using the PLC – Approaching a point
Executing
“Stop” of the axes in emergencies
Stop modules for the axes
“MC_MoveAbsolute” module
“MC_MoveAbsolute” modules Move1
“MC_MoveAbsolute” modules Move2
Project 16: Monitoring and controlling drive controllers using the PLC – Picking up and storing a workpiece
MC_MoveRelative module
 Additional PLCopen modules
MoveAbsolute modules for the axes.
Settings for the “Station 3” program
Project 17: Networking the entire system and
communication test
Networking stations 1-3
Ethernet network connections
Connection test to network participants
Project 18: Integration of the RFID communication into station 1
RFID hardware integration into IndraWorks project – Station 1
IndraWorks PROFIBUS participant ID200
ID200 library module
Single Read Data
Enhanced Read Data
Enhanced Write Data
RFID_Visu
LUNCH BREAK
Project 19: Integration of the RFID communication into station 2
SATURDAY RFID hardware integration into IndraWorks project – Station 2
IndraWorks PROFIBUS participant 1 ID200
Single Read Data
Project 20: Integration of the RFID communication into station 3
IndraWorks PROFIBUS participant ID200
The module (ST) can be created as “RFID1” for station 1
Single Read Data
Single Write Data
Enhanced Read Data
Enhanced Write Data
Project 08: Transferring data via OPC UA server
Example: Pragma
Example: Symbol configuration
Pragma integration into variable lists
Transfer via symbol configuration
Test of the variable transfer
Project 09: Open Core Interface for access to the mMS 4.0 via MLPI
MLPI_SDK installation
Transferring Accounts.xml
Project 10: MES system via SAP ME
SAP ME use – start of the programs
SAP ME use – operation of the programs
Create new production order
Release production orders
SAP ME use – operation of the PODs
Project 11: MES system via Excel
Excel use – start of the program
Excel use – operation of the program
Project 12: Use of the WebConnector
WebConnector - Installation
WebConnector - use
Project 13: mMS use and illustration of data using the ActiveCockpit
SUNDAY
ActiveCockpit – Setup
ActiveCockpit – Operation, administration interface
Administration interface
Creating widgets
Creating layouts
Creating meetings
Project 14: Condition monitoring - Air flow measurement
SD5000 configuration
Reading out the SD5000 measured values using IndraWorks
Transfer value to OPC UA
Project 15: Condition Monitoring - current consumption measurement
Reading out the WAA current transformer measured values using IndraWorks
Reading out measured values
Transfer value to OPC UA
Final Assessment