DC-R/Copyright Festo Didactic GmbH&Co. KG Principles of Mechatronics Technology Professional Development Instructor Workshop Presented by David Kempskie Senior Technology Consultant

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

DC-R/Copyright Festo Didactic GmbH&Co. KG Mechatronics is... 3 Vending Machines 3D printers Industrial Automation ATM Machines Medical Devices

DC-R/Copyright Festo Didactic GmbH&Co. KG Manufacturing of Cars at Ford 4 x y

DC-R/Copyright Festo Didactic GmbH&Co. KG Production of Cars with Industrial Robots 5 x y z

DC-R/Copyright Festo Didactic GmbH&Co. KG Automated Assembly Line 6

DC-R/Copyright Festo Didactic GmbH&Co. KG MecLab ® 7

DC-R/Copyright Festo Didactic GmbH&Co. KG Air Compressor 8 Industrial Compressor ISO Symbol

DC-R/Copyright Festo Didactic GmbH&Co. KG 4/2-Way Solenoid Valve 9 4/2-Way-Valve Monostable4/2-Way-Valve Bistable

DC-R/Copyright Festo Didactic GmbH&Co. KG Single and Double Acting Cylinder 10

DC-R/Copyright Festo Didactic GmbH&Co. KG Proximity Switches for Pneumatical Cylinders 11 Piston with MagnetBarrel

DC-R/Copyright Festo Didactic GmbH&Co. KG Programmable Logic Controllers 12

DC-R/Copyright Festo Didactic GmbH&Co. KG MecLab ® Station Stack Magazine 13

DC-R/Copyright Festo Didactic GmbH&Co. KG MecLab ® Station Conveyor 14

DC-R/Copyright Festo Didactic GmbH&Co. KG MecLab ® Station Handling 15

DC-R/Copyright Festo Didactic GmbH&Co. KG ACTUATORS 16

DC-R/Copyright Festo Didactic GmbH&Co. KG Profile Cylinder 17

DC-R/Copyright Festo Didactic GmbH&Co. KG Mechanical Grippers - Types 18

DC-R/Copyright Festo Didactic GmbH&Co. KG Mechanical Grippers – Working Principle 19 Housing Gripper jaws slider Piston Bearings

DC-R/Copyright Festo Didactic GmbH&Co. KG Vacuum Grippers – Working Principle 20 1Supply port 2Vacuum port 3Exhaust port Vacuum generator Suction Cup

DC-R/Copyright Festo Didactic GmbH&Co. KG Inline-Type Vacuum Generator 21 PSupply port VVacuum port RExhaust port P R V

DC-R/Copyright Festo Didactic GmbH&Co. KG DC-Motor – Picture and Symbol 22

DC-R/Copyright Festo Didactic GmbH&Co. KG Solenoid 23

DC-R/Copyright Festo Didactic GmbH&Co. KG CONTROL VALVES 24

DC-R/Copyright Festo Didactic GmbH&Co. KG One Way Flow Control Valve 25

DC-R/Copyright Festo Didactic GmbH&Co. KG Flow Control 26

DC-R/Copyright Festo Didactic GmbH&Co. KG 3/2 and 4/2 Way Valve – Working Principle 27

DC-R/Copyright Festo Didactic GmbH&Co. KG 4/2-Way-Valve - Cut-Away Drawing 28

DC-R/Copyright Festo Didactic GmbH&Co. KG 4/2-Way-Valve – Cut Away Drawing (II) 29

DC-R/Copyright Festo Didactic GmbH&Co. KG CONTROLS & SENSORS 30

DC-R/Copyright Festo Didactic GmbH&Co. KG Electrical Switches 31 Normally open contacttoggle switch Normally closed contact

DC-R/Copyright Festo Didactic GmbH&Co. KG Relays 32

DC-R/Copyright Festo Didactic GmbH&Co. KG Pressure Switch 33

DC-R/Copyright Festo Didactic GmbH&Co. KG Optical Proximity Switches (Thru Beam) 34 Transmitter Receiver TransmitterReceiver Without Object With Object

DC-R/Copyright Festo Didactic GmbH&Co. KG Thru Beam Sensor - Applications 35 Standstill control in feeding unitsParts detection in handling devices and transfer presses

DC-R/Copyright Festo Didactic GmbH&Co. KG Thru Beam Sensor – Applications (II) 36 Object detection in harsh environmentsObject detection at long distances

DC-R/Copyright Festo Didactic GmbH&Co. KG Optical Proximity Switches – Retro Reflective Sensor 37 S E S E Without Object With Object Mirror Retro-Reflective Sensor Transmitter + Receiver

DC-R/Copyright Festo Didactic GmbH&Co. KG Retro Reflective Sensor - Applications 38 Position control of small objectsIC-pins control

DC-R/Copyright Festo Didactic GmbH&Co. KG Optical Proximity Switches – Diffuse Sensor 39 S E S E Without Object With Object Object Diffuse Sensor Transmitter + Receiver

DC-R/Copyright Festo Didactic GmbH&Co. KG Diffuse Sensor - Applications 40 IC-Pin inspectionRecognition of objects with different contrasts

DC-R/Copyright Festo Didactic GmbH&Co. KG Inductive Proximity Switches 41 corecoilOscillatorMagnetic Field Without Object With Object

DC-R/Copyright Festo Didactic GmbH&Co. KG Inductive Sensors - Applications 42 Object Detection

DC-R/Copyright Festo Didactic GmbH&Co. KG Open and Closed Loop Control 43 x y Process Controller xy

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

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

DC-R/Copyright Festo Didactic GmbH&Co. KG THE AUTOMATION PYRAMID COMMUNICATION

DC-R/Copyright Festo Didactic GmbH&Co. KG AUTOMATION TECHNOLOGY by LEVELS LEVEL 1: Field Level SENSORS/TRANSDUCERS ELECTRICAL ACTUATORS MECHANICS PNEUMATICS HYDRAULICS ROBOTICS ARTIFICIAL VISION IDENTIFICATION SYSTEMS COMMUNICATIONS

DC-R/Copyright Festo Didactic GmbH&Co. KG LEVEL 2: Control Level PROGRAMMABLE LOGICAL CONTROLLER (PLC) P.I.Ds PERSONAL COMPUTERS FREQUENCY CONVERTER COMMUNICATIONS AUTOMATION TECHNOLOGY by LEVELS

DC-R/Copyright Festo Didactic GmbH&Co. KG LEVEL 3: Supervision Level SUPERVISION, CONTROL & DATA ACQUISITION (SCADA). COMMUNICATIONS AUTOMATION TECHNOLOGY by LEVELS

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

DC-R/Copyright Festo Didactic GmbH&Co. KG 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 AUTOMATION TECHNOLOGY by LEVELS

DC-R/Copyright Festo Didactic GmbH&Co. KG The Factory – Critical Elements to Production Manufacturing Engineering Design and conceive new production tools Develop and implement 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 Maintenance Management Implement preventive maintenance on equipment Diagnose and repair system failures Sales – Orders received and processed Purchasing/Planning – Raw materials purchased based on anticipated orders Production Management – In charge of all manufacturing operations Production Supervisor Dispatches orders Relays all critical information to upper management

DC-R/Copyright Festo Didactic GmbH&Co. KG Factory Network Communications COMMUNICATION

DC-R/Copyright Festo Didactic GmbH&Co. KG Factory Network Communications COMMUNICATION

DC-R/Copyright Festo Didactic GmbH&Co. KG Factory Network Communications COMMUNICATION

DC-R/Copyright Festo Didactic GmbH&Co. KG Factory Network Communications COMMUNICATION

DC-R/Copyright Festo Didactic GmbH&Co. KG Factory Network Communications COMMUNICATION

DC-R/Copyright Festo Didactic GmbH&Co. KG Factory Network Communications COMMUNICATION

DC-R/Copyright Festo Didactic GmbH&Co. KG Factory Network Communications COMMUNICATION

DC-R/Copyright Festo Didactic GmbH&Co. KG Factory Network Communications COMMUNICATION

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

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

DC-R/Copyright Festo Didactic GmbH&Co. KG LEVEL 2: Control Level Factory Operations Independent PLC-operated work cells Control level technology devices Semi-Autonomous start/stop/selection processes Human intervention Orders processed manually Device layer communication

DC-R/Copyright Festo Didactic GmbH&Co. KG LEVEL 2: Control Level Factory Operations Independent PLC-operated work cells Control level technology devices Semi-Autonomous start/stop/selection processes Human intervention Orders processed manually Device layer communication

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

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

DC-R/Copyright Festo Didactic GmbH&Co. KG LEVEL 4 & 5 : Integrated “Smart Factory” Operations MES and ERP integration Fully-Autonomous start/stop/selection processes Human intervention unnecessary Orders processed, scheduled and prioritized by Production, Sales and Purchasing management Information layer communications

DC-R/Copyright Festo Didactic GmbH&Co. KG LEVEL 4 & 5 : Integrated “Smart Factory” Operations MES and ERP integration Fully-Autonomous start/stop/selection processes Human intervention unnecessary Orders processed, scheduled and prioritized by Production, Sales and Purchasing management Information layer communications