Festo MPS transfersystem User manual

MPS transfersystem
manual
transfer line station

2 -transfer system
This document consists of 4 parts, divided up into:
Part A contains the manual of the system or station.
Part B, in as far as present, contains a collection of exercises together with the
relevant solutions or additional information.
Part C contains the circuit diagram of the system or station.
Part D contains the data sheets of the system or station.
Order-NR.:
Type:
Manual transfersystem
Designation
MPS_Transfer_line_manual_A004.doc
Printed:
April 10
Autor:
Schober
Graphics:
Schober
Layout:
Schober
© Festo Didactic GmbH & CoKG., D-73770 Denkendorf, 2010
Internet: www.festo.com/didactic
e-mail: [email protected]m
This manual, all text and illustrations included, is protected by copyright. Any utilization outside the
limits of the copyright law and other than training purposes are not permissible without our definite
approval. This applies in particular to reproductions, operations, translations, micro filming and the
storing and processing into electronic systems. Parts of this manual may be copied by the authorized
user, exclusively for teaching purposes. Distribution of this documentation, as well as reproduction,
use and spread of its contents is prohibited, insofar not permitted explicitly. Offences are liable to
compensation. All rights reserved, especially the right to execute registrations concerning patents,
designs for use and patterns.

Intended use
© Festo Didactic GmbH & -transfer system 3
The User Manual must be to hand at all times. Keep it close to the machine.
Intended use
This installation was developed and manufactured only for use in basic and further
training in the fields of automation and communications. The training company
and/or the training staff must ensure that the trainees observe the safety
precautions described in the accompanying manuals.
Furthermore this manual describes setup and possible uses of the singular stations.
It contains all information and data required for commissioning, maintenance and
operation.
Festo Didactic accepts no liability for injury or harm to trainees, the training
company and/or any third parties occurring when the installation is used for any
purpose apart from training, except Festo Didactic has caused such injury or harm
intentionally or by grossly negligence.

4 -transfer system

-transfer system 5
Content
1Introduction _______________________________________________________ 9
1.1 General information MPS transfer system ___________________________ 9
1.2 Transfer line __________________________________________________12
1.2.1 Drive variants _____________________________________________14
1.2.2 Extension of transfer line with operation panel__________________18
1.2.3 Extension of transfer line with sensor set MT ___________________20
1.2.4 Extension of transfer line with function modules MW_____________22
1.2.5 Extension of transfer line with function modules MP _____________25
1.2.6 Controller options__________________________________________27
1.2.7 Net work possibilities ______________________________________29
1.2.8 Profibus adresses module ___________________________________30
1.2.9 Combination of transfer lines with a working place ______________30
1.2.10 Combination of transfer line with a working place and MPS stations 31
1.2.11 Combination multi transfer lines______________________________32
1.3 Work pieces and workpiece carriers _______________________________33
1.3.1 Workpiece variants_________________________________________33
1.3.2 Transportation variants _____________________________________34
1.3.3 Workpiece carrier variants___________________________________35
2General safety instructions __________________________________________37
2.1 Use according to regulations_____________________________________37
2.2 Handling the system____________________________________________37

Content
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2.2.1 Dangers in handling the machine _____________________________37
2.2.2 Safety precautions in standard operation ______________________37
2.2.3 Dangers due to electric current_______________________________38
2.2.4 Dangers due to pneumatic energy ____________________________38
2.2.5 Maintenance Servicing Malfunction removal_________________39
2.2.6 Organizational measures____________________________________39
2.3 Personnel ____________________________________________________39
2.3.1 Notes on personnel ________________________________________39
2.3.2 Training operations ________________________________________39
2.3.3 Outside training operations _________________________________39
2.3.4 Safety symbols ____________________________________________40
3Start-up __________________________________________________________41
3.1 Transport_____________________________________________________41
3.2 Set-up _______________________________________________________42
3.2.1 General information ________________________________________42
3.2.2 Assembly of modules _______________________________________43
3.2.3 Pneumatical connection of modules __________________________44
3.2.4 Electrical connection of modules _____________________________45
3.2.5 Connection from modules with operation panel _________________49
3.2.6 Connection from modules without operation panel ______________54
3.3 Commissioning ________________________________________________60
3.3.1 Pneumatical commissioning _________________________________60

Content
© Festo Didactic GmbH & -transfer system 7
3.3.2 Electrical commissioning ____________________________________60
3.3.3 SYS link interface __________________________________________61
3.3.4 37 pol Sub-D plug (X1) at module distributor ___________________62
3.3.5 37 pol Sub-D socket (X2) at module distributor _________________63
3.3.6 Prepare electrical connections _______________________________64
3.3.7 Prepare motor connections DC-motor _________________________66
3.3.8 Prepare motor connections AC-motor _________________________74
3.3.9 Mini terminal______________________________________________79
3.3.10 Drive variant with gear box __________________________________81
3.3.11 Change motor _____________________________________________83
3.3.12 Emergency stop system _____________________________________85
3.4 Visual check __________________________________________________87
3.5 Start-up ______________________________________________________87
4Operation ________________________________________________________89
4.1 General notes on operation ______________________________________89
4.1.1 Handling regulations _______________________________________89
4.1.2 Operating regulations ______________________________________89
4.2 Transfer line __________________________________________________90
5Fault finding ______________________________________________________91

Content
8 -transfer system

-transfer system 9
The Festo Didactic Learning System is designed to meet a number of different
training and vocational requirements. The modules of the MPS transfer system are
industry-orientated vocational and further training. The hardware consists of
didactically for didactic training industrial components.
The stations provides an appropriate system for practice-orientated
education/classes of the following key qualifications
Social competence,
Technical competence and
Method competence
Moreover, training can be provided to instill team spirit, willingness to cooperate
and organizational skills.
Actual project phases can be taught by means of training projects, such as:
Planning,
Assembly,
Programming,
Commissioning,
Operation,
Maintenance
Fault finding and
Trouble shooting.
This manual describes the handling of the MPS transfer system. It contains
explanations and descriptions of all the processes required for operation. Facts are
partly described with the help of graphics or images subserving an easier
understanding.
Complete operating instructions which explain the processes of the system are
available for working with the system. Additionally to technical and social
competence, the comprehension of the process and the interaction of the respective
components appear in clear presentation. Festo Didactic succeeded in using the
most updated industrial hard- and software for this model production.
1Introduction
1.1 General information
MPS transfer system

Introduction
10 -transfer system
The MPS transfer system is developed for all apprentices who want to move
someth- or metal profession, for
mechatronics, technician- or engineer education.
During technical lessons for pupils we use our simple models with o-ring drive. In
the MPS transfer system the material flow is realized with a common industrial belt.
In industrial, automated production, special belts are essential part of the
production system. Products with different measurements are transported on belts
with different widths or on double belts.
The transfer system is a modular system which consists of two essential
components. First the transfer line which can be equipped with different drive
concepts and second the constitutive modules for topics like sensors, electrical
positioning, handling, assembling, camera inspection, barcode scanning, RFID and
many others.
A range of laboratory equipment and a trolley specially tailored to the MPS transfer
system creates the optimum working environment for you.
Standardised interfaces, A4 mounting mounting frame and a wide range
of different control components complete the system.
The module families are different in the way of transport. The workpiece is
transported and processed directly on the belt in the MW family.
In the MP family the workpiece is transported on a workpiece carrier. The carrier is
on the belt, the workpiece is processed on the carrier.
Concept
Transfer system with
modules
Workstation
Control concept
Module families

Introduction
© Festo Didactic GmbH & -transfer system 11
System overview

Introduction
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The transfer line is the basic component of the MPS® transfer system. It is made up of
a belt, drive, controls and sensors and comes fully assembled. The transfer line can
be used to transport workpieces or workpiece holders. The transfer line can be fitted
with up to two mechatronic modules.
according to customer needs extension and
additions are possible at each time.
The length of the belt in the transfer line is 700 mm and the width is 80 mm.
Transfer line front view
Position
Description
Position
Description
1
Empty plate
4
Operation panel
2
Motor controller DC / variant
5
Emergency stop
3
Mini terminal
1.2 Transfer line

Introduction
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Transfer line back view
Position
Description
Position
Description
1
Belt 80mm width
transfer line 700mm length
5
Pneumatic distributor
2
Redirection
6
Drive head
3
Module distributor
7
motor different variants possible
4
Clamping unit
The system ports are realized that all additional modules can easily be connected at
the transfer line. The clamping unit is designed for additional customer applications.

Introduction
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1.2.1 Drive variants
DC motor, AC motor, servomotor or motor with integrated CAN Controller it is
easily possible to combine the conveyor with all these drives. Professional clutches
or drive belt gearboxes provide a maximum of industrial practice at optimal didactic
modularity.
Position
Description
Position
Description
1
AC-motor variant
2
DC motor variant
The AC and DC motor variants are already implemented; other drives are for optional
disposal.

Introduction
© Festo Didactic GmbH & -transfer system 15
For operation with DC-motors a 4 quadrant drive controller is available.
With the 4-quadrant drive controller it is possible to realize a clockwise or a anti
clockwise rotation. The controller is triggered directly via I/O or via AS-Interface.
With the buttons on the controller it is possible to control the connected drive
manually during the commissioning or the maintenance and diagnostic process.
Pos.
Description
Technical data
1
Connection panel with I/ O
interface
Mini-Terminal (378355)
2
Connection panel with AS-i
interface
ASI Module (56419)
3
Drive controller DC 4Q
M-MZS-4-30
4
DC-Motor
Voltage: 24 VDC
Current: 1,5 A
Duty cycle motor: 100 % ED
Nominal rotation: 75 U/Min
DC motor with 4Q
controller
with I/O or AS-I

Introduction
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For operation with DC-motors a starting current limiter is available.
The current limiter reduces the start up peak to 2amp during start up. Besides the
module is operated like a relay.
Pos.
Description
Technical data
1
Connection panel with I/ O
interface
Mini-Terminal (378355)
2
Connection panel with AS-i
interface
ASI Module (56419)
3
Current limiter
Voltage:24 VDC
Current: 1 A
Current limit: 2 A
Time of limiting max. 50 ms
Frequency of operation 1 / sec.
4
DC-Motor
Voltage: 24 VDC
Current: 1,5 A
Duty cycle motor: 100 % ED
Nominal rotation: 75 U/Min
DC motor with current
limiter
with I/O or AS-I

Introduction
© Festo Didactic GmbH & -transfer system 17
For operation with AC-motors the frequency converter MM420 is necessary.
Pos
Description
Technical data
1
Motor
Voltage motor: 240 V AC
Current motor: 0,17 A
Power: 22 W
Engine speed: 2600 U/min
Torque: 8,7 Ncm
Gear box: 1:35
2
Frequency converter MM420
Build up in A4 casing with Profibus interface
and operation panel
AC motor with frequency
converter

Introduction
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1.2.2 Extension of transfer line with operation panel
Pos.
Description
1
Variant without operation panel
2
Variant with operation panel
The functions of the operation panel are described in the respective chapter.

Introduction
© Festo Didactic GmbH & -transfer system 19
Backside operation panel
Pos.
Description
1
Plug Sub-D 15 pins (2x available)
2
SYS-link plug 24 pins (2x available)
3
Clamp unit (1x available, parallel wired to Pos. 4)
4
Plug Sub-D 15 pins (1x available, parallel to Pos. 3)

Introduction
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1.2.3 Extension of transfer line with sensor set MT
The sensors at front- and rear end of belt are made of one way optical-fibre
waveguides. The fibre-optic is easy to assemble at the conveyors profile. Adjust the
fibre-optic in dependence of the application. Assemble maximum 3 sensor sets.
Sensor set MT
Description
Ordernumber
Fibre-optic cable
SOEZ-LLK-SE-2,0-M4
165360
Fibre-optic unit
SOEG-L-Q30-NA-S-2L
165327
Plug socket with cable
SIM-M8-4WD-2,5-PU
158962
Angle for fibre-optic unit
Sensor bracket M4
Sensor bracket 12 mm