Festo Distributing Station User manual

648811 EN
04/06 R2.2
Distributing station
Manual

This station has been developed and produced solely for vocational and further
training purposes in the field of automation and technology. The company
undertaking the training and/or the instructors is/are to ensure that trainees
observe the safety precautions described in the manuals provided.
Festo Didactic herewith excludes any liability for damage or injury caused to
trainees, the training company and/or any third party, which may occur if the system
is in use for purposes other than purely for training, unless the said damage/injury
has been caused by Festo Didactic deliberately or through gross negligence.
Order No.:
Status:
Authors:
Graphics:
Layout:
648811
04/2006
Frank Ebel, Markus Pany
Doris Schwarzenberger, Albert Sigel
04/2006
© Festo Didactic GmbH & Co. KG, D-73770 Denkendorf, 2006
Internet: www.festo-didactic.com
e-mail: [email protected]
The copying, distribution and utilisation of this document as well as the
communication of its contents to others without express authorisation is
prohibited. Offenders will be held liable for the payment of damages. All rights
reserved, in particular the right to carry out patent, utility model or ornamental
design registration.
Intended use

© Festo Didactic GmbH & Co. KG  3
1. Introduction ____________________________________________________ 5
1.1 Training contents ________________________________________________ 6
1.2 Important notes _________________________________________________ 7
1.3 Duty of the operating authority _____________________________________ 7
1.4 Duty of trainees__________________________________________________ 7
1.5 Risks involved in dealing with the Modular Production System___________ 8
1.6 Warranty and liability _____________________________________________ 9
1.7 Intended use ____________________________________________________ 9
2. Notes on safety_________________________________________________ 11
3. Technical data _________________________________________________ 13
3.1 Combinations __________________________________________________ 13
4. Transport/Unpacking/Scope of delivery ___________________________ 15
5. Design and function _____________________________________________ 17
5.1 The Distributing station __________________________________________ 17
5.2 Function _______________________________________________________ 19
5.3 Sequence description____________________________________________ 19
5.4 Stack magazine module __________________________________________ 20
5.5 Changer module ________________________________________________ 21
6. Commissioning _________________________________________________ 23
6.1 Workstation ____________________________________________________ 23
6.2 Mechanical set up _______________________________________________ 24
6.2.1 Assembling profile plate and control console ________________________ 24
6.2.2 Assembling the station___________________________________________ 25
6.3 Adjust sensors__________________________________________________ 26
6.3.1 Proximity sensor (Stack magazine, ejecting cylinder) __________________ 26
6.3.2 Through-beam sensor (Stack magazine, filling level) __________________ 27
6.3.3 Micro switch (Changer, swivel drive) _______________________________ 28
6.3.4 Vacuum switch (Changer, vacuum suction cup) ______________________ 29
6.4 Adjusting one-way flow control valves ______________________________ 30
6.5 Visual check____________________________________________________ 30
6.6 Cable connections_______________________________________________ 31
6.7 Pneumatic connection ___________________________________________ 32
6.7.1 Manual override ________________________________________________ 32
6.8 Voltage supply _________________________________________________ 32
Contents

Contents
4© Festo Didactic GmbH & Co. KG 
6.9 Loading the PLC program _________________________________________ 33
6.9.1 Siemens controller ______________________________________________ 33
6.9.2 Festo controller _________________________________________________ 36
6.9.3 Allen Bradley controller __________________________________________ 38
6.9.4 Mitsubishi/MELSEC controller _____________________________________ 41
6.10 Starting the sequence ___________________________________________ 43
6.11 Combination of stations __________________________________________ 44
6.11.1 Networking ____________________________________________________ 44
6.11.2 Hardware modifications __________________________________________ 44
7. Maintenance ___________________________________________________ 45
Appendix ____________________________________________________________ 47
Distributing station with AS-Interface_______________________________ 47
Updates ____________________________________________________________ 49

© Festo Didactic GmbH & Co. KG  5
The Festo Didactic Learning System for Automation and Technology is designed to
meet a number of different training and vocational requirements. The systems and
stations of the Modular Production System (MPS ) facilitate industry-orientated
vocational and further training and the hardware consists of didactically suitable
industrial components.
The Distributing station provides you with an appropriate system for practice-
orientated tuition of the following key qualifications
Social competence,
Technical competence and
Methodological competence
Moreover, training can be provided to instil team spirit, willingness to cooperate and
organisational skills.
Actual project phases can be taught by means of training projects, such as:
Planning,
Assembly,
Programming,
Commissioning,
Operation,
Maintenance and
Fault finding.
1. Introduction

1. Introduction
6© Festo Didactic GmbH & Co. KG 
Training contents covering the following subjects can be taught:
Mechanics
Mechanical construction of a station
Pneumatics
Piping connections of pneumatic components
Vacuum technology
Pneumatic linear and rotary drives
Electrical
Correct wiring of electrical components
Sensors
Correct use of limit switches
PLC
Programming and use of a PLC
Structure of a PLC program
Commissioning
Commissioning of a production system
Fault finding
Systematic fault finding on a production system
Topics for project work
Replacing a relay control system with a PLC
Selecting pneumatic components
Linear drives
Rotary drives
Vacuum cups
Safety during pneumatic power failure
Vacuum reservoir
PLC programming
Programming of an operational section
Programming of a RESET sequence
Programming of an EMERGENCY-STOP function
Optimising cycle time
1.1
Training contents

1. Introduction
© Festo Didactic GmbH & Co. KG  7
The basic requirement for safe use and trouble-free operation of the MPS is to
observe the fundamental safety recommendations and regulations.
This manual contains important notes concerning the safe operation of the MPS .
The safety recommendations in particular must be observed by anyone working on
the MPS .
Furthermore, the rules and regulations for the prevention of accidents applicable to
the place of use must be observed.
The operating authority undertakes to ensure that the MPS is used only by persons
who:
are familiar with the basic regulations regarding operational safety and accident
prevention and who have received instructions in the handling of the MPS ,
have read and understood the chapter on safety and the cautionary notes in this
manual.
Safety-conscious working of the persons should be regularly vetted.
Prior to commencing work, all persons assigned to working on the MPS have a duty
to:
read the chapter on safety and the cautionary notes in this manual and,
observe the basic regulations regarding operational safety and the prevention of
accidents.
1.2
Important notes
1.3
Duty of the operating
authority
1.4
Duty of trainees

1. Introduction
8© Festo Didactic GmbH & Co. KG 
The MPS is designed according to state of the art technology and in compliance
with recognised safety regulations. However when using the system there is
nevertheless a risk of physical or fatal injury to the user or third parties or of damage
being caused to the machinery or other material assets.
The MPS is to be used only:
for its intended purpose and
in an absolutely safe conditions.
Faults impairing safety must be rectified immediately!
1.5
Risks involved in dealing
with the Modular
Production System

1. Introduction
© Festo Didactic GmbH & Co. KG  9

operating authority upon conclusion of the contract at the latest. Warranty and
liability claims for persons or material damage are excluded if these can be traced
back to one or several of the following causes:
Use of the MPS not in accordance with its intended purpose
Incorrect assembly, commissioning, operation and maintenance of the MPS
Operation of the MPS using faulty safety equipment or incorrectly fitted or non
operational safety or protective devices
Non observance of notes in the manual regarding transport, storage, assembly,
commissioning, operation, maintenance and setting up of the MPS
Unlawful constructional modifications on the MPS
Inadequate monitoring of components subject to wear
Incorrectly carried out repairs
Catastrophies as a result of foreign bodies and vis major.
Festo Didactic herewith rules out any liability for damage or injury to trainees, the
training company and/or other third parties which may occur during the
use/operation of the system other than purely in a training situation, unless such
damage has been caused intentionally or due to gross negligence by Festo Didactic.
This system has been developed and produced exclusively for vocational and further
training in the field of automation and technology. The training authority and/or the
instructors is/are to ensure that trainees observe the safety precautions described
in the manual provided.
The use of the system for its intended purpose also includes:
following all advice in the manual and
carrying out inspection and maintenance work.
1.6
Warranty and liability
1.7
Intended use

1. Introduction
10 © Festo Didactic GmbH & Co. KG 

© Festo Didactic GmbH & Co. KG  11
General
Trainees must only work on the station under the supervision of an instructor.
Observe the data in the data sheets for the individual components, in particular
all notes on safety!
Electrics
Electrical connections are to be wired up or disconnected only when power is
disconnected!
Use only low voltages of up to 24 V DC.
Pneumatics
Do not exceed the permissible pressure of 8 bar (800 kPa).
Do not switch on compressed until you have established and secured all tubing
connections.
Do not disconnect air lines under pressure.
Particular care is to be taken when switching on the compressed air. Cylinders
may advance or retract as soon as the compressed air is switched on.
Mechanics
Securely mount all components on the plate.
No manual intervention unless the machine is at rest.
2. Notes on safety

2. Notes on safety
12 © Festo Didactic GmbH & Co. KG 

© Festo Didactic GmbH & Co. KG  13
Parameter
Value
Operating pressure
6 bar (600 kPa)
Voltage supply
24 V DC, 4.5 A
Digital inputs
7
Digital outputs
7
Possible direct MPS downstream stations
MPS
station
Testing
(PR)
Proces-
sing
(BE)
Hand-
ling
(HA)
Buffer
(PU)
Pick&
Place
(PP)
Fluidic-
Muscle
Press
(FP)
Separat-
ing
(TR)
Storing
(LA)
Robot
(R)
Assembly*
(MO/HS)
Sorting**
(SO)
Distributing***
(VE)
Testing
(PR)
Processing
(BE)
Handling
(HA)
Buffer
(PU)
Pick&Place
(PP)
FluidicMuscle
Press (FP)
Separating
(TR)
Storing
(LA)
Robot
(R)
Assembly*
(MO/HS)
* Assembly with Punching / ** Sorting DP / *** Distributing AS-Interface
3. Technical data
3.1
Combinations

3. Technical data
14 © Festo Didactic GmbH & Co. KG 

© Festo Didactic GmbH & Co. KG  15
Transport
The MPS is delivered in a container with a pallet base.
The container must be transported on a suitable fork lift truck at all times and must
be secured against tipping or falling off.
The carrier and Festo Didactic are to be notified immediately of any damage caused
during transport.
Unpacking
Carefully remove the padding material in the container box when unpacking the
station. When unpacking the station, make sure that none of the station assemblies
have been damaged.
Check the station for any possible damaged once unpacked. The carrier and Festo
Didactic are to be notified immediately of any damage.
Scope of delivery
Check the scope of delivery against the delivery note and the order. Festo Didactic
must be notified immediately of any discrepancies.
4. Transport/Unpacking/Scope of delivery

4. Transport/Unpacking/Scope of delivery
16 © Festo Didactic GmbH & Co. KG 

© Festo Didactic GmbH & Co. KG  17
The Distributing station is a feed device. According to VDI 3240, feed devices are
defined as units which fulfil the function of bunkering, sorting and feeding of
components. In addition, feed devices can facilitate the sorting of components
according to various sorting characteristics (shape, weight etc. of the component).
The following are feed devices:
Magazines with feed limiting,
Vibratory bowl feeder,
Inclined conveyors and
Hoppers with sorting devices.
Workpieces handled by feed devices are
Electroplated parts,
Shaped parts made of plastic,
Punched parts and
Turned components.
5. Design and function
5.1
The Distributing station

5. Design and function
18 © Festo Didactic GmbH & Co. KG 
The function of the Distributing station is
to separate out workpieces from a magazine and
to transfer workpieces by means of a rotary drive using a suction cup.
The Distributing station consists of the following:
Stack magazine module
Changer module
Profile plate
Trolley
Control console
PLC board
Distributing station with trolley, control console and PLC board

5. Design and function
© Festo Didactic GmbH & Co. KG  19
The Distributing station separates workpieces from the Stack magazine module. The
magazine barrel of the stack magazine holds up to 8 workpieces. The filling level of
the stack magazine is monitored by means of a through-beam sensor. A double-
acting cylinder pushes out the workpieces individually.
The Changer module grips the separated out workpiece using a suction cup. A
vacuum switch checks whether a workpiece has been picked up. The arm of the
transfer unit, which is driven by a rotary drive, conveys the workpiece to the transfer
point of the downstream station.
Start prerequisites
Magazine is filled with workpieces
Initial position
Ejecting cylinder is extended

Vacuum is off
Sequence
1. 
identified in the magazine and the START button is pressed.
2. The ejecting cylinder retracts and pushes a workpieces out of the magazine.
3. 
4. The vacuum is switched on. When the workpiece is securely held, a vacuum
switch switches.
5. The ejecting cylinder advances and releases the workpiece.
6. 
7. The vacuum is switched off.
8. 
5.2
Function
5.3
Sequence description

5. Design and function
20 © Festo Didactic GmbH & Co. KG 
The Stack magazine module separates workpieces from a magazine. Up to
8 workpieces can be stacked in any order in the magazine barrel. The workpieces
must be inserted with the open side facing upwards.
A double-acting cylinder pushes the lowest workpiece from the gravity-feed
magazine up to the mechanical stop. This position serves as a transfer point to the
next module (e.g. Changer module).
The available workpiece in the magazine barrel is detected by means of a through-
beam sensor. The position of the ejecting cylinder is sensed electrically via inductive
sensors. The advancing and retracting speed of the ejecting cylinder is infinitely
adjustable by means of one-way flow control valves.
5.4
Stack magazine module