Festo MPS 2000 User manual

© Festo Didactic GmbH & Co. • MPS 1
Handling Station
MPS 2000
Instructors Edition

Order no.:
Description: Mechatronics Teachware Handling Station MPS 2000
Designation: Instructors Edition
Status:
Author: Wolfgang Eckart, ADIRO Automatisierungstechnik GmbH
Graphics: Wolfgang Eckart, Festo Didactic GmbH & Co
Layout: Festo Didactic GmbH & Co
© Festo Didactic GmbH & Co., D-73770 Denkendorf, 2002
Internet: www.festo.com/didactic
e-mail: [email protected]
All rights reserved, including translation rights. No part of this publication may be reproduced or
transmitted in any form or by any means, electronic, mechanical, photocopying, or otherwise, without
the prior written permission of Festo Didactic.

© Festo Didactic GmbH & Co. • MPS 1
Table of Contents.....................................................................................................1
Introduction.............................................................................................................3
What is Mechatronics ...........................................................................................3
Project overview...................................................................................................6
Commissioning.........................................................................................................9
1.1 Analysis –Components identification .......................................................9
1.2 Analysis –Cable connections..................................................................11
1.3 Analysis –Input and Output adresses......................................................13
1.4 Analysis–Input and Output adresses expanded......................................17
1.5 Commissioning –Adjustment of the Station ............................................21
1.6 Commissioning –Adjustment of the Station expanded............................23
1.7 Commissioning –Download Project and Test..........................................28
Programming .........................................................................................................33
2.1 Programming -Hardwareconfiguration....................................................33
2.2 Programming –Basics in Digital Technology –AND .................................46
2.3 Programming –Basics in Digital Technology –OR....................................61
2.4 Programming –Basics in Digital Technology –RS-Flip-Flop......................66
2.5 Programming –Basics in Digital Technology –AND NOT..........................71
2.6 Programming –Basics in Digital Technology –IDENTITY..........................74
2.7 Programming –Condition Call of a Program.............................................76
2.8 Programming –Condition Call of a Program expanded.............................79
2.9 Programming –On-Delay-Timer function .................................................88
Table of Contents

Table of Contents
2© Festo Didactic GmbH & Co. • MPS
2.10 Programming –Off-Delay-Timer function .............................................93
2.11 Programming –Counter Down function................................................95
2.12 Programming –Programming of a Flashlight........................................97
2.13 Programming –Programming of a Auto/Manu sequence......................99
2.14 Programming –Move to Starting Position..........................................101
2.15 Programming –Expanded movement to Starting Position..................104
2.16 Project –Basics of I/O–communication.............................................109
2.17 Project –Test the I/O–communication ..............................................113
2.18 Project –Material-flow through the FMS ...........................................119
Trouble Shooting..................................................................................................135
3.1 Program –Trouble Shooting..................................................................135
3.2 Process –Trouble Shooting ..................................................................164

© Festo Didactic GmbH & Co. • MPS 3
Mechatronics is a comprehensive combination of Technologies and is mostly
mentioned as a new way of thinking and learning and not as a “stand-alone”
technology.
The technological part of Mechatronics could be called Automation Technology.
elec
TRON
ic
MECHA
nic
informatIC
MECHATRONIC
Structure of Mechatronics
The structure of Mechatronical training is devided into three levels:
Basics single
technologies
Partly integrated
systems
Totally integrated
system
single technology:
Mechanic,Electric
Pneumatic,PLC
combination of:
Mechanic,Electric
Pneumatic,PLC
FMS-process:
material- and
signal flow
What is Mechatronics
Introduction

Introduction
4© Festo Didactic GmbH & Co. • MPS
The Basic Training in the single technologies is another part of training. In the
following you will see some examples of the different levels:
for totally integrated training
in the „Production Automation“ field of MECHATRONICS
Totally Integrated System
a combination of single technologies ...
... to a various amount of STATIONS
Partly Integrated Systems
electronics pneumatics hydraulics PLC
sensorics robotics CAD/CNC mechanics
Basic Technologies

Introduction
© Festo Didactic GmbH & Co. • MPS 5
Basically in Automation and Mechatronics training, the contents should cover the
following learning steps, or functions within a company:
Commissioning: Analyse a system, Installation&Commissioning
Programming: Programming single Station, Communication with other Stations
Trouble Shooting: Programming Errors, Trouble Shooting in the Process
which are covered within the following projects.
Furtheron this Teachware is based on the idea of a Flexible Manufacturing System –
FMS, this means, this station should be and is connected to other stations, called
Previous and Following Station within this Teachware.

Introduction
6© Festo Didactic GmbH & Co. • MPS
The following table give you an overview about all projects within this
documentation in the structure of:
Commissioning: Analysis (Analyse a system) and
Commissioning (Installation&Commissioning)
Programming: Programming (Programming single Station and
Project (Communication with other Stations)
Trouble Shooting: Program (Programming Errors) and
Process *(Trouble Shooting in the Process)
The table also mention the time which is necessary to work out the respective
project. This time is based on experience with participants coming with no
knowledge about the MPS-Stations and less knowledge about programming a
Simatic PLC with STEP 7.
*Regarding the Process-Trouble Shooting, there is no big difference in time between
the single troubles-based on experience we can say, that each trouble needs around
1,5 hour including the preparation and test of the error by the instructor and if the
participants follow the three steps carefully and doing the documentation, which is
very important.
This structure allows you to put your specific workshop together according to your
needs and your learning targets.
Project overview

Introduction
© Festo Didactic GmbH & Co. • MPS 7
Project overview Commissioning and Programming
Learning Step Designation Project Description Proj.. Page Time [h]
Commissioning Analysis Components identification:
description of the function of some components used within the stations 1.1 91h 30min
Commissioning Analysis Cable connections in the system:
define and identificate all cable connections in the FMS-system 1.2 11 30min
Commissioning Analysis In-and Output adresses of the PLC:
find out the hardwareadresses of in-and outputs in the technical docum. 1.3 13 30min
Commissioning Analysis In-and Output adresses of the PLC expanded:
find out the hardwareadresses of in-and outputs in the technical docum. 1.4 17 1h 30min
Commissioning Commissioning Adjustment of the Station:
check the adjustment all sensors and mechanical components 1.5 21 1h
Commissioning Commissioning Adjustment of the Station expanded:
check the adjustment all sensors and mechanical components 1.6 23 3h
Commissioning Commissioning Download Project and Test:
download all project-programs and test the function of the FMS-system 1.7 28 1h
Programming Programming Hardwareconfiguration of the PLC:
define the existing Siemens S7-300 PLC-hardware with the software STEP 7
2.1 33 1h
Programming Programming Basics in digital technology–AND:
programming of the basic function AND 2.2 46 1h 30min
Programming Programming Basics in digital technology–OR:
programming of the basic function OR 2.3 61 1h
Programming Programming Basics in digital technology–RS-Flip-Flop:
programming of the basic function RS-Flip-Flop 2.4 66 1h 30min
Programming Programming Basics in digital technology–AND NOT:
programming of the basic function AND NOT 2.5 71 30min
Programming Programming Basics in digital technology–IDENTITY:
programming of the basic function IDENTITY 2.6 74 30min
Programming Programming Condition Call of a Program:
activate a program in OB1 by a condition of the Control Panel 2.7 76 1h
Programming Programming Condition Call of a Program expanded:
activate a program in OB1 by a condition of the Control Panel 2.8 79 1h
Programming Programming ON-Delay-Timer:
programming of a ON-delay timer function using the Control Panel 2.9 88 2h
Programming Programming OFF-Delay-Timer:
programming of a OFF-delay timer function using the Control Panel 2.10 93 1h
Programming Programming Counter down:
programming of a Counter down function using the Control Panel 2.11 95 1h 30min
Programming Programming Programming of one flashlight:
programming a flashlight with 500 ms on/off as long as a button is pressed
2.12 97 30min
Programming Programming Programming of a Auto/Manu-sequence:
program starts with Start-button/continues by Start or Auto/Manu-switch 2.13 99 2h
Programming Programming Move to Starting Position:
edit a program to move to the starting (home) position automatically 2.14 101 1h 30min
Programming Programming Move to Starting Position expanded:
advanced movement to the starting (home) position automatically 2.15 104 3h
Programming Project Theory Basics of I/O-communication:
example of different in-/output communications using different controllers
2.16 109 1h
Programming Project Test the I/O-communication:
edit a program to test the I/O-communication at the stations 2.17 113 1h 30min
Programming Project Material flow through the FMS:
one alu workpiece move through the whole FMS 2.18 119 3h

Introduction
8© Festo Didactic GmbH & Co. • MPS
Project overview Trouble Shooting
Learning Step Designation Project Description Proj.. Page Time [h]
Trouble Shooting Program Error in Project 2.2 3.1 136 30min
Trouble Shooting Program Error in Project 2.3 3.1 138 30min
Trouble Shooting Program Error in Project 2.4 3.1 140 30min
Trouble Shooting Program Error in Project 2.5 3.1 142 30min
Trouble Shooting Program Error in Project 2.6 3.1 144 45min
Trouble Shooting Program Error in Project 2.7 3.1 146 30min
Trouble Shooting Program Error in Project 2.8 3.1 148 45min
Trouble Shooting Program Error in Project 2.9 3.1 150 45min
Trouble Shooting Program Error in Project 2.10 3.1 152 30min
Trouble Shooting Program Error in Project 2.11 3.1 154 45min
Trouble Shooting Program Error in Project 2.12 3.1 156 30min
Trouble Shooting Program Error in Project 2.13 3.1 158 1h
Trouble Shooting Program Error in additional Project 3.1 160 30min
Trouble Shooting Process Maintenance Trouble Shootingà14 Process-Errorsàtime for each approx. 3.2 162 1h 30min

© Festo Didactic GmbH & Co. • MPS 9
Please list up all the “sensors” and “actuators” shown in the picture below (1 –3).
Name the elements with identification in the wiring diagram/pneumatic plan and
describe shortly their function generally (not the function within the system).
Information
Please use the technical manual-data sheets, pneumatic plan and wiring diagrams.
Please refer to the examples (Ex.1 –Ex.3) mentioned below in the table of the
execution work-sheet. Please follow the numbers (1 –3) shown in the pictures below
(Ex.1 is not shown in the graphics).
Instructor: Show one example to the participants how to find an in-and output in
the wiring diagrams and how to find the data sheet using the order number printed
on the element itself. Show the participants at the station itself which components
they have to identify. There are 4 different wiring diagrams for each station: the
station itself (Station), the Control Panel (Panel), the PLC-board (PLC-board) and
the Emergency-Stop (if available –optional). Please use one of the Examples-
Ex.2 or Ex. 3.
Planning
Please plan your project within the whole team carefully. Use the technical manual
and the real station to do this project. Please describe the function of the element in
general, not within the signal-and materialflow of the station. To find the data-sheet
of the elements, please see the list of components first and check the order no.
printed on the element itself.
The time to finish this project should be around 1,5 hours.
1.1 Analysis –
Components
identification
Commissioning

Commissioning
10 © Festo Didactic GmbH & Co. • MPS
Execution/Documentation
Please complete the list regarding the elements shown and numbered in the
pictures above.
No. Name Ident. Description Page #
Ex.1 Start-button S1 Push button with light on the Control
Panel, normally open contact,
connected to a PLC-input
no data sheet
Panel: inputs
Ex.2 Proximity
switch,
inductive
2B2 Inductive switch, normally open
contact, activated by a magnet ring in
the piston rod of the flat cylinder with
non-rotating piston rod, send the
information “piston rod of the cylinder
is in up position” to the PLC-input
SME-8-S-LED-24
Station: inputs
Station: pneumatic
PLC-board: inputs
Ex.3 Pneumatic
gripper
3A1 Double acting parallel gripper,
actuated by 2 parallel acting cylinders
inside, with magent ring for end-
position detection, gripper power 27 N
open and close
HGP-10-A
Station: outputs
Station: pneumatic
PLC-board: outputs
No. Name Ident. Description Page #
1Retro
reflective
sensor
3B1 Retro reflective optical sensor, send out
an infra-red signal and measure the
reflection of the light.
SOEG-L-Q30-PA-S-2L
Station: inputs
PLC-board: inputs
2Pneumatic flat
cylinder non-
rotating
2A1 Flat cylinder with non-rotating piston
rod, double acting, non-rotating by the
form of the piston rod, with magnet ring
for end-position detection
DGO-12-225-P-A
Station: outputs
Station: pneumatic
PLC-board: outputs
3Light barrier
sender
IP_N_FO Infrared sender to the previous station,
maximum range 6000 mm
SOEG-S-Q30-S-L
Station: inputs
PLC-board: inputs

Commissioning
© Festo Didactic GmbH & Co. • MPS 11
Please analyze the cable connections in your station and complete the drawing on
the next page (Execution and Documentation).
Information
Please fill out all cin the graphic and draw the connections. Use the real station to
check the connections. The standard station don´t have the Emergency Stop board,
which is optional. Therefor all the following projects are defined without this board.
Instructor: Please explain the structure of the PLC to the participants . Which
adress have which module and which module have which function in controlling
the process. Leave the cables all connected to help the participants. Show them
also how to use the technical manual to find out the adress of the module. Please
show the participants which steps and connections are necessary if the stations
are coming with the Emergency Stop board and how to connect the Emergency
switch buttons!!!
Planning
Please follow the explanations of the instructor first and then plan your activities
step-by-step. Use the real station to find out all connections and identifications.Use
also the technical documentation.
The time to finish this project should be around 0,5 hours.
1.2 Analysis –
Cable connections

Commissioning
12 © Festo Didactic GmbH & Co. • MPS
Execution/Documentation

Commissioning
© Festo Didactic GmbH & Co. • MPS 13
Please complete the below mentioned list of input-and outputadresses of the PLC.
Please define your own symbol adress using max. 8 characters.
Information
To find out the adresses, please refer to the technical manual-wiring diagram for the
station and the Control Panel. The inputs can also be checked directly at the PLC-
LED´s, the outputs not without a program. To move pneumatic actuators, please
switch off the air-pressure and move them manually by hand. Please be very careful,
move the actuators back before switching on the air-pressure again. Some
pneumatic and the electrical actuators can not be moved in this way-the pneumatic
components can be activated by the manual detection button on the valve (see
picture)
Instructor:show the participants how to find out an input and an output using the
wiring diagrams. Show them why some actuators can not be moved by hand even
without air-and power supply (DC-motors and 5/3-way valves) using the
pneumatic plan to explain.
Example: press 1 = vacuum is on, press 2 = vacuum is off
1.3 Analysis –
Input and Output
adresses

Commissioning
14 © Festo Didactic GmbH & Co. • MPS
Planning
Please plan your activities within your team. Check first, which actuator could be
moved by hand and which not-use the technical documentation-pneumatic plan.
Check the inputs in the wiring diagram and at the PLC.
The time to finish this project should be around 0,5 hour.

Commissioning
© Festo Didactic GmbH & Co. • MPS 15
Execution/Documentation
Please complete the list of the inputs and outputs of your station.
I/O Station
Adress Symbol Ident. Description
I0.0 Part_av Part_AV Workpiece is available
I0.1 Han_prev 1B1 Handling at previous station
I0.2 Han_foll 1B2 Handling at following station
I0.3 Han_sort 1B3 Handling at sorting position
I0.4 Lift_dow 2B1 Lifting cylinder with gripper is down
I0.5 Lift _up 2B2 Lifting cylinder with gripper is up
I0.6 Sen_mat 3B1 Material detection signal = 0 = black
I0.7 Follow IP_FL Light barrier to the following station
Q0.0 Handprev 1Y1 Solenoid of handling cyl.to previous station
Q0.1 Handfoll 1Y2 Solenoid of handling cyl.to following station
Q0.2 Lifting 2Y1 Solenoid of the lifting cylinder with gripper
Q0.3 Gripper 3Y1 Solenoid of the gripper = 1 = open
Q0.7 Previous IP_N_FO Light barrier to the previous station
I/O Control Panel
Adress Symbol Ident. Description
I1.0 START S1 Start button
I1.1 STOP S2 Stop button
I1.2 AUTOMAN S3 Switch automatic and manual cycle
I1.3 RESET S4 Reset button
I1.5 EMERGEN S1 Emergency stop switch-reset with Quit-button
Q1.0 L_START H1 Light inside the Start button
Q1.1 L_RESET H2 Light inside the Reset button
Q1.2 L_SPEC1 H3 Light no. 1 special function
Q1.3 L_SPEC2 H4 Light no. 2 special function

Commissioning
16 © Festo Didactic GmbH & Co. • MPS
I/O Communication
Adress Symbol Ident. Description
I1.4 CI1_Prev Input comm. from Q1.6 Previous Station
I1.6 CI1_Foll Input comm. from Q1.4 Following Station
I1.7 CI2_Foll Input comm. from Q1.5 Following Station
Q1.4 CQ1_Prev Output comm. to I1.6 Previous Station
Q1.5 CQ2_Prev Output comm. to I1.7 Previous Station
Q1.6 CQ1_Foll Output comm. to I1.4 Following Station

Commissioning
© Festo Didactic GmbH & Co. • MPS 17
Please complete the below mentioned list of input-and outputadresses of the PLC.
Please define your own symbol adress using max. 8 characters.
Information
To find out the adresses please use the technical manual-wiring diagram for the
station and the Control Panel. The inputs can also be checked directly at the PLC-
LED´s, the outputs not without a program. To move pneumatic actuators, please
switch off the air-pressure and move them manually by hand. Please be very careful,
move the actuators back before switching on the air-pressure again. Some
pneumatic and the electrical actuators can not be moved in this way-the pneumatic
components can be activated by the manual detection button on the valve (see
picture)
Instructor:show the participants how to find out an input and an output using the
wiring diagrams. Show them why some actuators can not be moved by hand even
without air-and power supply (DC-motors and 5/3-way valves) using the
pneumatic plan to explain. Show them also how to find out the communication in-
and outputs.
Example: press 1 = vacuum is on, press 2 = vacuum is off
1.4 Analysis–
Input and Output
adresses
expanded

Commissioning
18 © Festo Didactic GmbH & Co. • MPS
Planning
Please plan your activities within your team. Check first, which actuator could be
moved by hand and which not-use the technical documentation-pneumatic plan.
Check the inputs in the wiring diagram and at the PLC.
The time to finish this project should be around 1,5 hour.