Design-of-Automatic-Production-Line-Training-Syste

Sensors&Transducers,Vol.155,Issue8,August2013,pp.271-277271SSSeeennnsssooorrrsss&&&TTTrrraaannnsssddduuuccceeerrrsss©2013byIFSA:15210074161,213910766308E-mail:[e-mail],[e-mail]:25May2013/Accepted:12August2013/Published:20August2013Abstract:Automaticproductionlinetrainingsystemisusedtosimulatetheactualprocessofindustrialproduction.Accordingtotheactualneedsofteachinginstrumentmarketatpresent,forthepurposeofstudentsorstafftraining,theauthordesignsapracticalautomaticproductionlinesimulationtrainingsystem.UsingSiemensS7-200PLCasthecontrolcore,settingsensors,buttonsandlights,powersupplymodule,motors,pneumaticcomponents,mechanicalstructuresfortheintegration,dividingintofeeding,processing,assembly,sorting,robotunits,andachievinginterconnectionbetweentheunitcontrollersviaPROFIBUS.Itisusedtosimulatethevariousmanufacturingaspectsofworkpiecesfromrawmaterialstofinishedproductsintheactualindustrialproductionlines.Thesystemcoversmechanicalprinciples,pneumaticcontroltechnology,sensors,electricalcontroltechnology,programmablelogiccontrollerandotherrelatedknowledgepoints,supportsprofessionalexperimentalcoursesofautomation,mechanotronicsandsoon.Aseriesofpracticalideasareadoptedinthesubject.Theentiresystemisfullyopen,studentscanhaveacomprehensiveviewoftheinternalwiringsituation;freelydetachable,canoperateundersingle-stationoroverallsystem;supportingsecondarydevelopment,canbere-buildaccordingtotheinnovationrequirements.Copyright©2013IFSA.Keywords:Automaticproductionline,PLC,Trainingsystem.1.IntroductionAutomaticproductionlinetrainingsystemisusedtosimulatetheactualprocessofindustrialproduction.Itisusedintrainingroomofcollegesanduniversities,tocultivatestudents’cognition,operation,thenusinganddevelopingabilities.Inordertocatertotheeducationalphilosophyandteachingneedoftoday'scollegesanduniversities,thetrainingsystemisacomprehensiveexperimentalteachingsystemwhichisconnectingtheoreticalteachingwithpracticaltraining.Throughthedemonstrationexperiments,assemblydebuggingandprogramming,studentscanstimulatelearninginterests,exercisepracticalabilitiesandthinkingskills,consolidateexpertise,improveprofessionalismandguidestudentstoadapttothedemandforjobsinthefuture.1.1.ResearchStatusBeforethe1920s,theproductionlineandsemi-automaticproductionlineappearedintheautomotiveindustry;1920s,HenryFordfoundedtheautomotiveindustryassemblyline;later,combinationautomaticlinegraduallyemerged;thedevelopmentofautomaticcontrolandcomputertechnology,ArticlenumberP_SI_1314Sensors&Transducers,Vol.155,Issue8,August2013,pp.271-277272promptedthecompletionoftheautomationworkshopsandfactories[1].Today,automaticproductionlineisdevelopingtowardthedirectionofadjustablevarieties,higherflexibility,fasterandlowercost.Withtheautomaticproductionlinedevelopingbyleapsandbounds,thedevelopmentofautomaticproductionlinesimulationdevicehasbeengreatlyimproved[2].Atpresent,manyordinancesmanufacturershaveachievedtherapiddevelopmentofautomaticproductionlinesimulationordinances.Mostoftoday'sautomaticproductionsimulatorshaveachieveddemonstration,debuggingoperations,programmingandotherbasicfunctions,butthereisconsiderableroomforimprovement[3].Developingaremovable,secondarydeveloping,workingsub-stationorrun-onlinetrainingsystemisafar-reachingissue.1.2.IssuestobeAddressedThesystemusesSiemensS7-200PLCasthecontrolcore,settingsensors,buttonsandlights,powersupplymodule,motors,pneumaticcomponents,mechanicalstructuresfortheintegration,dividingintofeeding,processing,assembly,sorting,robotunits,canoperateundersingle-stationoroverallsystem.Itisusedtosimulatetheactualprocessofindustrialproduction.Theentiresystemisfullyopen,freelydetachable,supportingsecondarydevelopment,canbere-buildaccordingtotheinnovationrequirements.2.TheOverallSystemAutomaticproductionlinetrainingsystemconsistsoffiveunits:feedingunit,processingunit,assemblyunit,sortingunitandrobotunit.Theunitsareallinstalledinthealuminumalloyrailtrainingtable,theoverallsystemblockdiagramisshownasFig.1.Eachunitofthesystemisanindependentmechatronicsystem.Feeding,processing,assembly,sortingunitsbasicallydependonpneumaticactuator,robotunittakesthepositioncontrollingmodedrivenbythesteppermotor.Intermsofon-lineoperation,eachunitisundertakenbyaPLC,andachievinginterconnectionbetweentheunitcontrollersviaPROFIBUS.Theentiresystemcansimulatesupplying,processing,assembly,sorting,transportingandotherprocessofactualindustrialproductionline.Buttonandindicatormodulesincludingstart,stop,reset,functionbuttons,manual/automatic,single/overallknob,thealarmindicatorandemergencystopbutton.Startandstopbuttonsareusedtocontrolthestartandstopoperationoftheunit;resetbuttoncanresetalltheactionelementtoinitialposition;functionbuttonissetforsecondarydevelopment;spinningmanual/automatic,single/onlineknobatthesametimecanselectsingle-