SMART Factory Simulator Teaching Equipment Mechatronics Training Equipment

TB240813S501 SMART Factory Simulator Teaching Equipment Mechatronics Training Equipment

General Description

MECHATRONICS LEARNING SYSTEM (4 sets)

This system shall consist of a PLC, I/O connector kit, power supply, master control relay module, portable mounting console, student curriculum, and instructor’s guide for use with a separately specified Mechatronics Workstation. The minimum specifications for each item are below.

The controller shall be an industrial grade type PLC.

Portable Mounting Console

The portable console shall consist of a sloped, painted, 11-gauge steel panel mounted on a steel base with rubber feet that make it free standing. The PLC, power supply, master control relay and other components shall be mounted to this console and wired together to form a functioning circuit that can be connected to a Mechatronics

workstation or training module. The console shall contain raceways to neatly run all wiring in the system. It shall also be designed so that it can be removed without special tools from the Mechatronics workstation.

I/O Connector Kit

To consist of (3) wiring arms with plug-in DB25 connectors on one end and pre-wired to the PLC i/O on the other end. The cables shall carry a total of at least 24 inputs, 16 outputs.

24VDC Power Supply

This power supply shall be mounted on the training console using a DIN rail and wired to the 1/0 of PLC. It shall be powered by universal AC input, e.g., 220 VAC, 60 Hz, have total current output rating of 5.0 amps. It shall be regulated and have overload protection, an LED power on indicator, and voltage switch. It shall be totally enclosed and include protection for short circuit, overload, over voltage, and over temperature.

Master Control Relay Module

A master control relay shall be mounted to the training console and wired to the PLC so that only the power to the outputs of the PLC are de-energized when the master control relay is de-energized. The reversing motor starter shail use a 3-pole motor contactor with 24VDC coil, manuai override,IEC 60947 rated, and protected terminals.

Terminal connections shall be wired to a DIN rail mounted terminal blocks.

Student Curriculum

The student curriculum supplied shall be designed in a skill-based format that focuses on teaching industry-relevant tasks. This curriculum shall be designed for use in a self-directed student-learning environment, which promotes a sense of rapid accomplishment and student motivation. The objectives shall be accomplished by organizing the learning material into a series of learing activity packets, which are further subdivided into three or more segments per packet. All learning materials needed shall be contained in the packets including text material,laboratory equipment activities, and multimedia directions. No external text sources shall be required. The specific cognitive skills taught by each text passage shall be identified next to the passage. Each lab activity shall be identified by the industrial task taught. All activities shall be highly detailed with step-by-step instructions to facilitate a self-directed learning environment. A combination of step-by-step enabling activities and creative, problem-

solving activities shall be provided. A self-review of five to ten questions shall be provided after each segment.

The student curriculum shall consist of one (1) set of 12 Learning Activity Packets teaching industrial skills in mechatronics. The curriculum shall teach: machine setup, machine adjustment, machine operation, sequence programming, interfacing to IO devices, and program design and documentation of a wide variety of mechatronic applications including; MaterialInventory Feed, Gauging and Testing. Orientation and Processing, Buffering and Sorting. Robotic Assembly, Assembly Torquing, and Programmable Storage.The curriculum shall also cover the operation, adjustment and control of a wide variety of industrial automation components including; pneumatic and electrical lockout/ tagout, master control relay operation, 8 types of electronic sensors, ultrasonic gauging, reversing motor starters, stepper motors, DC PWM motor control, precision bali screw axis drives, clutches, pneumatic screw feed systems, synchronous belt drives, electric motor slides, pneumatic rodless cylinders, rotary actuators, pneumatic brakes, and electrical overloads. The curriculum must be capable of

completely self-diirected and instructor directed study. All subject content as well as hands-on activities shall be included in the student curriculum. All activities must correlate directly to the hardware supplied, with detailed illustrations and diagrams.

Teacher’s Assessment/ Portfolio Guide

The teacher’s package shall contain student data sheets, data sheet solutions, self-review answers, quizzes, quiz answers, student skill record sheets, and assessment directions. A quiz shall be provided for each packet. A question shall be provided in each quiz for each cognitive objective taught and correlated as such. All tasks listed in

the packet shail be listed on personalized student record sheets. The instructor’s Package shall include methods for both cognitive objective assessment and authentic skill assessment, with all skill assessment criteria explained in detail. Detailed instructions and any supplemental material shail be provided for the teacher to perform live assessment of each student.

Hand Tool Package (1 set)

Include the following:

• 3-Drawer Tool Box

Digital Multimeter

Diai Caliper-6-in.

• Hex Wrench Set-13 pieces

Metric Allen Wrench Set-11 pieces

Ultrasonic Meter Wrench

Adjustable Wrench-8-in.(2)

Ignition Wrench Set -20 pieces

Metric Ignition Wrench Set

Screwdriver Set – Straight and Phillips

Flat Blade Screwdriver

Combination Square-6-in.

Tap Handle and Tap

Die Handle and Die

PLC Programming Software (4 sets)

This product includes Programming Software for programmable controllers.

The software shall use ladder logic programming and have all standard programming functions.

It shall provide both online and offline programming, upload and download of programs, and hardcopy documentation. The software shall be supported with an operation and programming manual.

Pick and Place Feeding Station (1 set)

This station shall include

(1) Mobile Workstation,

(1) Operator Station,

(1) Powered Feed Module,

(1) Pick and Place Robot,

(1)Finished Parts Storage Module,

(1) Parts Set,

(1) Pneumatic Distribution Module,

(1) Electrical Distribution Module,

(1) Digital I/O Interface Module, and

(1)Electro-Pneumatic Valve Manifold.

These components shall be assembled, wired and tested to perform material feed sequences when interfaced to a separately-specified programmable controller. The components shall meet the below minimum specifications.

Mobile Warkstation

This workstation shall be constructed of heavy-duty 18-gauge steel, braced, welded, and powder coat painted. It shall be enclosed on the sides and bottom, contain two shelves that extend the length of the workstation and feature two 2-inch rubber grommet hoies on each side. The minimum dimensions shall be 32-in (81 cm) Lx 53.25-in(135

14. cm) Hx 14.5-in (37 cm) W. The overall length with the operator station attached shall be 30-in (76 cm). The top work surface shall be 1-inch (2.5 cm) extruded aluminum with slots for mounting. Also supplied shall be four casters, two of which shall be lacking.

and a quick release station connector set. This connector set shall consist of two connectors that join workstations to each other via a quick release method that requires no tools. All components shall be mounted to the workstation in a manner that permits students to easily reposition or replace them.

Operator Station

This station shall be constructed of heavy-duty 14-gauge steel, silkscreened and painted. The minimum dimensions shall be 4-in (10.0 cm) W x 4.63-in (11.8 cm) Hx13.25-in (33.7 cm) L. It shall be totally enclosed and mounted to the mobile workstation.

The operator station shall contain manual electrical pilot devices with industrial quality contacts. These pilot devices shall be mounted to an angled console that is part of the operator station. All devices shall be wired to a compact 14-point digital IO interface module located on top of the operator station enclosure to allow students to take signal

measurements. The following pilot devices shall be included: green, flush push button with N.O. contacts and indicator lamp; red, extended push button with N.C. contacts;

3-position selector switch, one position maintained and two sets of N.O.contacts;

yellow, flush push button with N.O. contacts and indicator lamp; and emergency stop pushbutton with red mushroom operator, illuminated, maintained actuation, and N.C. contacts. The emergency stop pushbutton shall be hardwired to an electrical circuit that connects via the operator station’s digital t0 interface module to the workstation’s PLC master control relay. A 3-inch yellow decal shall surround the e-stop pushbutton. The operator station shall contain relay circuitry that causes the emergency stop pushbutton, when pressed, to also engage the emergency stop function on other linked workstations. The operator station shall tink to other workstations upstream and

downstream via two DB9 connector ports. Each port shall include at least 2 inputs and 2 outputs for control handshaking and additional l0 for emergency stop functions. The operator station shall also include a main power switch with electrical lockout/ tagout with hasp, lock, and tagout. The main power switch shali include a hydraulic/magnetic

circuit breaker with trip free function and 15 Amp rating. The operator station shall also include an inter-station communications link cable with female DB9 connectors on each end.

Electrical Power Module

This module shall consist of a 14-gauge steel enclosure mounted flush to the rear section of the workstation, power distribution cable, and (1) power suppiy cable. The module shall include two electrical power outlets that are interconnected to each other and the power distribution cable. The power distribution cable shall be wired to the main power switch on the operator station. The power supply cable shal be 6-ft (1.82 m) grounded power cord.

Pneumatic Distribution Module

This module shall provide connections for the compressed air supply to various control devices on the workstation. It shall consist of a relieving type pressure regulator; filter, pressure gauge; pneumatic, relieving lockout/ tagout valve with hasp, tagout, and lock;

power air distribution unit with Tee fitting connected to female quick-connect fitting, 3 ft (0.91 m) of rubber air hose with male quick connect fitting, and rubber air hose plumbed to pneumatic lockout/ tagout. The air preparation unit and lockouttagout shall be mounted on top of the workstation at the front, and the power air distribution unit shall

be mounted flush with the rear of the workstation.

Digital I/O Interface Module

This module shall be DIN rail mounted on the workstation. It shall have 72 input/output control terminals and 72 separate terminal sets for power to 10. All control and power terminals shall be interally connected to one of three DB25 connectors and connected to all 10 devices on the workstation. The three DB connectors shall connect to plug-in

cables.

Electro-Pneumatic Valve Manifold

The valve manifold shall include a 4-station manifold with (1) single-solenoid 24 VDC, 2-position, directional control valve and (3) double-solenoid, 24 VDC,2-position, detent directional control valves. The manifold shall be connected via push-lock connectors and flexible, poiyurethane tubing to all pneumatic devices and the main air preparation unit. The manifold shall be mounted to the top of the workstation and wired to the 72- point digital 1O interface module. All valves shall have manual overrides.

Powered Feed Module

This module shall provide a powered material feed sequence that feeds components from an inventory storage unit to the manufacturing process. It shall consist of (1) double-acting pneumatic cylinder, (2) flow contral valves, (1) 8-component gravity-fed storage unit, (2) cylinder-mounted Hall-effect sensors, and (1) photo-electric sensor

with PNP output, diffused mode, and adjustable position. The unit will consist of aluminum structural components that can be adjusted.

Pick and Place Robot

This pick and place robot shall consist of 2-axis electro-pneumatic manipulator plus gripper. The motion shall be Cartesian. The X axis shall use a rodless cylinder with dual rail linear bearing module, adjustable stroke, 10-inch (25.4 cm) travel, (2) magnetic

sensors, (2) flow control valves, and adjustable shock absorber. The Z axis shall use a double-acting cylinder with dual rail linear bearing module, adjustable stroke, 4-inch (10.2 cm) travel, (2) magnetic sensors, and (2) flow control valves. The gripper shall be

a vacuum type with vacuum cup, vacuum generator, vacuum switch, pressure regulator, and pressure gauge. The robot shall be supported by an extruded aluminum structure that provides adjustment of the manipulator horizontally and vertically.

Finished Parts Storage Module

This module shall consist of a molded plastic storage container that mount to an extruded aluminum arm. The container shall be able to hold at least 10 completed components. The container shall be removable without use of tools when the station is used in a multi-station application.

Parts Set

The parts set shall consist of directional control valve parts. When combined with parts from other stations, the parts shall be capable of being assembled by an automatic process and result in a working, industrial-quality pneumatic directional control valve that is rated for at least 100 psi/ 690kPa. The parts set shall include: (8) acrylic valve bodies.

Gauging Station (1set)

This station shall include

(1) Mobile Workstation

(1) Operator Station,

(1) Traverse Shuttle,

(1) Ultrasonic Measurement Module,

(1) Proximity Gauging Module,

(1)Part Transfer Module,

(1) Part Reject Module,

(1) Finished Parts Storage Module,

(1) Pneumatic Distribution Module,

(1)Electrical Distribution Module,

(1) DigitalI/O Interface Module and

(1) Electro-Pneumatic Valve Manifold.

These components shal be assembled, wired and tested to perform a material thickness inspection, part feature presence inspection, and material transfer sequence when interfaced to a separately-specified programmable controller. The components shall meet the below minimum specifications:

Mobile Workstation

This workstation shall be constructed of heavy-duty 18-gauge steel, braced, welded, and powder coat painted. It shall be enclosed on the sides and bottom, contain two shelves that extend the length of the workstation and feature two 2-inch rubber grommet holes on each side. The minimum dimensions shall be 32-in (81 cm) L x 53.25-in(135

14. cm) H x 14.5-in (37 cm) W.The overali length with the operator station attached shall be 30-in (76 cm). The top work surface shall be 1-inch (2.5 cm) extruded aluminum with slots for mounting. Also supplied shall be four casters, two of which shail be locking, and a quick release station connector set. This connector set shal! consist of two connectors that join workstations to each other via a quick release method that requires no tools. All components shall be mounted to the workstation in a manner that permits students to easily reposition or replace them.

Operator Station

This station shait be constructed of heavy-duty 14-gauge steel, silkscreened and painted. The minimum dimensions shall be 4-in (10.0 cm) W x4.63-in (11.8 cm) H x 13.25-in (33.7 cm) L.It shall be totally enclosed and mounted to the mobile workstation.

The operator station shall contain manual electrical pilot devices with industry quality contacts. These pilot devices shall be mounted to an angied console that is part of the operator station. All devices shail be wired to a compact 14-point digital I0 interface module located on top of the operator station enclosure to allow students to take signal

measurements. The following pilot devices shall be included: green, flush push button with N.O. contacts and indicator lamp; red, extended push button with N.C.contacts;

3-position selector switch, one position maintained and two sets of N.O.contacts;

yellow, flush push button with N.O. contacts and indicator lamp; and emergency stop pushbutton with red mushroom operator, illuminated, maintained actuation, and N.C. contacts. The emergency stop pushbutton shall be hardwired to an electrical circuit that

connects via the operator station’s digital 10 interface module to the workstation’s PLC master control relay. A 3-inch yellow decal shall surround the e-stop pushbutton. The operator station shall contain relay circuitry that causes the emergency stop pushbutton, when pressed, to also engage the emergency stop function on other linked

workstations. The operator station shall link to other workstations upstream and downstream via two DB9 connector ports. Each port shall include at least 2 inputs and 2 outputs for control handshaking and additional 10 for emergency stop functions. The operator station shail also include a main power switch with electrical lockout/ tagout with hasp, lock, and tagout. The main power switch shall include a hydraulic/magnetic circuit breaker with trip free function and 15 Amp rating. The operator station shall also include an inter-station communications link cable with female DB9 connectors on each end.

Electrical Power Module

This module shall consist of a 14-gauge steel enclosure mounted flush to the rear section of the workstation, power distribution cable, and power supply cable. The module shall include two electrical power outlets that are interconnected to each other and the power distribution cable. The power distribution cable shall be wired to the main power switch on the operator station. The power supply cable shall be 6-ft (1.82 m) grounded power cord.

Pneumatic Distribution Module

This module shail provide connections for the compressed air supply to various control devices on the workstation. It shall consist of a relieving type pressure regulator, filter, pressure gauge; pneumatic, relieving lockout/ tagout valve with hasp, tagout, and lock;

power air distribution unit with Tee fitting connected to female quick-connect fitting,3 ft (0.91 m) of rubber air hose with male quick connect fitting, and rubber air hose plumbed to pneumatic lockout/ tagout. The air preparation unit and lockout/tagout shall be mounted on top of the workstation at the front, and the power air distribution unit shall be mounted flush with the rear of the workstation.

Digita/ I/O interface Module

This module shall be DIN rail mounted on the workstation. It shall have 72 input/output control terminals and 72 separate terminal sets for power to 10. All control and power terminals shall be internally connected to one of three DB25 connectors and connected

to all 10 devices on the workstation. The three DB connectors shall connect to plug-in cables.

Electro-Pneumatic Valve Manifoid

The valve manifold shall include a 3-station manifold with (2) single-soienoid 24 VDC, 2-position,directional control valves and double-solenoid, 24 VDC, 2-position, detent directional control valve. The manifold shall be connected via push-lock connectors and flexible, polyurethane tubing to all pneumatic devices and the main air preparation unit.

The manifoid shall be mounted to the top of the workstation and wired to the digital lO interface module. All valves shal! have manual overrides.

Traverse Shuttle

The traverse shuttle shall provide linear transport of parts across the width of the workstation. It shall be a D.C. electric motor with precision gearbox reduction unit, powered using a reversing motor starter control. The reversing motor starter shall use

(2) 3-pole motor contactors with 24 VDC coils, manual overrides, mechanical interlock, IEC 60947rated, and protected terminals. The traverse shall consist of two linear guide rods and two precision linear bearings that guide the carriage. The maximum travel shall be 11 inches (27.9 cm) with adjustable stops. Two adjustable position, over-travel limit switches shall be provided. The motor shall drive a precision ball screw through a paraliel shaft arrangement that uses a synchronous beit and overrunning clutch.

Industrial quality ball bearing modules shall precisely position the bail screw. The carriage shall be designed with fixtures to locate and transport components for the manufacturing process. A single-acting, non-rotating component lift cylinder shall be mounted to the axis. This cylinder shall use a quick exhaust valve.

Ultrasonic Measurement Module

This module shall consist of an ultrasonic sensor that provides a measurement of part thickness. It shall have an adjustable threshold window mode, 50-500 mm sensing range, with 24 VDC output, 3 LED’s (for power, status, and error), 0.007-inch accuracy, 50 m.s. response, and 0.020-inch hysteresis. It shall also have a programming input

and sync input. An inductive sensor shall trigger the uitrasonic read action. The inductive sensor shail have PNP output and adjustments for horizontal and vertical position.

Proximity Gauging Module

This module shall consist of a photo-electric sensor that performs a port presence inspection process. The sensor shall have PNP output, diffused mode operation with background suppression, visible red LED light source,3 mm spot, 25 mm sensing distance, and adjustabie vertical and horizontal position.

Powered Parts Transfer Module

This module shall provide a powered material transfer sequence that feeds components to either the finished parts storage module or another workstation. It shall consist of a double-acting pneumatic cylinder, (2) flow control valves, 10-component, molded, plastic storage container, and (2) cylinder-mounted magnetic sensors.

Powered Parts Reject Module

This module shall provide a powered material reject sequence that feeds components to a rejected parts storage container. It shall consist of a double-acting pneumatic cylinder, (2) flow control valves, 10-component, molded, plastic storage container, and (2) cylinder-mounted magnetic sensors. The reject container shall be mounted to an extruded aluminum arm.

Finished Parts Storage Module

This module shall consist of a molded plastic storage container that mounts to an extruded aluminum arm. The container shall be able to hold at least 10 completed components. The container shall be removable without use of tools when the station is used in a multi-station application.

Parts Set

The parts set shall consist of (4) acrylic reject directional control valve bodies.

Orientation-Processing Station (1 set)

This station shall include

(1) Mobile Workstation,

(1)Operator Station,

(1) 8-Station Rotary Index Table,

(1) Pick and Place Pneumatic Robot,

(1) Fiber Optic Gauging Module,

(1) Part Transfer Module,

(1) Finished Part Storage Module,

(1) Pneumatic Distribution Module;

(1) Electrical Distribution Module,

(1) DigitalI/O Interface Module and

(1) Electro-Pneumatic Valve Manifoid.

These components shall be assembled, wired and tested to perform part orientation inspection, reorientation, and material processing (with separately-specified optional drill module) when interfaced to a separately-specified programmable controller. The components shal meet the below minimum specifications.

Mobile Workstation

This workstation shall be constructed of heavy-duty 18-gauge steel, braced, welded.

and powder coat painted. It shall be enclosed on the sides and bottom, contain two shelves that extend the length of the workstation and feature two 2-inch rubber grommet holes on each side. The minimum dimensions shali be 32-in(81 cm) L x 53.25-in(135cm) Hx14.5-in(37 cm) W. The overall length with the operator station attached shail

be 30-in (76 cm). The top work surface shall be 1-inch (2.5 cm) extruded aluminum with slots for mounting. Also supplied shall be four casters, two of which shall be locking.

and a quick release station connector set. This connector set shali consist of two connectors that join workstations to each other via a quick release method that requires no tools. Ail components shall be mounted to the workstation in a manner that permits students to easily reposition or replace them.

Operator Station

This station shall be constructed of heavy-duty 14-gauge steel, silkscreened and painted. The minimum dimensions shall be 4-in (10.0 cm)W x4.63-in(11.8 cm)Hx 13.25-in(33.7 cm) L. It shall be totally enclosed and mounted to the mobile workstation.

The operator station shail contain manua| electrical pilot devices with industry quality contacts. These pilot devices shall be mounted to an angled console that is part of the operator station. All devices shall be wired to a compact 14-point digital1O interface module located on top of the operator station enclosure to allow students to take signal

measurements. The following pilot devices shall be included: green, flush push button with N.O.contacts and indicator lamp; red, extended push button with N.C. contacts;

3-position selector switch, one position maintained and two sets of N.O.contacts;

yellow, flush push button with N.O. contacts and indicator lamp; and emergency stop pushbutton with red mushroom operator, illuminated, maintained actuation, and N.C.

contacts. The emergency stop pushbutton shall be hardwired to an electrical circuit that connects via the operator station’s digital 10 interface module to the workstation’s PLC master control relay. A 3-inch yellow decal shall surround the e-stop pushbutton. The operator station shall contain relay circuitry that causes the emergency stop

pushbutton, when pressed, to also engage the emergency stop function on other linked workstations. The operator station shall link to other workstations upstream and downstream via two DB9 connector ports. Each port shall include at least 2 inputs and 2 outputs for control handshaking and additional lO for emergency stop functions. The

operator station shall also include a main power switch with electrical lockout/ tagout with hasp, lock, and tagout. The main power switch shall include a hydraulic/magnetic circuit breaker with trip free function and 15 Amp rating. The operator station shall also include an inter-station communications link cable with female DB9 connectors on each end.

Electrical Power Module

This module shall consist of a 14-gauge steel enclosure mounted flush to the rear section of the workstation, power distribution cabie, and power supply cable. The module shali include two electrical power outlets that are interconnected to each other and the power distribution cable. The power distribution cabie shall be wired to the main power switch on the operator station. The power supply cable shall be 6-ft (1.82 m) grounded power cord.

Pneumatic Distribution Module

This module shail provide connections for the compressed air supply to various control devices on the workstation. It shail consist of a relieving type pressure regulator; filter;

pressure gauge; pneumatic, relieving lockout/ tagout valve with hasp, tagout, and lock;

power air distribution unit with Tee fitting connected to female quick-connect fitting, 3 f (0.91 m) of rubber air hose with male quick connect fitting, and rubber air hose plumbed to pneumatic lockout/ tagout. The air preparation unit and lockout/tagout shall be mounted on top of the workstation at the front, and the power air distribution unit shall

be mounted flush with the rear of the workstation.

Digital I/O Interface Module

This module shall be DIN rail mounted on the workstation. It shall have 72 input/output control terminals and 72 separate terminal sets for power to 10. All control and power terminals shall be internally connected to one of three DB25 connectors and connected

to all 10 devices on the workstation. The three DB connectors shall connect to plug-in cables.

Electro-Pneumatic Vaive Manifold

The valve manifold shall include a 4-station manifold with single-solenoid 24 VDC, 2- position, directional control vaive and (3) double-solenoid,24VDC,2-position, detent directional control vaives. The manifold shall be connected via push-lock connectors and flexible, polyurethane tubing to all pneumatic devices and the main air preparation unit. The manifold shall be mounted to the top of the workstation and wired to the digital IO interface module. Ail valves shall have manual overrides.

Rotary Index Table

The rotary index table shall provide positioning of parts at 8 software-programmable positions located 45 degrees apart from each other around the table. The table disk shall consist of painted 11-gauge steel on top of 16-gauge brushed stainless steel and have a minimum diameter of 15 inches (38.1 cm). The table shall be designed with

fixtures to locate and transport parts for the manufacturing process. It shall be operated by a motion control system that uses a precision stepper-motor. The stepper motor shall have a resolution of 51,200 steps per revolution and operate in the 12-48 VDC range.

The motion control system shall be integrated with the motor. It shall be PC software programmable via RS-485 communications and include the following programming functions: home, limit plus, limit minus, go, stop, pause, jog plus, jog minus, analog in, moving, fault, stall, velocity change, trip on input, trip on position, basic math functions, logical math expressions, and branch and call subroutines. The motion control system shall include (4) 24 VDC discrete I/O, and analog input (0-5VDC or 4-20 ma). The system shall include Windows-compatible programming software and RS-485 to RS-

232communications cable with serial port. The motion control system shall be connected to the rotary table via a zero-backlash, flexible coupling, precision worm gear right-angle drive, and ball bearing guides. A homing sensor shall be mounted to the table structure. This sensor shall be an inductive type with (2) PNP outputs, cylindrical body, indicator light, and shall be position adjustable. A part present sensor shall be installed at position 1. This sensor shall be a capacitiye type with cylindrical body, PNP output, indicator light, adjustable sensitivity, and adjustable horizontal and vertical position. A part present sensor shall also be installed at position 3. This sensor shall be a capacitive type with cylindrical body, PNP output, indicator light, adjustable sensitivity, and adjustable horizontal and vertical position.

Pick and Place Pneumatic Robot

This pick and place robot shall consist of a 2-axis electro-pneumatic manipulator plus gripper. The motion shall be Cartesian. The Z axis shall use a twin bore double-acting pneumatic cylinder module with adjustable stroke,0.75-inch(1.9 cm) travel, (2) magnetic sensors, and (2) flow control valves. The rotary axis shall use a rack and pinion pneumatic actuator with adjustable stroke,180-degree rotation with 45-degree adjustment on each end, (2) magnetic sensors, and (2) flow control valves. The gripper shall be a 2-point curvilinear type with double acting actuator, and (2) flow control valves.

Parts Transfer Module

This module shall provide a powered material transfer sequence that feeds components to either the finished parts storage module or another workstation. It shall consist of double-acting pneumatic cylinder, (2) flow control valves and (2) cylinder-mounted magnetic sensors.

Finished Parts Storage Module

This module shall consist of a molded plastic storage container that mount to an extruded aluminum arm. The container shall be able to hold at least 10 compieted components. The container shali be removable without use of tools when the station is used in a multi-station application.

Servo Robot Assembly Station (1 set)

This station shall include:

(1)Mobile Workstation,

(1) Operator Station,

(1) Spool Insertion Module,

(1) Screw Feed Module,

(1) Spring/ Knob Feed Module,

(1) Screw/ Knob Engagement Module,

(1)Assembly Shuttle Module,

(1) Finished Parts Storage Module,

(1) Parts Presentation Module,

(1) Pneumatic Distribution Module,

(1) Electrical Distribution Module,

(1) Digital I/O Interface Module,and

(1) Electro-Pneumatic Valve Manifold.

These components shall be assembled, wired and tested to perform an assembly sequence when interfaced to a separately-specified programmable controller. The components shall meet the below minimum specifications.

Mobile Workstation

This workstation shall be constructed of heavy-duty 18-gauge steel, braced, welded, and powder coat painted. It shall be enclosed on the sides and bottom, contain two shelves that extend the length of the workstation and feature two 2-inch rubber grommet holes on each side. The minimum dimensions shall be 32″ (81 cm) Lx 53.25″ (135 cm) H x 14.5″ (37 cm) W. The overali length with the operator station attached shall be 30″ (76 cm). The top work surface shail be 1-inch (2.5 cm) extruded aluminum with slots for mounting. Also supplied shall be four casters, two of which shall be locking, and a quick release station connector set. This connector set shall consist of two connectors that join workstations to each other via a quick release method that requires no tools.All components shall be mounted to the workstation in a manner that permits students to easily reposition or replace them.

Operator Station

This station shall be constructed of heavy-duty 14-gauge steel, silkscreened and painted. The minimum dimensions shall be 4″ (10.0 cm) Wx 4.63″ (11.8 cm) H x 13.25″ (33.7 cm) L. It shall be totally enclosed and mounted to the mobile workstation. The operator station shall contain manual electrical pilot devices with industrial quality

contacts. These pilot devices shall be mounted to an angled console that is part of the operator station. All devices shall be wired to a compact 14-point digital 10 interface module located on top of the operator station enclosure to allow students to take signal measurements. The foliowing pilot devices shall be included: green, flush pushbutton with N.O. contacts and indicator lamp; red, extended push button with N.C. contacts;

3-position selector switch, one position maintained and two sets of N.O.contacts;

yellow, flush pushbutton with N.O.contacts and indicator lamp; and emergency stop pushbutton with red mushroom operator, illuminated, maintained actuation, and N.C. contacts. The emergency stop pushbutton shall be hardwired to an electricai circuit that connects via the operator station’s digital 1O interface module to the workstation’s PLC master control relay. A 3-inch yellow decal shall surround the e-stop pushbutton. The operator station shali contain relay circuitry that causes the emergency stop pushbutton, when pressed, to also engage the emergency stop function on other linked workstations. The operator station shall link to other workstations upstream and downstream via two DB9 connector ports. Each port shall include at least 2 inputs and 2 outputs for control handshaking and additional l0 for emergency stop functions. The operator station shall also include a main power switch with electrical lockout/ tagout with hasp, lock, and tagout. The main power switch shall include a hydraulic/magnetic circuit breaker with trip free function and 15 Amp rating. The operator station shall also include an inter-station communications link cable with female DB9 connectors on each end.

Electrical Distribution Module

This module shail consist of a 14-gauge steel enclosure mounted flush to the rear section of the warkstation, power distribution cable, and (1) power supply cable. The module shall include two electrical power outlets that are interconnected to each other and the power distribution cable. The power distribution cable shall be wired to the main power switch on the operator station. The power supply cable shall be 6-ft(1.82 m) grounded power cord.

Pneumatic Distribution Module

This module shall provide connections for the compressed air supply to various control devices on the workstation. It shall consist of a relieving type pressure regulator; filter, pressure gauge; pncumatic, relieving lockout/ tagout valve with hasp, tagout, and lock; power air distribution unit with Tee fitting connected to female quick-connect fitting.3ft (0.91 m) of rubber air hose with male quick connect fitting, and rubber air hose plumbed to pneumatic lockout/ tagout. The air preparation unit and lockout/tagout shail be mounted on top of the workstation at the front, and the power air distribution unit shall

be mounted flush with the rear of the workstation.

Digital I/O Interface Module

This module shall be DIN rail mounted on the workstation. It shall have 72 input/output control terminals and 72 separate terminal sets for power to 10. All control and power terminals shall be internally connected to one of three DB25 connectors and connected

to all t0 devices on the workstation. The three DB connectors shall connect to plug-in cables.

Eloctro-Pneumatic Valve Manifold

The vaive manifold shall include a 6-station manifold with (5) single-solenoid 24 VDC, 2-position, directional control valves and (1) double-solenoid, 24 VDC,2-position, detent directional control valve. The manifold shall be connected via push-lock connectors and flexible, polyurethane tubing to all pneumatic devices and the main air

preparation unit. The manifold shal be mounted to the top of the workstation and wired to the digital 10 interface module. All valves shall have manual overrides

Spool Insertion Module

This module shall provide a powered materlal feed sequence that can feed one of two types of spools from two inventory storage units to the manufacturing process. It shall consist of (1) single-acting pneumatic cylinder, double-acting pneumatic cylinder. (3) flow control valves, (2) 8-component storage units,(4) cylinder-mounted magnetic sensors, and (2) inductive parts-empty sensors with PNP output. The unit will consist of aluminum structural components that can be adjusted.

Screw Feed Module

This module shall provide pneumatic feeding ofscrews to the assembly process. It shall consist of {1) flexible, polyurethane, transparent screw feed tube, 36-inches(91.5cm) long and 0.875-inches(22 mm) diameter, and (1) pressure regulator valve. The module

shall also include a screw escapement mechanism and screw queue mechanism that are pneumatic-powered. These mechanisms shall include: (3) single-acting pneumatic cylinders and (1) inductive sensor. This unit will include aluminumstructural components that can be adjusted.

Spring/ Knob Feed Module

This module shall provide a material feed device that feeds manual button-type operators and springs from an inventory storage unit to the manufacturing process via a servo robot. It shall consist of gravity feeder and fixtures to interact with the robot.

Screw/ Knob Engagement Module

This module shall perform final assembly of screw, operator, spring, spoal and valve body. It shail consist of (1) double-acting pneumatic cylinder, (1) flow control valve, (2) cylinder-mounted magnetic sensors, and a screw engagement motor. This motor shall be a D.C. motor with foot mount, precision gearbox reduction unit, and friction engagement tool. The motor shall be powered using a motor starter control. The motor starter shall use 3-pole motor contactor with 24 VDC coil, manual override,IEC 60947rated, and protected terminals.

Assembly Shuttle Module

This module shall provide a powered material handling sequence that transports part assemblies between two assembly positions. It shall consist of (1) double-acting rodiess pneumatic cylinder, (2) flow control valves, and (2) cylinder-mounted magnetic sensors.

Two powered clamps sha”also be provided. These clamps will include fixtures, (2) singie-acting pneumatic cyunders, (2) flow control valves, and (2) cylinder-mounted magnetic sensors.

Finished Parts Storage Module

This module shall consist of a molded plastic storage container that mounts to an extruded aluminum arm. The container shall be able to hold at least 10 completed components. The container shall be removable without use of tools when the station is used in a muiti-station application.

Parts Presentation Module

This module shall consist of an extruded aluminum structure and fixture for part presentation to the system. The module shall be able to be adjustable vertically and horizontally.

Parts Set

The parts set shall consist of directional control valve parts. When combined with parts from other stations, the parts shall be capable of being assembied by an automatic process and result in a working, industrial-quality pneumatic directional control valve that is rated for at least 100 psi/690kPa.The parts set shall include: (8) 3-way valve

spools, (8) 4-way valve spools, (8) manual operators, (8) bolts and (8) spool return springs.

Smart Robot Workcell (1 set)

Components include:

Robot with Advanced Software and Ethernet IP

Area Laser Scanner

Smart Robot Workstation with discrete1/O, pneumatic, Ethernet I/O Interface

Panel

Robot-to-PLC Interface

Cabling Set

Gripper Fixture Set

• Quick Connect System; SystemConfiguration and Integration Prep

Robot Arm Integration to Mechatronics(1set)

(2) Custom Mounting Brackets with Actuators

(1)Compressed Air Piping

Single-Station Laser Scanner (1 set)

This product provides safety at the front of the Smart Robot Workcell. For Mechatronics systems with multiple Robot Workcells, customers must have (2) Laser Scanners and (1)Communication Kit.

.Laser Scanner System with one laser scanner

Mounting Fixture Set

Cable Set

• Integration Engineering and Programming

Mechatronics HMI Terminal Learning System (1 set)

This system teaches how to use human machine interface (HM!) to control and monitor an automated line.

HMI

• 5.5-in. screen
• 320×240 resolution

HMI Terminal Module

EtherNot Cable

• Cat 5E patch cable, 14′, gray

Workstation Pedestal Mounting Module

• Rigid, adjustable mounting module allows the HMI to be situated in the optimal position

Student Curriculum

This system shall consist of three (3) Learning Activity Packets containing no less than thirteen (13) industry skilis. Topics shall include: HMI construction;HMI configuration; HMI operation; application editing; component identification; The student curriculum

supplied shall be designed in a skill-based format that focuses on teachingindustry relevant tasks. The objectives shall be accomplished by organizing the leaming material into a series of leaming activity packets, which are further subdivided into three or more

segments per packet. All leaming materials needed shall be contained in the packets including text material and laboratory equipment activities. No external text sources shail be required. The specific cognitive skills taught by each text passage shall be identified next to the passage. Each lab activity shall be identified by the industrial task

taught. All activities shall be highly detailed with step-by-step instructions to facilitate a self-directed learning environment. A combination of step-by-step enabling activities and creative, problem-solving activities shall be provided. A self-review of five to ten

questions shail be provided after each segment. The curriculum must be capable of both self-directed and instructor directed study. All activities must correlate directly to the hardware supplied, with detailed illustrations and diagrams.

Teacher’s Assessment Guide

A teacher’s assessment guide shall be provided. It shall contain student data sheets, data sheet solutions, self-review answers, quizzes, quiz answers, student skill record sheets, and authentic assessment. A quiz shall be provided for each packet. A question shall be provided in each quiz for each cognitive objective taught. All tasks listed in the packet shall be listed on personalized student record sheets. The teacher’s assessment guide shall include directions for authentic skill assessment.

Mechatronics Smart Device Learning (1 set)

This learning system shall be designed to teach communications between a stack light and other intelligent automation devices using EtherNetIP in a Smart Factory environment. At minimum, the learning system shail consist of: EtherNet/iP communications I/O module, stack light module, cable set, student curriculum, student

reference guide, and instructor’s guide. The system shall be fully assembled and wired to mount to a mobile workstation or a table top surface.

Smart Factory Ethernet Learning System (1 set)

This learning system shall be designed to teach EtherNet/1Pcommunications between various intelligent automation devices in various topologies in a Smart Factory environment to efficiently control and monitor an automated manufacturing process. At minimum, the learning system shall consist of: (1)managed EtherNet/IP switch module, (1) unmanaged Ethernet switch module, (1) cabie sot, (1) student curriculum, student reference guide, and (1) instructor’s guide. The system shall be fully assembled and wired to mount to mobile workstations or a table top.

Smart Factory Mechatronics Barcode (1 set)

This learning system teaches learners how barcode readers are used within an automated line to identify components, enter serial numbers in a database, and sort items into groups.

Multi-technology Interactive e-Learning solution with the use of different teaching tools such as text, 3D animation, video, audio and virtual simulation (1 year subscription)

Learning Management System {LMS) Inckuded

‘ User-friendly Navigation with Skills on/OffControl

SCORM to Other LMS Systems

Custom LMS Branding Available. Put your school logo or organization’s logo and colors on the LMS home screen.

Pre-/Post-Course Quizzes. Create a valuable metric to track progress.

Easy-to-Use Reporting Tools. Customizable reporting tools will help evaluate progress.

Custom Course Set-Up

Choose from thousands of eLeaming modules to create an almost innumerable combination of courses that can exactly fit your training needs.

Reduce Training Cost with eAssessment

Distance eLeaming eAssessment to quickly reveal strengths and identify weaknesses.

Utiize this program to assess individuals, departments, or the entire organization.

eLearning Categories

1. AUTOMATION
2. Ethernet for Mechatronics

2.Mechatronics HMI

3.Mechatronics

4.Mechatronics Profibus

5.Mechatronics Troubleshooting

6.Mechatronics Troubleshooting with PLC

7.Mechatronics-PLC

8.Mechatronics-Ethernet/IP

9. Panel view Operator interface

10.Mechatronics Simulation (Smart Factory)

11.Mechatronics Simulation

12. Pegasus Robotics Simuiation

13.Robotics and Computer Programming

14.Robotics 1

15.MechatronicsCNC Mill

16. Machine Vision Inspection Systems
17. Machine Vision Inspection Systems

18.Mechatronics Troubleshooting System-PLC

19.MechatronicsRF Identification System

20.Mechatronics Barcode Identification

21.MechatronicsRF Identification System

22.Mechatronics RF Identification System-PLC

23. Tabletop Mechatronics

25.Mechatronics HMi

25.Mechatronics Barcode Identification -PLC

26. Mechatronics Barcode Identification-Barcode

27.Table-Top Mechatronics Servo Robot System

28.Table Top Smart Factory RFID/Sensors

29.Mechatronics Barcode Product Identification-PLC Controller

30. Tabletop Smart Factory Ethernet

31.Tabletop Smart Factory Manufacturing Execution System

32. Smart Factory Barcode System
33. Mechatronics RFID

34.Smart Factory Vision Inspection System

35. Smart Factory Visual Communication System

36.Mechatronics System

37.Mechatronics – Professional

38. Smart Factory Sensor System – Pneumatics/Vacuum
39. Smart Factory Sensor System -Ultrasonic
40. Smart Factory Sensor System -Photoeye
41. Smart Factory Device Learning System – Stack Light
42. Smart Factory Sensor System- Electrical Current
43. Smart Factory Sensor System -Analog Position
44. Smart Factory Sensor System -Analog Pressure

45.Tabletop Smart Factory Visual Communications

46. Smart Factory Barcode System – Basic
47. MechatronicsRFID AB L16
48. 48. Smart Factory Ethemet

    49.Smart Factory Network Security Leaming System

    50. Smart Factory Manufacturing Execution System

    51.Smart Factory Visual Communications

    52.Smart Factory Sensor System- Pneumatics/ Vacuum Advanced

    53. Smart Factory Sensor System – Ultrasonic Advanced
    54. Smart Factory Sensor System – Photoeye Advanced
    55. Smart Factory Device Leamning System Stack Light

    56.Smart Factory Sensor System- Electrical Current

    57.Smart Factory Sensor System -Analog Position

    58.Smart Factory Sensor System-Analog Pressure

    59.Mechatronics

    60.Computer Control 2

    61. Principles of Robotics
    62. Principles of Factory Automation

    63.Principles of Robotics

    II.ELECTRONICS

    1.DC Electronic Drives

    2. Portable Pic
    3. Portable Plc Troubleshooting

    4.PLC Analog Application

    5.PLC ControlNet

    6.Mastering Programmable Controllers

    7.PLC Statement List

    8.PLC Analog

    9. PLC Profibus

    10.MPC

    11.PLC Graph Programming-

    12.MPC-iBus

    13.MPC

    14.Mastering Programmable Controllers

    15.PLC Troubleshooting

    16. Programmable Controller
    17. Mastering Programmable Controllers
    18. Power and Control Electronics

    19.AC Motor Drives

    20.AC Motor Drive Troubleshooting

    21.Electrical Control Systems

    22.Variabie Frequency AC Drive

    23.AC Electronic Drives

    24.PLC Motor Control

    25.PLC Motor Control

    26.Portable PLC Learning System

    27. Portable PLC with Troubleshooting

    28.PLC Troubleshooting-PLC

    29.PLC Troubleshooting

    30.Computer Control 1

    III.ELECTRICAL

    1.Electric Motor Control

    2.AC/DC Electrical Systems

    3.Electrical Control 1

    4. Portable Electric Relay Control Troubleshooting
    5. Electric Relay Control

    6.AC/DC Electrical Systems

    7. Electric Motor Control
    8. Electric Motor Control Troubleshooting
    9. Electrical Fabrication 1

    10.Motor Braking

    11.Reduced Voltage Starting

    12.Electronic Sensors

    13.Electronic Counter

    14.SCR Speed Control

    15. Electric Wiring System

    16.PLCNFD Wiring System

    17. Industrial Soldering
    18. Ethernet and Analog Wiring
    19. Electrical Power Distribution
    20. Electric Motor Control
    21. Motor Troubleshooting System

    22.Rotating Electric Machines

    23.DC Generators

    24.Wound Rotor Motor

    25.Rotating Electrical Machines

    1. GREEN ENERGY

    1.Wind Concepts

    2. Turbine Electric Hub Troubleshooting
    3. Turbine Generator Control Troubleshooting
    4. Turbine Nacelle Troubieshooting

    5.Solar Concepts

    6.Solar Site Anatysis

    7. Altemative Energy
    8. Solar Thermal Troubleshooting – Open-Loop

    9.Solar Thermal Troubleshooting – Closed-Loop

    10.Solar Thermal Instailation

    11.Solar PV Troubleshooting

    12.Solar Grid-Tie

    13. Data Acquisition
    14. Solar Photovoltaic Installation

    V.LEAN MANUFACTURING

    1.Lean Overview and Workplace Organization

    2. Introduction to Lean

    3.5S

    4.Total Productive Maintenance

    5.Poka-Yoke

    6.Lean Theory

    7.Lean Process Flow

    8. Visual Workplace
    9. Standardized Work
    10. Kaizen

    11.Value Stream Mapping

    12.Set-Up Reduction

    13.Six Sigma

    1. MACHINING

    1.Machine Tools 1

    2.Machine Tools 2

    3.Machine Tools 3

    4.Manuai Machine Tools

    5.CNC Machine Tools 1

    6.CNC Machine Tools 2

    7.CNC Machine Toois 3

    8. Principles of CNC

    9.CNC Control

    10.Principles of Tuming

    11.Principles of Machining Centers

    12.Principles of Grinding

    13.Principles of Workholding

    14. Principies of Coolants and Oils
    15. Principies of Gear Manufacturing

    16.Principles of Tooling

    17.Tooling for Tuming

    18.Tooling for Machining Centers

    19.Tooling for Grinding

    20.Tooling for Tapping

    VII. MANUFACTURING PROCESS

    1.Product Finishing

    2. Production Assembly
    3. Split Flange Coupling Assembly
    4. Eiectric Torque Wrench Assembly

    5.Print Reading 1

    6.Welding Technology 1

    7. Computer-Aided Design 1
    8. Computer Aided Design 2

    9.Wiring Harness Assembly

    10. Contamination
    11. Fasteners
    12. Gaskets

    13.Stall Bar Assembly

    14. Instrumented DC-Electric Torque Wrench Assembly

    15.Computer-Aided Manufacturing 1

    16. Blueprint Reading

    17.AWS Welding Symbols on Blueprints

    18. General Dimensioning and Tolerances

    19.Geometric Dimensioning and Tolerancing

    VIII.MATERIALS

    1. Plastic Mold Design
    2. Manufacturing Processes 3
    3. Structural Engineering 1
    4. Structural Engineering 2
    5. Surveying
    6. Materials Engineering 1
    7. Principles of Materlals -Ferrous Metals
    8. Principles of Materials -Non-Ferrous Metals
    9. Principles of Heat Treating

    10.Principles of Plastics

    11.Principies of Composites

    12.Principles of Ceramics

    IX.MECHANICAL

    1.Vibration Analysis

    2. Pump Systems

    3.Multiple ‘Pump

    4.Turbine Pump

    5.Diaphragm Pump

    6.Peristaltic Tubing Pump

    7.Piston Pump

    8.Gear Pump

    9.Magnetic Pump

    10.Centrifugal Pump

    11. Rigging 3

    12.Mechanical Drives 4

    13. Floor Standing Belt Conveyor
    14. Predictive Maintenance Vibration Analysis

    15.Roller Pack Machine Tool Axis

    16. Plain Bearing Machine Tool Axis
    17. Mechatronics Simulation

    18.Pipings

    19.Central Lubrication

    20.Mechanical Systems 1

    21.Mechanical Fabrication 2

    22.Rigging Systems 1

    23.Rigging Systems 2

    24.Mechanical Fabrication 1

    25. Mechanical Drives 1

    26.Portable Mechanical Drives 2

    27.Mechanical Drives 2

    28. Mechanical Drives 3
    29. Laser Shaft Alignment
    30. Portable Laser Shaft Alignment

    31.Mechanical Systems 2

    1. PROCESS CONTROL

    1.Temperature Process Control

    2. Data Acquisition

    3.Analytical Process Control

    4.Data Acquisition Systems

    5.Process Control

    6. Process Control Systems: Ultrasonic Level Measurement and Control

    7.Process Control Systems: Differential Pressure Flow Measurement and Control

    8. Process Visualization Control 1
    9. Pressure Process Control Systems

    10.Foundation Fieldbus Process Control 1

    11.HART Process Control 1

    12. Mastering Programmable Controllers

    13.PLC Process Control

    14.PLC Process Control 2

    15. Process Control Systems
    16. 1. QUALITY ASSURANCE

        1.Metroiogy 1

        2.Measurement Tools 1

        3.Quality Assurance 1

        4.Portable Precision Gauging 1

        5. Portable Measurement Tools
        6. Inspection Techniques 1
        7. Surface Plates
        8. Gauge Blocks

        9.Test Indicators

        10.Height Gauges

        11.Bench Comparators

        12.Optical Comparators

        13.Bore Gauges

        14.Air Gauges

        15.Specialty Micrometers

        16. Miscellaneous Inspecticn Instruments
        17. ISO 9000 and TS 16949

        18.Statistical Process Control 1

        19.Statistical Process Control 2

        20.Quality Cantrol Concepts

        XII.SAFETY

        1.Safety Practices and Regulations

        2. Personal Protective Equipment

        3.Hazardous Communication

        4.Confined Spaces

        5.Lockout/Tagout

        6.Accident Response

        7. Overhead Crane Safety

        XIII.THERMAL

        1.Air Conditioning/Heat Pump

        2. Steam Systems

        3.Thermal Systems 1

        4.Environmentai Applications

        5.Gecthermal

        6. Geothermal Troubleshooting

        7.Geothermal Desuperheater

        8. Geothermal Troubleshooting with Desuperheater

        9.Geothermal Flush Cart Learning System

        10. Thermal Technology 1
        11. Thermal Technology 2

        XIV.WORKPLACE EFFECTIVENESS

        1.Enterprise Systems 1

        2.Principles of Advanced Manufacturing

        3.Mathematics 1

        4.Trigonometry 1

        5.Communication Skills

        6.Conflict Resolution

        7.Working in Groups