of Ahievements in Mterils nd Mnufturing Engineering VOLUME 15 ISSUE 1-2 Mrh-April 2006 Lortory support for the didti proess of engineering proesses utomtion t the Fulty of Mehnil Engineering J. Świder, P. Mihlski, G. Wszołek* Institute of Engineering Proesses Automtion nd Integrted Mnufturing Systems, Silesin University of Tehnology, ul. Konrskiego 18, 44-100 Gliwie, Polnd * Corresponding uthor: E-mil ddress: grzegorz.wszolek@polsl.pl Reeived 15.11.2005; epted in revised form 15.02.2006 Edution nd reserh trends ABSTRACT Purpose: The sope of the pper is to present effets of reting the lortory support for the didti proess of utomti ontrol of engineering proesses. Design/methodology/pproh: The disussed lortory frmework is omplex system, flexile in terms of further development, operting on four si levels: rudimentl- serving generl introdutory lsses to the sujet, dvned level- suitle for speilistion lsses, hrdwre nd softwre for individul or tem work ssignments ompleted in the ourse of self-studies, semester projets, BS nd MS. theses, nd the sophistited level designed for PhD nd DS reserh workers. Findings: Close oopertion with industry nd prtil implementtion of joint reserh projets ply ruil role in the funtioning of the lortory frmework. Prtil implitions: The edution of modern engineers nd Msters of Siene in utomti ontrol nd rootis is hllenging tsk whih my e suessfully omplished only if fed with industril relity. Continuously dvning industril ompnies demnd grdutes who n quikly djust to the workflow nd who n instntly utilize the knowledge nd skills quired in the omplex, interdisiplinry field of mehtronis. Originlity/vlue: The disussed lortory frmework suessfully ouples softwre nd hrdwre, providing omplex yet flexile system open for further development, enling tehing nd reserh into the design nd opertion of modern ontrol systems, oth y mens of virtul onstrution nd testing in simultion progrms, s well s on rel industril strutures onfigured in lortory worksttions. Keywords: Automti ontrol of engineering proesses; Didti proess; Mehtronis 1. Introdution Nowdys in the relity of the mrket eonomy ll industries must e ompetitive. To mintin their mrket positions, ompnies ontinuously redue the mnufturing osts, while simultneously improving qulity, reliility, esthetis, modernity nd durility of produts. To hieve suh gols, pproprite methods of prodution mngement nd optimistion re required, whih is impossile without the implementtion of utomti ontrol nd rootis of proess tehnologies [1,2]. The mintenne of onstnt, repetle nd urte prmeters of industril proesses with the required dynmis of their run nd in onsidertion of ll the negtive impts tht my use disruptions, led to onsistent elimintion of the humn ftor from the performne of numerous repetitive nd tedious tsks nd limittion of humn lour to generl supervision nd deision-mking responsiilities. The role of humn stff is tken over y externlly supplied tehnil systems in the form of utomti regultion systems, ontrol systems, or speilised industril roots [12,13]. The trining of speilists who re to e responsile for the design, mnufturing Copyright y Interntionl OCSCO World Press. All rights reserved. 2006 Reserh pper 199
Journl of Ahievements in Mterils nd Mnufturing Engineering nd opertion of meh-eletroni systems is serious edutionl hllenge. Nowdys engineering studies nnot e limited to one disipline only nd modern mehnil engineers, rther thn hving nrrow-minded knowledge on how to trnsform input signls to the output, should hve n insight into eletronis nd mhine ontrol [4]. The design of eletro-pneumti or eletro-hydruli systems would e very diffiult without the grsp of miro-proessing tehniques nd lerning how to design eletri ontrol systems or how to progrm logil PLCs [5,15]. The implementtion of omplex proess tehnologies must e sed on the knowledge out utomti ontrol of ontinuous proesses, s some of their ruil prmeters, suh s: temperture hnges, fluid or loose mterils ontents in tnks or hoppers, medium pressure in the system, light intensity, rottionl veloity of virting mhine elements, et. Hene, it is neessry to teh students the rudiments of utomtis nd ontrol theory, rules of the funtioning of sensor systems, regultors nd opertionl systems. 2. Lortories 2. Lortories In view of the ove, the Lortory of Automtis, Mehtronis, Integrted Mnufturing Systems nd Prodution Mngement Methods ws founded t the Fulty of Mehnil Engineering, Silesin University of Tehnology in Gliwie, Polnd, on the sis of the hrdwre nd prtly softwre offered Volume 15 Issue 1-2 Mrh-April 2006 y FESTO DIDACTIC, thnks to whih it is possile to edute mehnil engineers in the fields of utomti ontrol of proess tehnologies, with pneumti nd eletro-pneumti systems, logil PLCs, nd ontinuous proess regultors, to meet, t lest prtilly, the demnd for up to dte- university grdutes [1,2]. The lortory ommodtes l nd projet lsses for students of four study lines: Automtis nd Rootis, Tehnil nd IT Edution, Mehnis nd Mhine Building, Prodution Engineering nd Mngement tht offer ourses in the following sujets: rudiments of utomti ontrol nd rootis, utomti regultion nd mnufturing mesuring nd ontrol systems, s well s lsses for ll students speilizing in the fields within the sope of the Institute, involving utomtion of industril proesses nd systems. The Lortory Study Rooms of Engineering Proesses Automtion (Fig.1 nd 2) re equipped with three doule sttions for onfigurtion nd testing of pneumti systems, eletropneumtis nd progrmmle PLCs with logil SIEMENS S7 ontrollers nd FESTO ontrollers (Fig.3), five-segment modulr prodution system (MPS) whih ontins the following modules: distriution, ontrol, tretment, trnsport nd sorting (Fig.4), worksttion for ontinuous proesses ontrol (level of fluid in the tnk, fluid temperture, flow intensity) furnished with industril PID Burkert regultor (Fig.6), dvne sorting system sed on three-xis mnipultor used for storing nd trnsporting mterils nd elements in rootized mnufturing system (Fig.5) [6,7,8,9,10,11], nd- s desried in detil in this pper- the mehtroni ssemly system (Fig.4 f), onstruted s prt of student MS thesis [3]. Fig. 1. The Lortory study room of Engineering Proesses Automtion 200 Reserh pper J. Świder, P. Mihlski, G. Wszołek
Edution nd reserh trends Fig. 2. The seond Lortory study room of Engineering Proesses Automtion f e h d g d e f Fig. 4. Modules: ) distriution, ) ontrol, ) tretment, d) trnsport, e) sorting- mps lortory work stnd mde y Festo, f) mehtroni ssemly module, Fig. 3. Lortory worksttion for the oneting nd testing pneumti systems, eletro-pneumtis nd progrmmle PLCs: ) ssemly pnel with n exemplry ontrol system, ) pnel of mounting eletri feeders, logil trnsmitters nd ontrollers, ) feeder, d) set of relys, e) PLCs mde y Siemens, f) omputer stnd for progrmming of logil ontrollers, g) set of slugged relys, h) set of uttons nd swithes Students t the Fulty of Mehnil Engineering omplete their semester nd diplom works (BS nd MS theses) in the L using the worksttions pled in the Automtion of Proess tehnologies Workshop (Fig.7) [3,20,21]. The results of their work re expressed in the retion of innovtive work-sttions (Fig.7,9) within the frmework of the oopertion etween the Institute nd industry. Lortory support for the didti proess of engineering proesses utomtion t the Fulty of Mehnil Engineering 201
Journl of Ahievements in Mterils nd Mnufturing Engineering d e Volume 15 Issue 1-2 Mrh-April 2006 f Fig. 5. ) high-level sorting module, ) visuliztion nd workstnd ontrol system, ) work stnd for omputer progrmming of ontrollers nd system visuliztions Fig. 7. Eletro-pneumti student work stnd with pl for olour seprtion Fig. 6. Lortory work stnd for the ontrol of ontinuous proesses: ) pipeline systems, ) wter tnk systems, ) eletri feeders, d) Burkert pid industril regultor There is lso new industril FANUC root (Fig. 8) pled in the Lortory Study Room, whih in the ner future will e surrounded with mny neessry equipment to uild professionl root ell, inluding sfety rriers nd CNC milling mhine. In prtie, ll of the ove-mentioned lortory work-stnds ontin elements nd susystems of high integrtion with mehni nd eletri susystems nd IT systems, whih fore the users of the lortory to work in the integrted environment of modern mehtroni systems [12,13,14]. 202 Reserh pper Fig. 8. Industril FANUC root intended for tehing of progrmming J. Świder, P. Mihlski, G. Wszołek
Edution nd reserh trends Fig. 9. Rootized lortory stnd with olour seprtion module Fig. 10. Mehtroni ssemly sttion, ) model reted in ti v5 progrm, ) pneumti one-sided tutor ssemled on the sttion Lortory support for the didti proess of engineering proesses utomtion t the Fulty of Mehnil Engineering 203
Journl of Ahievements in Mterils nd Mnufturing Engineering The Lortory Study Room of Engineering Proesses Automtion is lso equipped with 4 omputer work-sttions, where the following softwre hs een instlled: FluidSIM-P for tehing the design nd simultion of the opertion of pneumti nd eletro-pneumti systems, FluidSIM-H for tehing the design nd simultion of the opertion of hydruli nd eletro-hydruli systems, FluidStudio-P for tehing the rudiments of pneumtis, FluidStudio-H for tehing the rudiments of hydrulis, COSIMIR for tehing the rudiments of modeling prodution work entres ooperting with industril roots, Digitl Trining Studio for tehing the rudiments of digitl eletronis, COSIVIS for tehing the rudiments of design, simultion, visuliztion nd ontrol of industril proesses, Cti for supporting 2D nd 3D designs, In-Touh Wonderwre for visuliztions of mnufturing proesses. The FluidSIM-P, FluidSIM-H, FluidStudio-P, FluidStudio-H, Digitl Trining Studio, COSIMIR nd COSIVIS re used for modelling nd simultions of proesses tht n e relised on lortory work-stnds in the Study Room of Engineering Proesses Automtion. Volume 15 Issue 1-2 Mrh-April 2006 The sope of one of the BS theses ompleted in the ourse of study t the Fulty of Mehnil Engineering ws the retion of MAS (Mehtroni Assemly Sttion - Fig.10) [3] designed s n dditionl module of FESTO s MPS. The sttion involves the ssemly of one sided tutor (Fig.10). The min prt of the tutor (ylinder) is supplied y MPS sorting module, wheres the other prts (piston with the rod, spring, over) re pled in the relevnt MAS setions. The mehtroni ssemly sttion onsists of 6 su-setions performing elementry proess opertions, stritly oordinted y progrmmle PLCs. Eh module ontins the required numer of sensors informing out the lotion nd ondition of the working elements nd elements deposited in the stores. On the ses of Siemens S7 ontroller softwre, the generted input signls ontrol the opertionl systems: eletro-pneumti vlves tht diret the pneumti opertors (tutors), trnsmitters ontrolling diret urrent engines nd eletro-mgneti oils opened up y the store feeder work-stnds. Another prt of the Lortory is the Sensors nd Industril Networks Study Room (Fig. 11). The Study Room is equipped with five doule worksttions for onfigurtion nd testing tive sensor systems nd vrious stndrds of industril networks sed on PLCs. Fig. 11. Sensoris nd industril networks study room 204 Reserh pper J. Świder, P. Mihlski, G. Wszołek
Edution nd reserh trends There is n tive disply on the Study Room wlls enling the first introdution into sensoris (indution sensors, volumetri sensors, optimeters, speil onstrutions for the food proessing industry, olor nd ontrst sensors, het sensors nd pressure trnsduers, et). Speil disply ords show rel elements of industril utomtion, desriing the wys of ontrolling eletro-pneumti mehtroni systems nd fundmentl elements used for industril networks. The stff of the Institute Engineering Proesses of Automton nd Integrted Mngement Systems hve ensured lose oopertion with industry to equip the Sensoris nd Industril Networks Study Room with PLCs, drives, frequeny onverters, industril omputers, sensory systems, feeders, regultors, LCDs, elements of liner pneumtis, s well s omplete mehtroni systems: SEWsttered drive systems (Fig. 12), nd FlexLink elt onveyor system (Fig. 13) [3,15,16,17,18,19,20,21]. Fig. 12. Mehtroni system of roller onveyor- ontrol y sew sttered drive systems used for profius industril networks Fig. 13. Mehtroni system of flexlink elt onveyor-ontrol sed on mitsuishi frequeny onverters nd ifm eletroni sensory systems Nowdys PLC ontrollers re ommonly omined into industril networks for dt exhnge with other mhines. Network onnetions filitte the following tsks: onstrution of very omplex ontrol systems; ontrol of systems remote from entrl PLC unit; visuliztion of the mnufturing proess; storge of dt on the mnufturing proess; dignostis of fults nd filures. Currently, the Sensoris nd Industril Networks Study Room hs seprte worksttions for onfigurtion nd testing the following systems: mesurements of the ngle of rottion nd liner displement y mens of inrementl nd solute enoders; detetion of the presene of elements y mens of indutive sensors, pitive sensors, optimeters (lser, infrred, diffusion, refletive, opti gtes, olor nd ontrst sensors); mesurements nd storge of temperture dt y mens of temperture monitors (PT100 nd PT1000) nd nlogue input modules of vrious industril ontrollers; mesurements nd storge of pressure dt y mens of pressure monitors with nlogue output modules of vrious industril ontrollers; mesurements of pressure drops depending on the seletion of elements of liner pneumtis; strt-up of industril networks sed on ifm eletroni ontrollers for AS-i v.2.0 network; strt-up of industril networks sed on ifm eletroni ontrollers for AS-i v.2.1 network with gtes to higher level networks; strt-up of industril networks sed on SIEMENS S7 ontrollers for ProfiBus network; strt-up of industril networks sed on ifm eletroni moile ontrollers for CANopen network: strt-up of industril networks sed on MITSUBISHI Q nd A2, A4 ontrollers for CC-Link, MelseNet nd MelseNetB networks; pplition of moile tehnologies nd WIFi wireless networks for proess tehnologies ontrol; pplition of the Internet topology nd TCP/IP protool for proessing nd olleting dt on proess tehnologies. The opertion of the Sensors nd Industril Networks Study Room hs filitted lerning nd dissemintion of the informtion on the design of the following industril networks: Ethernet, WiFi, ProfiBus, AS-I, CC_Link, MelseNET, MelseNET B, CANOpen. In the ourse of diplom works or other projets PhD students nd individul study ourse students onstrut different testing nd mesuring systems. Thnks to effetive oopertion with the industry (Mitsuishi Eletri, MPL Tehnology, ASTOR, BiusMenos, FESTO, Norgren Herion, Newteh Engineering, ifm eletroni, Siemens, SMC, Bosh Rexroth, Flexlink, SEW Eurodrive, Automotive Lighting, Lenze, Frisko, B&R) new elements of industril utomtion re quired s well s orders for further reserh works. The Study Room provides venue for workshops nd trining. The workshops offered to students nd stff of the Institute re run y representtives of industry nd foused on filitting work with newly quired elements of utomtion nd inditing Lortory support for the didti proess of engineering proesses utomtion t the Fulty of Mehnil Engineering 205
Journl of Ahievements in Mterils nd Mnufturing Engineering Volume 15 Issue 1-2 Mrh-April 2006 new diretions for further reserh projets. The trinings (on si nd dvned levels) re run y well-qulified university stff of the Institute. The trinings involve industril networks nd onstrution of sensory systems. They re often offered to the employees of the ompnies tht ooperte with the Institute. The Sensors nd Industril Networks Study Room hs een operting effetively for one yer. Students who used it to prepre for the Ntionl Contest of Mehtronis hve won the seond ple nd the Contest Cup in 2004. 3.Conlusions The edution of modern engineers nd Msters of Siene in utomti ontrol nd rootis is hllenging tsk whih my e suessfully omplished only if fed with industril relity. Continuously dvning industril ompnies demnd grdutes who n quikly djust to the workflow nd who n instntly utilize the knowledge nd skills quired in the omplex, interdisiplinry field of mehtronis. The disussed lortory frmework suessfully ouples softwre nd hrdwre, providing omplex yet flexile system open for further development, enling tehing nd reserh into the design nd opertion of modern ontrol systems, oth y mens of virtul onstrution nd testing in simultion progrms, s well s on rel industril strutures onfigured in lortory worksttions. Aknowledgements This work hs een onduted s prt of the reserh projet No. 4 T07C 01827 supported y the Committee of Sientifi Reserh in yers 2004-2007 Referenes [1] J. wider, G. Wszo ek, The methodil olletion of lortory nd projet tsks of tehnologil proess ontrol. Pneumti nd eletropneumti systems with logil PLC ontrol. Silesin University Pulishing Compny, Gliwie 2003, pp. 270, (in Polish). [2] J. wider (ed.), Control nd Automtion of Tehnologil Proess nd Mehtroni Systems. Silesin University Pulishing Compny, Gliwie 2002 (in Polish), pp.546. [3] S. Nowk, Mehtroni Assemly Sttion in Modulr Mnufturing System, Silesin University of Tehnology, MS. thesis, Gliwie 2004 (in Polish). [4] J. wider, G. Wszo ek, Colletion of lortory nd design tsks onerning the ontrol of proess tehnologies, Silesin University of Tehnology, Gliwie 2003 (in Polish). [5] T. Legierski, J. Wyrw, PLC Progrmming, Jsk Sklmierski s Pulishing Compny, Gliwie 1998 (in Polish). [6] K. Rdznek, Indexed rotry desks for flexile omplex mhine tools. Mehnil engineering Review, No 14 1998 (in Polish). [7] F. Eel, Distriution Sttion. Modulr Prodution System. Festo Didti, Denkendorf 1999. [8] F. Eel, Hndling Sttion. Modulr Prodution System. Festo Didti, Denkendorf 1999. [9] F. Eel, Proessing Sttion. Modulr Prodution System. Festo Didti, Denkendorf 1998. [10] F. Eel, Sorting Sttion. Modulr Prodution System. Festo Didti, Denkendorf 1998. [11] F. Eel, Testing Sttion. Modulr Prodution System Festo Didti, Denkendorf 1998. [12] G. Kost, Control systems for industril roots. SUT s Pulishing Compny, Gliwie 2000, (in Polish). [13] G. Kost, Rudiments of roots onstrution. SUT s Pulishing Compny, University Course Book No 1992, (in Polish). [14] R. Zdnowiz, Rootiztion of proess tehnologies. SUT s Pulishing Compny, Gliwie, 1999 (in Polish). [15] J. wider, G. Wszo ek, Anlysis of omplex mehnil systems sed on the lok digrms nd the mtrix hyrid grphs method. Journl of Mterils Proessing Tehnology, Elsevier, the Netherlnds, 157-158 (2004) 250-255. [16] J. wider, G. Wszo ek, Virtion nlysis softwre sed on mtrix hyrid grph trnsformtion into struture of lok digrm method. Journl of Mterils Proessing Tehnology, Elsevier, the Netherlnds, 157-158 (2004) 256-261. [17] G. Wszo ek, Virtion nlysis of the exvtor model in GRAFSIM progrm on the sis of lok digrm method. Journl of Mterils Proessing Tehnology, Elsevier, the Netherlnds, 157-158 (2004) 268-273. [18] G. Wszo ek, Modelling of mehnil system virtions y utilistion of the GRAFSIM softwre. Journl of Mterils Proessing Tehnology, Elsevier, the Netherlnds, 164-165 (2005) 1466-1471. [19] J. wider, G. Wszo ek, P. Mihlski, Physil nd geometril dt quiring system for virtion nlysis softwre. Journl of Mterils Proessing Tehnology, Elsevier, the Netherlnds, 164-165 (2005) 1444-1451. [20] J. wider, G. Wszo ek, W. Crvlho, Progrmmle Controller designed for eletro-pneumti systems. Journl of Mterils Proessing Tehnology, Elsevier, the Netherlnds, 164-165 (2005) 1459-1465. [21] J. wider, G. Wszo ek, A. Bier, G. Ciupk, O. Winter, Testing devie for eletril r networks. Journl of Mterils Proessing Tehnology, Elsevier, the Netherlnds, 164-165 (2005) 1452-1458. 206 Reserh pper READING DIRECT: www.journlmme.org