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WorldSkills international Mechatronics Competition 2011 1

Project 1:

Assembly, programming and commissioning of a production line including

Handling station with electrical drive and stack magazine and Robot station

Weighting (points out of total) 16/100

t max 180 min

All big pictures are also on CD-ROM

Scenario

You are responsible for the delivery of a production line purchased by a customer in the world to be used in the

partial automation of its production process.

Task

Assemble, wire and tube the production line on the profile plate according to the following guidelines and the

technical information.

Develop a program and commission the system.

Your task is complete when:

1. The production line has been mechanically assembled, correctly wired, connected and its correctoperation is guaranteed (based on evaluation using the simulation box).

2. Correct execution of the program with PLC activation (based on evaluation with PLC) is guaranteed.3. The system meets the specifications (in accordance with the 'Agreement on Professional Practice' which

has been handed out separately).

The system will be sent to the customer as soon as you are finished. You will have no opportunity to make

improvements later.

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WorldSkills international Mechatronics Competition 2011 2

1Production line layout:

1. Handling station (HS)2.

Magazine pickup position

3. Slide Drop down position 14. Slide Drop down position 2 (not used)5. Robot station (RS)6. Pallet 1 Place 1 to 67. Pallet 2 Place 1 to 6Initial position:HS:

Stack magazine ejecting arm retraced (cylinderextended)

Gripper unit in Magazine position Gripper open Gripper upRS:

See Touch Panel

2

3

4

5

6

7

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WorldSkills international Mechatronics Competition 2011 4

Back side of the Handling unit

Fixing of the linear axes

left and right

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WorldSkills international Mechatronics Competition 2011 5

Motor controller R/L:

A1 : move to right side / A2 : move to left side

1, 2 : Motor

VCC: 24 V / GND: 0V

A3 and I-OUT are not used

Wiring control panel

wiring additional signals to - X7 (pin 5-8 Input; pin 13-16 Output)

Multipol I/O module

Motor controller

Valve terminal

Optical Sensor

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WorldSkills international Mechatronics Competition 2011 7

The StationLink receiver on the

u stream station.

The StationLink Transmitter

is mounted on the

downstream station.

The robot station (downstream station) is sending a busy signal via the optical transmitter. This signal can be

detected with the receiver at the Handling station (upstream station) in order to achieve a safe material flow.

By switching on or off the StationLink transmitter, the downstream station signals the upstream station whether

it is ready to receive a pot or busy.

Pallet 1

Pallet 2

Front

P2 P3

P4

P5 P6

P7

TP

TP

A B

E

D C

F

malfunction/

collision

malfunction

collision

Position P1 is the pickup position in the Robot station!

TP

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WorldSkills international Mechatronics Competition 2011 8

Position P1 is the pickup position in the Robot station!

Wiring allocation valve terminal

PIN Core colour Coil Ouput Function

1 White 0 2 Move gripper down

2 Brown 1 3 Open gripper

3 Green 2 not used but switch for manual use is ON (--)

4 Yellow 3 4 Ejecting arm push out pot

5-13

14 Brown-green 0V

15 White-yellow 0V

Wiring allocation of sensors to Multipol (MPV)

Pin Core colour M8

socket/

Pin

Input function

1 White 0 / 4 1 Gripper unit in magazine position

2 Brown 1 / 4 2 Gripper unit in downstream station position

3 Green 2 / 4 3 Gripper unit in slide position

4 Yellow 3 / 4 4 Gripper is down

5 Grey 4 / 4 5 Gripper is up

6 Pink 5 / 4 6 Pot is not black

7 Blue 6 / 4 Not used

8 Red 7 / 4 Not used

9-12

13 White-green 0-7 / 1 24V DC

14 Brown-green 0-7 / 3 0V

15 White-yellow 0-7 / 3 0V

Wiring to the Control panel

Connector I/O (IN) Comment: 1 signal indicates Connector I/O (OUT) Comment: 1 signal set

DI 0 - 3 Used by Control panel DO 0 - 3 Used by Control panel

DI 4 - 5 Not used DO 4 - 5 Not used

DI 6 Ejecting cylinder extended DO 6

DI 7 Ejecting cylinder retracted DO 7

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

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WorldSkills international Mechatronics Competition 2011 9

Evaluation sheet Project 1:

Assembly, programming and commissioning of a production line includingHandling station with electrical drive and stack magazine and Robot station

Team:

Verification of acceptance by experts (names, signatures):

Maximum time: 180 min. / Maximum points: 16

Description Evaluation

Function to be checked using simulation box and wiring of the I/O

Terminal for the station

Done Max points

Preparation: Connect the simulation box to the I/O terminal (Output 07: signal 1 or 0); (Input 07: signal 1 or 0)

Connector I/O

Terminal (IN)

Comment

1 signal indicates

DI 0 Pot is in magazine pickup position 0,3

DI 1 Gripper unit is in magazine position 0,3

DI 2 Gripper unit is in downstream station position / Robot slide 0,3

DI 3 Gripper unit is in slide position 1 0,3

DI 4 Gripper is down 0,3

DI 5 Gripper is up 0,3

DI 6 Pot is not black 0,3

DI 7 Downstream station free 0,3

Connector I/OTerminal (OUT)

Comment1 signal set

DO 0 Gripper unit to left hand side (magazin position) 0,3

DO 1 Gripper unit to right hand side (drop off position) 0,3

DO 2 Gripper down 0,3

DO 3 Open gripper 0,3

DO 4 Ejecting arm push out pot 0,3

DO 5 Signal lamp green 0,3

DO 6 Signal lamp yellow 0,3

DO 7 Signal lamp red 0,3

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W ldSkill i t ti l M h t i C titi 2011 12

Description Evalua

tion

Maximum

evaluation

Professional practice List of

Professional

Practice will be

checked in

samples

PP item no. Not fulfilled

* -0,4

* -0,4

* -0,4

* -0,4

* -0,4

* -0,4

* -0,4

* -0,4

* -0,4

* -0,4

Professional Practice total 4

* Each deviation will result in 0,4 points being deducted

Total evaluation Project 1:

Description Evaluation Maximum

evaluation

Points for operation based on simulation box _____ 4,8

Points for operation based on PLC board _____ 7,2

Points for professional practice _____ 4

Total points _____ 16,0