Table of Contents. Table of Contents UniTrain UniTrain courses UniTrain mechatronic courses IMS 23/24 with 3/4 subsystems

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1 Table of Contents Table of Contents UniTrain UniTrain courses UniTrain mechatronic courses IMS 23/24 with 3/4 subsystems Lucas Nülle GmbH Page 1/16

2 UniTrain UniTrain is a multimedia e-learning system with integrated, mobile electronics lab for general education and advanced training in electrical engineering and electronics. UniTrain courses UniTrain courses Lucas Nülle GmbH Page 2/16

UniTrain mechatronic courses UniTrain mechatronic courses UniTrain multimedia courses on the topic of mechatronics provide the knowledge and skills required to understand, control, operate and

3 UniTrain mechatronic courses UniTrain mechatronic courses UniTrain multimedia courses on the topic of mechatronics provide the knowledge and skills required to understand, control, operate and maintain modern, automated mechatronics installations. With the aid of animations and numerous experiments, the various individual sub-systems are introduced, any necessary instrumentation or pneumatic cylinders are set up and adjusted and the active processes are explained. Individual mechatronic components and sub-systems are set up with the aid of detailed step-by-step instructions and automated sequences are programmed to control the equipment by means of a programmable logic controller. This should make moving up to an industrial PLC system a simple task. Lucas Nülle GmbH Page 3/16

4 IMS 23/24 with 3/4 subsystems IMS 23/24 with 3/4 subsystems The production line system can be used for the fully automatic manufacture of a three-part workpiece of up to eight different end products. IMS 12 consists of the sub-systems sorting, testing, handling (3 subsystems) and assembly (4 subsystems). All of the subsystems can be used individually or combined with each other in any given configuration. For the conveyance of workpieces between the individual subsystems a transport system with workpiece carriers is used on dual conveyor belt system. Using this training system the industrial processes of a complex production line can be realistically simulated. Only industrial-type actuators and sensors are used. Also for system control only industrial type PLC systems with Profibus and decentralised periphery are deployed. Optional expansions of additional modern, industrial communications systems are planned. The system promotes the learning of skills and qualifications while in a team and enables students to work independently while acquiring the basics needed for mastering mechatronic systems. Each sub-system is designed so that the student can acquire the necessary skills and knowledge step-by-step, starting with simple automation operations and sequences, and ending in development of complex automation programs. Standardized interfaces allow a use of various industrial PLC control units or the UniTrain-I system. Transport system: Dual conveyor belts with DC drive motors and a variable-speed, three-phase drive motor. Identification system: Three workpiece carriers are each furnished with a fixed code. A reading unit is mounted on the station. Identification system: An RFID identification system can be installed optionally. Supervisory level: Preparation of production orders on the control station PC; process visualization and operational-data acquisition Linkage of the process control station via TCP/IP IMS 3 sorting subsystem IMS 6 testing subsystem IMS 7 handling subsystem IMS 4 assembly subsystem (4 subsystems) Lucas Nülle GmbH Page 4/16

5 List of articles: Additional hardware required for four subsystems IMS 24 Pos. Product name Bestell-Nr. Anz. 1 Course - Mechatronics 23/24: production line with 3/4 stations SO4204-8Z 1 Includes: 1 experiment card including CPU with PLC capability and PROFIBUS-DP master interface, 8 digital inputs (4 accessed via 2 mm sockets) with simulation switches and status LEDs, 8 digital outputs with status LEDs accessed via 2mm sockets, 8 analog inputs 10-bit resolution, 4 analog outputs, potentiometer for simulation of analog inputs, selectable levels for digital signals, 5/24V DC, levels for analog signals 0-10V, connectors for external PROFIBUS devices CD-ROM with Labsoft browser, programming software and course software The following sub-systems are also needed to work through this course: IMS 3 Sorting IMS 4 Assembly IMS 6 Testing IMS 7 Handling Training contents: Assembly, adjustment and testing of pneumatic cylinders, valves and sensors Definition of processing procedures Use of basic principles of control technology, working with various actuators and sensors PROFIBUS project planning and commissioning Linking of multiple individual systems to create two different combined systems: IMS 23 and IMS 24 Course duration: 6 h approx. Lucas Nülle GmbH Page 5/16

2 Sorting station LM9680 1 Station with fully automatic feed, sorting and assembly of bottom section workpieces.

6 2 Sorting station LM Station with fully automatic feed, sorting and assembly of bottom section workpieces. In conjunction with a conveyor belt, the station accomplishes a portion of an assembly process for an end product made of three separate components. Gravity-feed magazine Micro switch for monitoring magazine level Two-way stop cylinder Magnetic end-limit sensor 1 x Sorting cylinders 1 x 3/2 way valves 1 x 4/2-way valve Pneumatic valve block PLC interface: 25-pin SUB-D connector PLC requirements: 2 x digital outputs, 2 x digital inputs To assure functionality and a long working life for pneumatic components and controls, a maintenance unit is required, consisting of: filters, pressure control valve with pressure gauge and lubrication. Lucas Nülle GmbH Page 6/16

3 Handling station LM9683 1 Automated handling station with a vertical lifting cylinder at the end of a pneumatic jib that can be used in conjunction with conveyor belt segments to sort workpieces

90 turning pneumatic jib Vacuum generator with sensor Vertical cylinder with vacuum lifter and microswitch 3 x One-way restrictor valves 3 x 4/2-way valves 1 x 3/2-way valve 4-valve block 2 position

7 3 Handling station LM Automated handling station with a vertical lifting cylinder at the end of a pneumatic jib that can be used in conjunction with conveyor belt segments to sort workpieces according to preset criteria. 90 turning pneumatic jib Vacuum generator with sensor Vertical cylinder with vacuum lifter and microswitch 3 x One-way restrictor valves 3 x 4/2-way valves 1 x 3/2-way valve 4-valve block 2 position sensors Two-way stop cylinder PLC interface: 25-pin SUB-D connector PLC requirements: 4 x digital outputs, 5 x digital inputs To assure functionality and a long working life for pneumatic components and controls, a maintenance unit is required, consisting of: filters, pressure control valve with pressure gauge and lubrication. 4 Testing station LM A testing station that checks workpieces on a conveyor belt for material and colour. 4 Binary testing sensors (2 x optical, inductive, capacitive) Magnetic end-limit sensor Two-way stop cylinder 4/2-way valve PLC interface: 25-pin SUB-D connector PLC requirements: 1 x digital output, 5 x digital inputs To assure functionality and a long working life for pneumatic components and controls, a maintenance unit is required, consisting of: filters, pressure control valve with pressure gauge and lubrication. Lucas Nülle GmbH Page 7/16

5 Double conveyor belt segment, passive LM9603 2 Basic mechatronic module with no built-in drive, primarily designed for extending powered conveyor belts in complex mechatronic systems.

8 5 Double conveyor belt segment, passive LM Basic mechatronic module with no built-in drive, primarily designed for extending powered conveyor belts in complex mechatronic systems. Drive is provided via a belt transmission or by mechanical coupling to another belt or curved segment. Length = 600mm/23,6", width = 160mm/6,3", belt width = 120mm/4,7" Extra drive belt 6 Double conveyor belt segment, 24V motor LM Basic mechatronics module driven by a variable speed 24-V geared motor and complete with end-limit sensors and integrated PROFIBUS DP slave. Designed for basic experiments on a conveyor system or for incorporation into a complex mechatronics system for controlling the flow of materials. The conveyor belt conveys work pieces on carriers and can be used to link individual sub-systems. It is designed for connection to a PLC control system. It can be combined with other conveyor belts, curve units or transfer junctions. IMS stations can be connected directly to the belt and jointly controlled via PROFIBUS. Length = 600 mm/23,6", width = 160 mm/6,3", belt width = 120 mm/4,7" Geared motor, 24 V DC Pulse width modulation system for controlling belt at various speeds Continuous speed adjustment via potentiometer or analogue input, 0-10 V Manual switches for movement to left or right 2 inductive end-limit sensors 2 x M12 interfaces for additional actuators/sensors Sockets for emergency shut-off circuit (disconnection of all voltage to output modules) External power supply via 4-mm safety sockets or co-axial power connector 9-pin SUB-D connector for contactors, LOGO! or PLC Incremental encoder disc for detecting position and speed via optical sensors Visualisation as interactive 3D model in IMS-virtual database Control requirements: 4 x digital inputs, 3 x digital outputs PROFIBUS DP slave module: Lucas Nülle GmbH Page 8/16

9 Address range: 16 digital input/outputs PROFIBUS DP connector: 9-pin DSUB socket Rotary switch for setting address Transmission rates of up to 6 Mbits/s GSD file for use with control software (e.g.: STEP7) 25-pin DSUB socket for connecting IMS station Output current: 500 ma (total current: 1 A) Variable speed control of conveyor belt via PROFIBUS conveyor belt segment LM Conveyor belt segment with turntable for changing workpiece direction. For connection to subsystems or assembly in a complex mechatronic or pallet rotation system. The resulting curved segment is driven by coupling it to a driven conveyor belt and can be connected in either direction. Angle = 180 Belt width = 120 mm Radius = 250 mm 8 IMS manual control unit LM Manual control unit used for the control of IMS-subsystems or IMS manufacturing systems. EMERGENCY SHUTDOWN switch Illuminated START switch Illuminated STOP switch 2 x illuminated pushbuttons, configurable as desired Manual/automatic switch Selection switch, touch-type, configurable as desired Selection switch, latching type, configurable as desired Connection cable, length 2 m, 25-pin D-Sub Lucas Nülle GmbH Page 9/16

9 Workpiece transport pallet LM9620 1 Pallets for carrying and transporting workpieces on conveyor belts. The pallet has a 4-bit identification code.

Colour: white Magnetic clip for attachment to top section Dimensions (L x W x H): (100 x 50 x 40) mm / 3,9" x 1,97" x 1,57" 11 Workpiece, bottom section, black LM9624 2

10 9 Workpiece transport pallet LM Pallets for carrying and transporting workpieces on conveyor belts. The pallet has a 4-bit identification code. Length = 180mm/7,1", width = 119mm/4,7", height = 15mm/0,6" Position sensor 4-bit identification code 10 Workpiece, bottom section, white LM Material: plastic Colour: white Magnetic clip for attachment to top section Dimensions (L x W x H): (100 x 50 x 40) mm / 3,9" x 1,97" x 1,57" 11 Workpiece, bottom section, black LM Material: plastic Colour: black Magnetic clip for attachment to top section Dimensions (L x W x H): (100 x 50 x 40) mm / 3,9" x 1,97" x 1,57" Lucas Nülle GmbH Page 10/16

11 12 Assembly station LM Station with fully automatic feed, sorting and assembly of top section workpieces. In conjunction with a conveyor belt, the station accomplishes a portion of an assembly process for an end product made of three separate components. Gravity-feed magazine Micro switch for monitoring magazine level Two-way stop cylinder Magnetic end-limit sensor 2 x Sorting cylinders 1 x 3/2 way valves 1 x 4/2-way valve Pneumatic valve block PLC interface: 25-pin SUB-D connector PLC requirements: 2 x digital outputs, 2 x digital inputs To assure functionality and a long working life for pneumatic components and controls, a maintenance unit is required, consisting of: filters, pressure control valve with pressure gauge and lubrication. 13 Double conveyor belt segment, 24V motor LM Basic mechatronics module driven by a variable speed 24-V geared motor and complete with end-limit sensors and integrated PROFIBUS DP slave. Designed for basic experiments on a conveyor system or for incorporation into a complex mechatronics system for controlling the flow of materials. The conveyor belt conveys work pieces on carriers and can be used to link individual sub-systems. It is designed for connection to a PLC control system. It can be combined with other conveyor belts, curve units or transfer junctions. IMS stations can be connected directly to the belt and jointly controlled via PROFIBUS. Length = 600 mm/23,6", width = 160 mm/6,3", belt width = 120 mm/4,7" Geared motor, 24 V DC Pulse width modulation system for controlling belt at various speeds Continuous speed adjustment via potentiometer or analogue input, 0-10 V Manual switches for movement to left or right Lucas Nülle GmbH Page 11/16

2 inductive end-limit sensors 2 x M12 interfaces for additional actuators/sensors Sockets for emergency shut-off circuit (disconnection of all voltage to output modules) External power supply via

12 2 inductive end-limit sensors 2 x M12 interfaces for additional actuators/sensors Sockets for emergency shut-off circuit (disconnection of all voltage to output modules) External power supply via 4-mm safety sockets or co-axial power connector 9-pin SUB-D connector for contactors, LOGO! or PLC Incremental encoder disc for detecting position and speed via optical sensors Visualisation as interactive 3D model in IMS-virtual database Control requirements: 4 x digital inputs, 3 x digital outputs PROFIBUS DP slave module: Address range: 16 digital input/outputs PROFIBUS DP connector: 9-pin DSUB socket Rotary switch for setting address Transmission rates of up to 6 Mbits/s GSD file for use with control software (e.g.: STEP7) 25-pin DSUB socket for connecting IMS station Output current: 500 ma (total current: 1 A) Variable speed control of conveyor belt via PROFIBUS 14 Workpiece, top section, white LM Material: plastic Colour: white Magnetic clip for attachment to bottom section Spring-loaded bearing for attaching bolt Dimensions (L x W x H): (100 x 50 x 40) mm / 3,9" x 1,97" x 1,57" Lucas Nülle GmbH Page 12/16

15 Workpiece, top section, black LM9622 2 Material: plastic Colour: black Magnetic clip for attachment to bottom section Spring-loaded bearing for attaching bolt Dimensions (L x W x H): (100 x 50 x

16 25-pin serial interface cable, Sub-D plug/socket LM9061 4 25 pin Sub-D connection cable Length: 2m Connection: 25-pin plug / 25-pin socket Pin assignment: 1:1 17 Connection cable for PROFIBUS, per

13 15 Workpiece, top section, black LM Material: plastic Colour: black Magnetic clip for attachment to bottom section Spring-loaded bearing for attaching bolt Dimensions (L x W x H): (100 x 50 x 40) mm / 3,9" x 1,97" x 1,57" Accessories: Pos. Product name Bestell-Nr. Anz pin serial interface cable, Sub-D plug/socket LM pin Sub-D connection cable Length: 2m Connection: 25-pin plug / 25-pin socket Pin assignment: 1:1 17 Connection cable for PROFIBUS, per metre LM Cabling for the construction of PROFIBUS networks, per metre 18 Connection plugs for PROFIBUS with PG socket and terminating resistor LM With integrated PG socket for connecting PC/PG without need for any extra installations plus integrated combination of resistors with slide switches for isolating functionality. Includes Fast-Connect connector using crimp terminals with 90 terminal outlets. Lucas Nülle GmbH Page 13/16

19 Wire stripper for PROFIBUS cables LM9184 1 For quick and easy connection of PROFIBUS plugs to PROFIBUS bus lines 20 Safety measurement cable

2.5 mm 2 Rating: 600V, CAT II, 32A 21 Safety measurement cable (4mm), 100cm/40", blue SO5126-9A 5 Safety measurement lead with stackable,

14 19 Wire stripper for PROFIBUS cables LM For quick and easy connection of PROFIBUS plugs to PROFIBUS bus lines 20 Safety measurement cable (4mm), 100cm/40", red SO5126-8U 5 Safety measurement leads with stackable, contact-proof 4mm plugs Colour: red Length: 100 cm Wire cross-section, 2.5 mm 2 Rating: 600V, CAT II, 32A 21 Safety measurement cable (4mm), 100cm/40", blue SO5126-9A 5 Safety measurement lead with stackable, contact-proof 4mm plugs Colour: blue Length: 100 cm Wire cross-section 2.5 mm 2 Rating: 600V, CAT II, 32A Lucas Nülle GmbH Page 14/16

IMS furniture IMS furniture The IMS furniture system is used together with the Industrial Mechatronics System. The mobile trolleys can be used for individual components or sub-systems.

15 IMS furniture IMS furniture The IMS furniture system is used together with the Industrial Mechatronics System. The mobile trolleys can be used for individual components or sub-systems. In order to build complex, mechatronics systems, the trolleys can be lined up alongside one another and can be supplemented by frames to accommodate training panels. A power console allows the trolley to be equipped with a wide variety of 3 HU modules. The trolleys can be extended by means of various add-ons attachable to the aluminium rails to make up a multi-function PC experiment trolley. Pos. Product name Bestell-Nr. Anz. 22 SybaPro mobile IMS experiment trolley, 1200mm ST7200-3U 3 These mobile, mechatronics trolleys with aluminium rails that can be lined up alongside one another are specially designed to accommodate mechatronics set-ups with production lines or pallet rotation systems. The trolleys can be cascaded and are equipped with strong table-top connectors for this purpose. The mobile experiment stand is delivered in kit form and needs to be assembled by the customer Aluminium rail with integrated grooves to accommodate a wide variety of add-on components (e.g. PC shelf, extension panels, C rails) 4 swivelling dual casters, including 2 with brakes Work top 1200 x 25 x 900mm (WxHxD) Board 1200 x 25 x 800mm (WxHxD), e.g. to accommodate compressors or hydraulic equipment Boards with compressed multi-layer chipboard conforming to DIN EN 438-1; colour light grey; with slightly textured 0.8 mm coating on both sides (Resopal) conforming to DIN Work top frame with impact resistant protective edging made of 3mm thick coloured plastic, colour RAL 7047 Coating and adhesives are PVC-free Power strip with 5-outlet sockets and power switch, lead and earthed plug Height of worktop 750 mm Lucas Nülle GmbH Page 15/16

Additionally required: Pos. Product name Bestell-Nr. Anz. 23 Compressor, low-noise SE2902-9L 1 Extremely quiet compressed air system with compressor motor, thermo switch and automatic pressure switch.

34 kw Suction capacity: 50 l/min Power consumption at 8 bars: 2.9 A Pressure: 8 bars Tank capacity: 15 l. Noise level: 40 db(a)/1m Operating voltage: 230V AC incl.

16 Additionally required: Pos. Product name Bestell-Nr. Anz. 23 Compressor, low-noise SE2902-9L 1 Extremely quiet compressed air system with compressor motor, thermo switch and automatic pressure switch. Tanks made of special steel with security valve and non-return valve, master pressure gauge, condensation drain, stop valve and maintenance unit Motor output: 0.34 kw Suction capacity: 50 l/min Power consumption at 8 bars: 2.9 A Pressure: 8 bars Tank capacity: 15 l. Noise level: 40 db(a)/1m Operating voltage: 230V AC incl. tube and connection set Dimensions: 500x410x410 mm (HxWxL) Weight: 19 kg 24 Tubing and accessory set for mechatronics systems LM Universal tubing and accessory set with the required components and adapters for connecting a compressor to mechatronic systems. 1 x Compressor connector with plug-in sleeve 8 mm 1 x Plug adapter 6 mm/8 mm 1 x Plug adapter 4 mm/6 mm 2 x Angle connectors 4 mm 5 x T-connectors 4 mm 5 x T-connectors 6 mm 5 x T-connectors with 6 mm/4 mm adapters 20 m polyurethane tubing, 4mm 10 m polyurethane tubing, 6mm 10 Stoppers for plug connectors 4 mm 1 x 3/2 directional control valve, manual, 5 mm Lucas Nülle GmbH Page 16/16

Table of Contents. 95 IMS 25 flexible manufacturing line with 5 stations. 104 IMS 26 flexible manufacturing line with 6 stations

Table of Contents. 95 IMS 25 flexible manufacturing line with 5 stations. 104 IMS 26 flexible manufacturing line with 6 stations Table of Contents Table of Contents Automation Technology IMS Industrial mechatronics system Mechatronics Sub-Systems with UniTrain-I IMS 1.2: DC transport system IMS 1.3: AC transport system IMS 3 Sorting