Handling Station

Technical significance
Movement, orientation and assembly of work pieces are a requisite for all automated assembly
systems. These tasks are performed by automated handling machines, the best known and most
powerful of which are the industrial robots (cf. Figure 1).

Industrial robots are freely programmable and have at least four axes (i.e. driven joints), making
them extremely flexible. Industrial robots are also very fast (over 1 m/s) and accurate (repetition
accuracy of better than 50 μm).

Simpler handling devices are adequate for many assembly tasks.

Figure 1: Industrial robot (picture by Festo Didactic)

When considering a handling station for a particular job, there are three important criterions to
consider
 Speed, how quickly the part is produced

 Accuracy, the allowed tolerances of the part being produced

 Working space, how much space the handling station will take up.

One of the most important components in a handling device is the gripper used to establish
contact with the work piece. There are many different designs of grippers:

 Mechanical grippers with two or three gripper jaws grip work pieces like a hand. Since
these grippers' fingers are not as flexible as the fingers on an actual hand, however, it
means that the gripper jaws generally have to be adapted to the work piece to be gripped.

 Vacuum grippers hold the work pieces by means of vacuum. They are especially suitable
for flat work pieces but less suitable for porous ones because no vacuum can be built up.

 Magnetic grippers for magnetizable work pieces.

 Adhesive grippers where the work pieces are held using an adhesive film. These are used
less frequently because they are very sensitive to soiling.

Since two-axis automated handling machines are most frequently used to remove (pick) work
pieces from a magazine and then deposit or assemble (place) them somewhere else, they are also
called pick and place devices. The handling station for the Mechlab trainer is an example of a
pick and place device.

Figure 2: Handling station

Components of the Handling Station
The handling station consists of

 Two pneumatic linear axes, moves the gripper left, right, up and down.

 One pneumatic gripper, opens and closes to pick up and place work piece

 Three valves for controlling the pneumatic actuators,

 Four magnetic proximity sensors for detecting the position of the axes and further
components.

The following table provides an overview of the components, their significance to the handling
station and the corresponding circuit symbol

Handling Station Components

Description Illustration Circuit Representation
Gripper for holding work
piece

Magnetic proximity sensor

detects the position of the
cylinder

3/2 way stop cock for shutting

off the compressed air and
exhausting

T-Distributor distributes the

compressed air to the rest of
the circuit
 Double acting guided cylinder.
Linear drive movement for
whatever direction the
cylinder is mounted.

Storage plate for storing work

pieces

N/A

One way flow control valve,

used to regulate the speed of
the pneumatic device.

4/2 way solenoid valve, with

pneumatic spring return

4/2 way double solenoid valve

Multi-pin plug distributor,

interface for connecting all
actuators and sensors of the
handling station to the control
PC

Table 1: Handling station parts and description

Commissioning the handling station
The handling station consists of a two-axis handling device that is fully adequate for simple
assembly tasks.

Example
Joining the lid and base of a work piece.

The handling station can perform numerous tasks:

 Moving a work piece

 Assembling the base and lid

 Sorting or assembly functions in cooperation with other MecLab® stations

Integrated in the handling station is a mechanical two-jaw gripper whose gripper jaws have been
adapted to the cylindrical work piece. This gripper can be exchanged for a vacuum gripper that is
available as an accessory.

The handling station is supplied fully assembled. It may, however, be necessary to readjust the
holders for the work pieces so that the gripper can cleanly pick up and deposit the work pieces.
An aluminum profile plate with slots on which the individual components of the module are
mounted using T-head nuts serves as the base for the handling station. All other components are
likewise bolted on and can be disassembled and assembled using the supplied spanner and Allen
key. The supplied screwdriver is primarily used to adjust the one-way flow control valves.

*include instructions for adjusting gripper head*

The pneumatic tubing required can be cut to the correct length using the tubing cutter (do not use
scissors or other knives as this can result in leaks).

For commissioning, the handling subsystem must be connected to the USB port of the PC using
the EasyPort as well as to the power supply using the 24V power supply unit.

Correct wiring of the actuators and sensors must be ensured if the supplied sample programs are
to be used. The correct pin assignment is described in a schematic diagram in the sample
program.
Executing a simple task using the handling station
In a production line, the handling station often represents the interface between two
workstations. It can carry out the conveying of work pieces between two stations. The following
sample exercise explains step by-step the mode of operation of the FluidSIM® software as well
as its interaction with the handling station.

The presented solution process is just one possible version of a solution and is only provided as a
means of explaining the system.

Task
Develop a computer-aided manual control with the following functions:
 Advance the x-axis when a pushbutton is actuated, but only if the cylinder is in the
retracted end position.
 Retract the x-axis when a pushbutton is actuated, but only if the cylinder is in the forward
end position.

Procedure for solving the task

The solution to this task can be broken down into five phases:

1. Initial considerations and schematic diagram

2. Assignment tables for the components

3. Circuit diagram creation and programming using FluidSIM®

4. Testing with FluidSIM® via simulation

5. Testing the program on the actual handling station

Initial considerations

Schematic diagram of the handling setup: To start it is a good idea to produce a schematic
diagram of the mechanical setup to identify the position of the sensors and actuators. A possible
schematic diagram of the components involved in the task could look something like Figure 3.
The schematic diagram can be drawn by hand or created using a computer.

Figure 3: Schematic diagram of handling station

Pneumatic circuit diagram

It is also a good idea to produce a pneumatic circuit diagram as well as an assignment table for
the input and output signals. This circuit diagram can be created using FluidSIM® or drawn by
hand.

Figure 4: Pneumatic circuit diagram (x axis only)

 Slot Assignment Description
0 1S2 Sensor for forward end position
2 1S1 Sensor for retracted end position
1 1M1 Valve solenoid (advance cylinder)
3 1M2 Valve solenoid (retract cylinder)
Table 2: Assignment station for the handling station

Analysis of the task

Before starting programming, you should be clear about the task. To ensure this, it is a good idea
to describe the task in your own words or to create a flow chart.

 The piston of the horizontal, double-acting cylinder is to advance from its normal
position (retracted). The command for this is issued via a pushbutton in FluidSIM®.

 The cylinder may only advance, however, if it is in the retracted end position. This can be
queried using the proximity sensor. This proximity sensor is labeled 1S1 in the schematic
and circuit diagrams.

 The return stroke is also to be executed by means of a pushbutton signal. In this case too,
the cylinder may only retract if it was previously fully advanced.

 The sensor for the forward end position is labeled 1S2 in the schematic diagram.

 Two pushbuttons for operation are needed in the FluidSIM® program.

 The horizontal cylinder is activated using a 4/2-way double solenoid valve. Switching on
the valve solenoid 1M1 advances the cylinder, switching on the valve solenoid 1M2
retracts the cylinder. Since the valve is a double solenoid valve, a short current pulse is
sufficient to keep the valve (and thus also the cylinder) in the respective switching
position.
Circuit diagram creation and programming using FluidSIM®
The supplied FluidSIM® software is used for programming. This enables the circuit to be
simulated first on the computer. If the simulation does not reveal any errors, then the station can
be directly activated and operated.

Since the test setup consists of electrical and pneumatic components, a circuit plan must be
created in the FluidSIM® program for both system components. It is recommended to create the
pneumatic circuit diagram first, followed by the electrical circuit diagram.

Step 1: Opening FluidSIM®

In preparation for creating the circuit diagram, it is first necessary to create a new page to get an
active workspace. To this end, FluidSIM® must be opened by double-clicking on the program
icon:

Create a new workspace

Click on the blank white page on the left in the second menu bar (or on "File > New").
A new empty workspace for a controller appears.

Save the new controller

To do this select "File > Save As ..." in the menu bar and save the file to the desired location on a
data storage medium under a user-defined name.
Step 2: Inserting the components
The components needed to create the pneumatic circuit diagram are located in the toolbar on the
left side of the screen. They are inserted in the circuit diagram by:
 Clicking on the appropriate symbol,
 Keeping the left mouse button pressed,
 Dragging the symbol to the required location in the circuit diagram and then releasing the
mouse button.

The pneumatic system consists of a double-acting cylinder, a 4/2-way double-solenoid valve,

two one-way flow control valves and the compressed air supply. Figure 5 shows the components
in the workspace.

Figure 5: Components of the pneumatic circuit diagram

Step 3: Rotate the one-way flow control valves

The one-way flow control valves should be rotated to produce a clear circuit diagram. To do this,
right-click on the symbol for the one-way flow control valve in the workspace; in the context
menu that opens, select the menu item "Rotate" followed by "270°".

Figure 6: Rotating the one-way flow control valve

Step 4: Install tubing between the components

Next, the tubing between the components must then be installed. This is done by dragging the
mouse over a node point of the symbol until a crosshair is displayed. With the left mouse button
pressed, move to the required node point of the next symbol. Release the left mouse button as
soon as the crosshair symbol confirms the connection.

The pneumatic circuit diagram then looks as follows:

Figure 7: Installing the tubing for components

Step 5: Set labels and insert proximity sensors

Labels need to be set so that the link with the electrical circuit diagram and the actual hardware
can be established later. These labels are needed for all electrical components, i.e. valve
solenoids and proximity sensors.

To label the valve solenoids, right-click on the valve solenoid and select the menu item
"Properties". Enter the valve solenoid designation in the "Label" field, in this case 1M1 and 1M2
(for the first or second valve solenoid respectively of the first valve).

Figure 8: Entering a label for a valve solenoid

To mount the proximity sensors on the cylinder, right-click on the cylinder. A window opens
where you can enter the proximity sensors mounted on the cylinder and their position.

There are two proximity sensors on the cylinder; one in the retracted end position and one in the
forward end position. The position of one of the proximity sensors is therefore 0 mm, the
position of the other 100mm. The proximity sensors are labeled 1S1 and 1S2 (for the first and
second proximity sensors of the first cylinder).

Clicking on "OK" closes the input window again.

Figure 9: Entering proximity sensors

Step 6: Test the pneumatic circuit

The simulation is started by clicking on the Start button. If one of the two manual overrides is
clicked on, the valve reverses and the cylinder retracts or advances.

Figure 10: Simulating the pneumatic circuit diagram

Step 7: Components and wiring of the electrical circuit

The components of the electrical circuit are inserted and connected in the same way as the
pneumatic components.

The workspace should look as follows after the components are inserted and wired:

Figure 11: Inserting and wiring electrical components

Step 8: Assign labels

To connect the electrical and the pneumatic components, the electrical components must also be
labeled.

This is done in the same way as for the pneumatic components, i.e. by right-clicking on the
component and entering the labels in an input window. Labels are needed for the valve solenoids
and the sensors.

Figure 12: Assigning labels for the electrical components

In addition, the two pushbuttons are labeled with S1 and S2.

Step 9: Create the control program

To be able to enter the control program in the digital module, the digital module must be opened
by double clicking on it. A new window containing the digital module's input and output
channels is displayed.

Figure 13: Input and outputs channels of

the digital module

On the left side are the

inputs marked I1 to I6,
on the right side the outputs
marked Q1 to Q6. You now
link the inputs and
outputs using logic
modules. These are in the
toolbar on the left side of
the screen and are dragged
to the workspace like
all other components.

The task demands that the

cylinder retract or advance when the respective pushbutton is actuated and the cylinder has
reached the relevant end position:

 Valve solenoid 1M1 is switched on when pushbutton S1 and proximity sensor 1S1 are
actuated.

 Valve solenoid 1M2 is switched on when pushbutton S2 and proximity sensor 1S2 are
actuated.

This means that two AND gates are needed in the program. Since the AND gate in FluidSIM®
has three inputs, two high gates are used so that the third, redundant one can always be set to
high. Otherwise FluidSIM® would issue an error message that there is one unassigned input.
Figure 14: Digital module with logic gates

Note
Unassigned AND gate inputs are always set to high in FluidSIM®.

The logic gates are now connected and the logic program therefore created (cf. Figure 15).
Closing the input window stores the program in the digital module (or PLC). The simulation can
be started after the window closes.

Figure 15: Complete logic program

Testing the solution via simulation

The simulation is started by clicking on the Start button. If pushbutton S1 is then actuated, the
cylinder advances in the simulation, pushbutton S2 retracts it again.
*Note*
The cylinder cannot be reversed until it has reached the respective end position.

Figure 16: Simulating the circuit

Testing the solution on the actual handling station

To connect the handling station to FluidSIM®, the EasyPort must be plugged into the multi-pin
plug distributor on the station and this must be connected to the PC (using the USB cable) and to
the power supply.

The symbol for the multi-pin plug distributor is then dragged into the workspace in the
FluidSIM® program.

Figure 17: Multi-pin plug distributor symbol for connecting the station

The labels in the symbol for the multi-pin plug distributor must still be adapted. To do this, open
the symbol by double-clicking on it (Figure 18).

Labels are then modified as per Table 2. The labels must match those used in the pneumatic and
electrical circuit diagrams. The multi-pin plug symbol then establishes the connection to the
station. It is of no importance what the labels are called (1M1 is the usual designation in
engineering; the label could also be called "left valve solenoid"). It is important, though, that the
same labels are used for the same component in the pneumatic and electrical circuit diagrams
and that this component is plugged into the correct slot on the multi-pin plug distributor.

*Note*
The "Priority when hardware connected" box must be ticked. This ensures that the signals for the
actual sensors are used and not those simulated in the program.

If the simulation is now started and the pushbutton S1 is actuated, the cylinder in the station is
advanced. The status of the input and output channels is indicated in color on the multi-pin plug
symbol. On the station's multi-pin plug distributor, the status of the input and output channels is
indicated by LEDs. The program can then be extended step-by-step to incorporate the other
actuators and sensors into the station.

Figure 18: Dialog box of the multi-pin plug distributor before the labels are changed

Figure 19: Dialog box of the multi-pin plug distributor after the labels are changed

The schematic diagram, the circuit diagram and the logic program together form the technical
documentation for the project. These can be supplemented with operating instructions and data
sheets if necessary.