Control lab equipment

Sl. no. Name of the Equipment Manufacturer

1 Digital Servo Training System Lab-Volt, Canada

2 Industrial Process Control Training System Festo, Germany

3 Mobile Robot platform for research and training Festo, Germany

(Robotino 4)

4 Industrial Collaborative Robot Universal Robots,

Denmark

5 Industrial PLC Training System Festo-Siemens, Germany

6 Industrial Control Components for projects and Festo, Cognex & Various
research

1. Digital Servo Training System

Description:

The Digital Servo Training System is designed to familiarize students with the fundamentals of
digital servo motion control. The system features a single-axis, belt-driven positioning system, a
digital servo controller, and software tools. Users can create their own control strategies by
modifying the existing ones or by developing new ones through the open-source firmware and
software controls.
The 32-bit microcontroller is coupled to a power amplifier, specially designed for DC brush and
DC brushless motor control. Motor control can be achieved in several ways: by using the
included hardware controller, LABVIEW or MATLAB/SIMULINK, or an optional analog controller.
The control algorithm can be performed either by the microcontroller to ensure fast response
and smooth closed loop control, or by a computer.

Major Components:

● Servo Controller
● Linear Axis
● LVSERVO Software

Contents of the experiments:

● Equipment and Software Familiarization

● Open Loop Servo Motor Static Characteristics
● Open Loop Servo Motor Transient Characteristics
● Servo Closed Loop Speed Control
● Motor Shaft Angular Position Control
● Linear Position Sensing
● Linear Position Control
● Following Error in a Linear Position Control System

2. Industrial ​Process​ Control Training System

Description:

The industrial process control training system is a compact workstation comprising level, flow
rate, pressure and temperature controlled system. The four control systems can be operated
individually. The level and flow rate control systems can be structured as a cascade control
system through the addition of an appropriate controller.

The layout of the sensors and servo drives permits experimentation with both continuous (e.g.
P, I, PI, PID) and discontinuous action controller types (e.g. 2-point controllers). The pump can
either be controlled directly or operated in controlled-speed mode.

The manipulated variable of the controller in the flow rate and pressure control systems can
alternatively act upon a proportional directional control valve. A ball valve with pneumatic drive
is built into the return between the high-level container and the lower reservoir. The pneumatic
drive can be used to simulate a “load” for switching on a disturbance in the level control system
or as an on-off valve for emergency
switch-off.
Major Components
● Mechanical components: 2 reservoirs, pressure reservoir, plug-in tube system, filter
regulating valve, mounting frame, profile plate.
● Sensors: 2 capacitive sensors, 2 float switches, ultrasound sensor, flow sensor,
pressure sensor, temperature sensor PT100.
● Actuators: pump, proportional directional control valve, 2-way ball valve with pneumatic
quarter turn actuator and end-position sensing, double-acting, heating.
● Control Kit: EduTrainer® Universal S7-1512C-1PN with Siemens Touch Panel (HMI)
● Electrical components: I/O connection board with measuring transducer, motor
controller, I/O terminal, SysLink, 8I/8O, analog terminal, SysLink, 15-pin.
● Accessories: Water-air cooler, Cooling unit with heat exchanger, Trolly.
● Media: Technical documentation with workbook.

Contents of the experiments:

● Closed-loop control technology: Basics of closed-loop control technology. Analyse and

optimise a closed-loop system. Closed-loop controller. Configuration, assigning
operation parameters and optimization of a closed-loop controller.
● Sensor technology: Sensors, designs and function, correct use of sensors. Measurement
of non-electrical process and control variables.
 ● Process engineering: Reading and drawing of function charts and documentation.
Pneumatics in process automation.
● Commissioning of a closed-loop process control system. Correct wiring of electrical
components. Connections of process control components.
● Systematic fault finding, examination and maintenance of process engineering system.

3. Mobile Robot Platform for Research and Education

Description:

Robotino is a mobile robot platform for learning autonomous control systems. With its
omnidirectional drive, sensors, interfaces and application specific extensions, Robotino is
equipped for universal use. There is full access to the entire source code for the implementation
of robot applications with common programming languages and systems. Robotino may be
configured and programmed in many ways to behave as industrial robots executing a great
variety of tasks, thus challenging the students to go further in their study of autonomous control
systems. The Robotino Wiki provides a knowledge base for further applications.

Major Components
 ● Omnidirectional actuator: The three drive modules of the Robotino are integrated in a
stable stainless-steel frame. Three sturdy industrial DC motors with optical rotary
encoders permit speeds of up to 10 km/h with high reliability. Using an omnidirectional
actuator, Robotino moves quickly forwards, backwards and sideways and also turns on
the spot.
● The frame contains nine infrared distance sensors and numerous prepared mounting
options. An analogue inductive sensor and two optical sensors are additionally included,
enabling the Robotino to recognize and follow predefined paths.
● Power is supplied via up to four 18 V lithium-ion rechargeable batteries, each of which
permits a running time of two and a half hours.
● Robotino uses a powerful 4-core processor with hyperthreading. The operating system
and all user data are stored on a replaceable solid-state disk (SSD) with 64 GB. A 32-bit
microcontroller that directly generates the PWM signals for actuating up to four electric
DC motors is responsible for the motor control.
● Robotino is delivered with an extended image processing system, which uses a
stereo/RGBd camera unit to independently perceive the environment, and can navigate
freely in it.

Contents of the experiments:

The robotic learning system covers the following fields:

● Mechatronics
● Programming
● Sensors
● Motor and drive technology
● Control engineering

Example Lab Exercises

● Incoming inspection and commissioning of the Robotino
● Linear travel for a mobile robot system in any direction
● Linear travel and positioning of a mobile robot system
● Path tracking of an automated guided vehicle system with two diffuse light sensors
● Accurately positioned approach to a loading station
● Approaching an obstacle and maintaining a defined distance
● Circling a station and approaching various transfer positions
● Path tracking for an automated guided vehicle system using analogue inductive sensor
● Ascertaining optimised travel performance
● Path tracking of an automated guided vehicle system with the help of a webcam
● Searching and approaching a coloured object with the help of a webcam
 4. Industrial Collaborative Robot
Description:

The Universal Robots' collaborative robots (COBOTS) are 6-joint robot arm with very low
weight. This 6 DOF robot should give the opportunity to learn about robotics first hand. Within
interactive learning environments, students get introduced to automation and industrial
applications, mastering robot programming and its versatile applications. This COBOTS can
work right alongside personnel with no safety guarding.

Major Components

● Articulated Robotic Arm

- Degrees of freedom: 6 rotating joints
- Working radius: Max. 850mm
- Payload: 5 Kg
- Protection: IP54
- Weight: 18.4 Kg
● Controller Box
- Controls the Robots
- I/O ports: 16 DI, 16 DO, 2 AI, 2 AO
- Communication: TCP/IP 100Mbit, Modbus TCP, Profinet, Ethernet / IP
- Protection: IP44
● Teach Pendant: Intuitive 12” touchscreen teach pendant with on-line programming
features
 ● End Effector: Pneumatic Suction Gripper with vacuum generator

Contents of the experiments:

● 6 axis robot programming

● Concept of different end effectors
● Industrial Communication among PLC, Controller I/Os and Industrial Robots
● Concept of Tool center point, center of gravity of load and payload adjustment
● Simulation with URSIM
● Remote control of UR robots with safety feature

Example Lab Exercises

● Pick & Place operation
● Packaging and Palletising of products
● Universal Robot with Vision system for performing various inspection and assembly.
● Design and build custom applications like screw driving, welding, painting system for
industrial purpose

5. Industrial PLC Training System

Description:

The Advanced PLC Training System is a customized training kit equipped with Festo
EduTrainer and Siemens Industrial PLC. Students learn how to establish communication,
program, and transfer projects to a PLC and a touchscreen (HMI). The System is compatible
with numerous applications. Students can learn realistic exercises and processes through Easy
veep- a graphical 2D process simulator with the help of Easyport USB.
Major Components
● EduTrainer® Universal with SIMATIC S7-1200
- Integrated 110/230 V/24 V, 4A power supply unit
- 16 Digital Inputs module
- 16 Digital Outputs module
- 4 Analog Inputs/2 Analog Outputs module with display
- 4 Relay output module
- 24V/ 0V module
● Siemens S7-1200 PLC
- CPU S7-1214C
- 75 kByte main memory
- 4 MByte program memory
- Interface: RJ45
- Inputs/outputs:
- 14 digital inputs (24 V DC)
- 10 digital outputs (24 V DC, 500 mA)
- 2 analog inputs, 10 bit (0 – 10 V)
● Siemens Simatic touch panel HMI KTP700
- Display: 7” up on a A4 board
- Connection: 1 x PROFINET and 1 x USB
- Number of function keys: 8
● EasyPort USB – An interface that connects the simulation to the real world Digital
universal connection unit
 ● Easy veep- a graphical 2D process simulator

Contents of the experiments:

● Familiarization PLC hardware

● Familiarization Siemens TIA Portal software
● Usage of standard PLC instructions
● Programming in different IEC 61131 languages with focus on ladder logic
● Designing human-machine interfaces (HMI)
● Troubleshooting
● PLC Training with Festo Easyport USB and Easyveep 2D process simulation program

Example Lab Exercises

1. Hot water Tank: With the aid of inlet and outlet valves, the user can fill and empty a tank
cyclically and maintain the water temperature between two limit values. Sensors can
also be moved with a mouse.
2. Three Cylinders: The user can perform numerous tasks and define various sequences
for one to three cylinders. The user can also use timers and counters in the exercises.
The user can use the free actuators to simulate pushbuttons and switch elements in
order to simulate the functionality of a control console
3. Lift: This module contains sensors and actuators to control a lift. Manual buttons are
available for controlling the lift.
4. Washing Machine: This is a model of a washing machine. All important statuses (motor,
direction of rotation, inlet and outlet valve, heating, door lock, water quantity and
temperature) are shown on the front panel. The door can be closed and opened with the
mouse.
5. 7-segment display: This is the model of a 7-segment display. The user can write a
program for displaying numbers into the 7-segment display.
6. Bottling Juice: Light or dark bottles are supplied to the juice bottling plant. The selection
is determined either by a random generator or by clicking with the mouse on one of the
buttons at the bottom. The conveyor belt speed can be varied by clicking with the
mouse.
7. Ball Sorting System: The user can fill a ball magazine by clicking on a green button with
the mouse. A random generator is used to select aluminum balls and black and yellow
plastic balls. By controlling two catching cylinders, the user can sort the balls into three
different buffer channels. Using the three 3 sensors (capacitive, inductive and optical),
the user can distinguish between the various types of ball.
8. Level crossing with barrier Trains may approach a level crossing with barrier from both
directions. When a train is approaching, the barrier must be closed in good time and the
traffic signal must be switched to red in good time with the track signaling unit. When the
 train has left the crossing and no further train is approaching, the barrier can be
reopened and the traffic light can be switched over.
9. Wind generator: The task is to control the switches so that the loads (lamps) are always
supplied optimally so that overcharging and undercharging of the accumulator are
avoided.
10. Tape recorder: This module is for controlling the playback of a tape recorder.
11. Treasure hunt: The task is to find and mark the concealed treasure troves using two
moveable search beams (horizontal and vertical). When the search beam strikes an item
of treasure, this is indicated by means of a signaling sensor.
12. Greenhouse: The task is to always maintain the ambient conditions (relative humidity,
temperature and soil moisture) in the greenhouse in the permitted limit value range for
the plants. The required parameters, statuses and limit values are shown on the screen.
All limit values are monitored by sensors. The limit values can be varied with the mouse.
13. Lock chamber: Ships arrive at the lock from both directions. The aim is to control the lock
chamber so that the ships can pass the section of river with no accidents. The ships
automatically enter the lock chamber when the entry signal shows green. They sail out
when the exit gate is fully open.
14. Multi-storey car park: Vehicles automatically enter the multi-storey car park when the
barrier is opened and the entry signal is green. Vehicles can exit when the
corresponding barrier is open and the exit signal is green. The user can link entry control
with a counter so that a maximum number of vehicles in the multi-storey car park is not
exceeded.
15. Lamp model: The lamp can be switched on and off via a light switch. The light switch can
also be actuated by clicking with the mouse on the graphic.
16. Cylinder model: A cylinder can be retracted and extended by means of a button. The
end position is monitored by sensors. The position of these sensors can be varied using
two rotary switches. In addition, the transparency of the cylinder display can be varied
using a switch element. These switch elements can be operated with the mouse. The
Start button for the cylinder movement can also be operated with the mouse.

6. Industrial Control Components for projects

These components have been selected by considering the compatibility and future research
scope with the above described training systems.

● Sensors for object detection:

- Magnetic proximity sensors
- Inductive proximity sensors
- Optical proximity sensors
- Capacitive proximity sensors
- Inductive sensors (analogue)
 -

● Industrial sensors:

- Photoelectric sensor
- Inductive proximity sensor
- Ultrasonic sensor
- RFID sensor
- Laser distance sensor
- Code reader sensor
- Pressure sensor
- Flow proximity sensor
- Temperature sensor
● LOGO PLC: LOGO is a low-cost PLC for small, stand-alone production machines and
various simple automation tasks.

● Arduino Uno R3 and Raspberry Pi 4 (Development Board)

● Nema Stepper Motor with L298N H-Bridge Dual Motor Driver, Stepper Motor Driver

● Continuous Rotation Servo Motor with Motor Shield L293D

● Cognex Vision System: