Table of Contents. Lucas Nülle GmbH 1/11

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1 Table of Contents Table of Contents Technika automatyzacji Smart Factories Smart factory CSF 1 Industry 4.0 with IMS CSF 2 WiFi control extension set CSF 3 Intelligent production extension set CSF 4 ERP LabDas ERP Lab ist ein didaktisch aufbereitetes ERP System (ERP - Enterprise Ressource P Lucas Nülle GmbH 1/11

2 Technika automatyzacji Acquire practical and project-oriented laboratory skills and expertise: Automation trainers, mechatronics trainers, PLC trainers Smart Factories Lucas Nülle GmbH 2/11

3 Smart Factories The "Industry 4.0" initiative describes the implementation of so-called smart factories, which includes intelligent interaction between human beings and machinery. It involves the integration of intelligent workpieces, manufacturing equipment and flexible value-adding procedures into the production process. This seeks to achieve distributed production with a maximum of flexibility at a minimum of cost. In a smart factory, systems keep people informed about production and status and provide assistance with the control and monitoring of the process. A smart factory is characterised by the communication between products and the machinery which makes them. The product retains information about its own manufacture in machine-readable form, on an RFID chip for example. With the help of this data, the passage of the product through the manufacturing system and the individual steps in its manufacture can be controlled. The available sets are aimed at various levels: Smart factory foundation set: This encompasses all the topics needed to understand and implement a smart factory. Bus systems play a key role in the communication aspect. Aspects such as cyber-physical systems (CPS) or flexibility of plant only become possible when bus systems are employed. RFID can be seen as being at the core of production in a smart factory. An RFID chip is used to process the requisite data so that the items being worked upon have their own memory. They know when the process begins how they are supposed to look at the end of it and they themselves take control of the processing stations to ensure that they are processed in the right way. The knowledge learned so far is put to use in a small, initial smart factory application. A compact station is used to cover the topic. Smart factory basic set: The basic set encompasses a complete production line on which production of a workpiece is controlled with the help of RFID tags. A three-part workpiece can be assembled in eight different combinations. Smart factory extension sets: Should a manufacturing plant be controlled and monitored solely from its own control centre or can that also be handled remotely by means of a smart phone, tablet or laptop? Should production be treated in a more intelligent way? A production list with memory for up to eight products. A variable productions sequence which depends on the raw materials available. Statistical monitoring and fault analysis These capabilities are provided by extension packages with various levels of expansion. Smart factory Smart factory Lucas Nülle GmbH 3/11

4 CSF 1 Industry 4.0 with IMS CSF 1 Industry 4.0 with IMS The Industry 4.0 system can be used for fully automated manufacture of three-part workpieces for up to eight different end products. A touch panel allows you to select a graphic of the desired workpiece assembly. This is saved on an RFID tag attached to the workpiece carrier when production is authorised. The workpiece carrier instructs the processing stations how the workpieces are to be combined and assembled. It is possible to program eight different workpieces in this way. After production is complete, the end product is removed from the mouth of the machine and can then be prepared for dispatch. Since the stations are fully networked via PROFIBUS and PROFINET, it is possible to monitor the functionality on a permanent basis and to carry out diagnosis. Transport system: Dual-belt conveyors with DC drive motors and variable speed three-phase drive motor. Identification system: An RFID identification system transmits the desired assembly procedure for the workpieces to the processing stations Control level: Configuration of manufacturing jobs from a governing PC, process visualisation and acquisition of operating data Transmission of process control data via TCP/IP Networking via PROFIBUS and PROFINET IMS 3 Sorting station IMS 4 Assembly station IMS 5 Processing station IMS 7 Handling station Wyposazenie, w którego sklad wchodza: Wyposażenie, w którego skład wchodzą: 1 Segment przenosnika transportowego 24 V z podwójnym pasem LM Dodatkowy segment przenośnika taśmowego łuk 180 stopni LM Stacja rozdzielająca LM Lucas Nülle GmbH 4/11

5 4 Stacja montażowa LM Stacja obróbcza LM Stacja manipulacyjna LM RFID Evaluation Unit CO3715-7T 1 8 RFID read/write head with bracket and connecting lead CO3715-7U 2 Programmable logic control (PLC) for IMS Production Lines 9 SIMATIC S PN/DP 32 DE, 32 DA, 8 AE, 4 AA, 24V / 6 A power supply CO3713-8R 1 10 Touch panel TP700 Comfort Trainer Package CO3713-4P 1 Materialy szkoleniowe: Materiały szkoleniowe: 11 Interactive Lab Assistant: CSF 1 Smart Factory SO2800-5V 1 12 Interactive Lab Assistant: IMS 1 Conveyor belt (DC) SO2800-5A 1 13 Interactive Lab Assistant: IMS 3 Sorting station SO2800-5C 1 14 Interactive Lab Assistant: IMS 4 Assembly station SO2800-5D 1 Lucas Nülle GmbH 5/11

6 15 Interactive Lab Assistant: IMS 5 Processing station SO2800-5E 1 16 Interactive Lab Assistant: IMS 7 Handling station SO2800-5G 1 17 Interactive Lab Assistant: RFID in logistics SO2805-4A 1 18 QuickChart IMS 1.2 Systemu transferowy z napędem prądu stałego SO6200-1A 1 19 Podręcznik IMS 3 Mechatroniczny podsystem separacja SO6200-1C 1 20 QuickChart IMS 4 Mechatroniczny podsystem montaż SO6200-1D 1 21 QuickChart IMS 5 Mechatroniczny podsystem obróbka SO6200-1E 1 22 QuickChart IMS 7 Mechatroniczny podsystem obsługa SO6200-1G 1 Akcesoria: 23 Płyta uchwytu przedmiotu obrabianego LM Część górna przedmiotu obrabianego, kolor biały LM Część górna przedmiotu obrabianego, kolor czarny LM Część dolna przedmiotu obrabianego, kolor biały LM Część dolna przedmiotu obrabianego, kolor czarny LM Sworzeń przedmiotu obrabianego, tworzywo sztuczne LM Lucas Nülle GmbH 6/11

7 29 Sworzeń przedmiotu obrabianego, metal LM Kabel połączeniowy do PROFIBUS, na metry LM Kabel połączeniowy do PROFIBUS z gniazdem PG i terminatorem LM Narzędzie do usuwania izolacji z kabli PROFIBUS LM Przewód interfejsu 25-biegunowy, gniazdo/wtyczka Sub-D LM Sprężarka, cichobieżna SE2902-9L 1 35 Węże i zestaw akcesoriów do systemów mechatronicznych LM Bezpieczny przewód pomiarowy, 4 mm, 100 cm, niebieski SO5126-9A 8 37 Bezpieczny przewód pomiarowy, 4 mm, 100 cm, czerwony SO5126-8U 8 38 Bezpieczna złączka z wtykiem 4 mm czerwona, 1000 V / 32 A CAT II SO5126-3U 2 39 Bezpieczna złączka z wtykiem 4 mm niebieska, 1000 V / 32 A CAT II SO5126-3V 2 40 Configuration Industry 4.0 LA IMS Virtual IMS Virtual 41 IMS Wirtualny pakiet szkoleniowy SO6001-7A 1 Lucas Nülle GmbH 7/11

8 42 Oprogramowanie szkoleniowe 1x STEP 7 TrainerPackage, 12 x STEP 7, S7-GRAPH, S7-SCL, PLC-Sim (niemiecki, angielski, francuski, hiszpański, włoski) SO6002-1R 1 43 Manual IMS Virtual SH5004-7V 1 IMS/IPA Tester and Fault Simulator 44 IMS/IPA test and fault simulator CO3713-7V 1 45 Kabel interfejsu szeregowego 9/9-biegunowy, dł. 1,8 m LM Przewód interfejsu 25-biegunowy, gniazdo/wtyczka Sub-D LM QuickChart IMS test and fault simulator SO6200-1Z 1 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. 48 Mobilne stanowisko doświadczalne IMS, SybaPro, 1200 mm, dwupoziomowe Rama doświadczalna ST7200-3T 1 49 Mobilne stanowisko doświadczalne IMS, SybaPro, 1200 mm ST7200-3U 2 Lucas Nülle GmbH 8/11

9 CSF 2 WiFi control extension set CSF 2 WiFi control extension set Control and monitor your IMS system or even individual stations using any WiFi-equipped device, whether it be tablet computer smart phone or notebook. Only a browser is required to call up the PLC system s web interface. No installation of additional software or apps is required. Clear depiction of the entire system or of individual stations Control and monitoring via any WiFi-equipped device with a browser installed Operation and observation via display Signal status displayed directly on the WiFi-equipped device The WiFi device can be used to set signals and therefore control the systems actuators Testing of individual station functions in maintenance mode Supplementary equipment set to the equipment set CSF 1: 50 Interactive Lab Assistant: CSF 2 WiFi control for IMS SO2800-5U 1 51 Router with DSL modem and WLAN access point CO3538-1R 1 52 Patch cable Cat5E 1m, grey LM Lucas Nülle GmbH 9/11

10 CSF 3 Intelligent production extension set CSF 3 Intelligent production extension set Extend your basic smart factory system CSF 1 with additional RFID components. This means that the current state of production is always available. An extension set includes two additional read/write heads. These allow the required steps in the production to be requested from any type of module and enable the current status to be written to specific modules. The extension set offers you the following benefits: Expanded selection of products: 12 different products can be selected Modification of visualisation system: Display of stations which are actively operating Fault display and analysis allowing the system to be shut down and repaired as necessary Creation of an order list: Up to eight products can be entered into an order list and will then be manufactured in sequence. It is possible to accept further orders during the course of production. Intelligent processing of orders: The order list is processed by the system itself. If the next product on the list cannot be made because a requisite part is not available at the processing station, then other products to make are sought from the list. The next product in sequence which can be made is moved to the top of the list and manufactured. This reduces the time that the system is inactive and ensures that less time is needed to realise a return on investment. Statistical monitoring: Variations in products: How often each product is made Number of faults: How often each station fails Number of operating cycles for stations: The number of operating cycles carried out by a station can be used to determine when maintenance needs to take place. The counter can be reset afterwards. It is also possible to count operating cycles over the entire lifespan of a station. When stations are older it is then possible to reduce their maintenance intervals. Supplementary equipment set to the equipment set CSF 1: 53 Interactive Lab Assistant CSF 3: Smart factory extension set SO2800-5X 1 Lucas Nülle GmbH 10/11

11 54 RFID read/write head with bracket and connecting lead CO3715-7U 2 CSF 4 ERP LabDas ERP Lab ist ein didaktisch aufbereitetes ERP System (ERP - Enterprise Ressource P Supplementary equipment set to the equipment set CSF 1: 55 SO2800-5Z 1 56 Płyta uchwytu przedmiotu obrabianego LM Lucas Nülle GmbH 11/11