Rotary Table Workstation: Feeding, Quality Control and Assembly (dimensional study) (AE-PLC-MR1)
PL-800181
The “AE-PLC-MR1” is an automatic rotary table equipped with an integrated parts feeder, quality control, and assembly system. The system includes vertical storage that supplies parts one by one to the rotary table. Once a part is placed on the table, a quality control system verifies its dimensions and material. If the part meets the requirements, it is assembled with a lid; otherwise, it is automatically discarded by the rotary table. The workstation is designed as a modular system to facilitate understanding and training.
The main components of the unit include: the PLC, composed of a CPU and all necessary expansion modules to ensure proper operation; the Control Panel, with start/stop, emergency, and reset buttons, as well as status indicators; the Pneumatic Circuit, which features solenoid valves, filters, regulators, and all required components to guarantee proper functioning; and the Workstation, built with real industrial components such as reed sensors, presence sensors, a DC motor, inductive sensors, and an 8-position rotary table.
This unit is designed to operate as a standalone workstation or as part of a Flexible Manufacturing System (FMS) when integrated with other EDIBON stations. (See section “6.-MECHATRONICS, AUTOMATION AND COMPUMECHATRONICS” for the complete FMS product list.)
The system is divided into several functional sections. The Air Treatment System includes a filter-regulator block with water trap, shut-off valve, and a dual-scale manometer to visualize supply pressure. The Parts Feeding Section uses a double-acting cylinder with adjustable airflow valves to supply parts from vertical storage one at a time. The Parts Displacement Section features the rotary table driven by a DC motor with encoder and brake, transporting parts through the verification and classification areas.
The Parts Verification Section uses height sensors and inductive sensors to determine whether parts have a central hole and whether they are made of metal or PVC. Based on this analysis, the Parts Sorting Section uses telescopic suction cups to discard non-compliant parts or activates a rotary actuator/gripper to store acceptable parts in the designated area. The system also includes a Signaling Tower (green, yellow, red LEDs) to indicate operational status.
Finally, the Solenoid Valve Block includes twelve valves: two 3/2 monostable, six 5/2 monostable, and four 5/2 bistable valves. The Electrical Terminal Block provides access to all unit signals for manual testing, with color-coded terminals (yellow for inputs, blue for outputs, grey for power and PE) and clear labeling for ease of identification.
- AE-PLC-MR1. Unit:
- Table with four wheels with brakes mounted with aluminum profiles.
- Programming software PLC:
- Programming software PLC:
- Programming software developed according to the norm IEC 61131-3.
- Compatible with Windows operating systems.
- 5 programming languages:
- Ladder diagram (LD).
- Structured text (ST).
- Instructions list (IL).
- Sequential function chart (SFC).
- Function block diagram (FBD).
- Programming, service and remote diagnostics.
- Minimun program size.
- Powerful debugging and monitoring tools.
- Support for user-created functions and function blocks.
- Save project files in plc.
- Quick start tutorial example included.
- Electrical Panel:
- Differential magneto-thermal switch.
- Power supply of 24 VDC.
- Control Panel:
- Mushroom head emergency stop push button switch.
- Start and stop pushbuttons.
- Switch for manual or automatic operation.
- Light indicator.
- Led stack light.
- Fault Injection Key Box Module:
- Red key box module with switches inside.
- DB37 connectors.
- Each fault is generated via toggle switches.
- Electrical Components:
- Round table with 8 positions.
- DC motor.
- 1 dryve D8, step/direction stepper motor control system.
- Pneumatic Circuit:
- Air treatment unit:
- Filter-regulator with water trap.
- Manometer with double scale indicator.
- Shut-off valve.
- 24 flow control valves.
- 8 single acting pneumatic actuators.
- 2 pneumatic solenoid valves 3/2 monostable.
- 6 pneumatic solenoid valves 5/2 monostable.
- 4 double acting pneumatic actuator.
- 4 pneumatic solenoid valves 5/2 bistable.
- Individually identified tubes and push in fittings.
- Vacuum Circuit:
- 2 Telescopic suction cup.
- 2 Venturi effect vacuum ejector.
- 2 pneumatic solenoid valves 3/2 monostable.
- 2 pressure relief valve.
- Sensors:
- 16 reed effect limit switches.
- 2 capacitive sensors.
- Inductive sensor.
- Height sensor.
- Encoder of the rotating table
- Cables and Accessories, for normal operation.
- Manuals: This unit is supplied with manuals: Required services, Assembly and Installation, Control software, Starting-up, Safety, Maintenance and Practices manuals.
EXERCISES AND PRACTICAL POSSIBILITIES TO BE DONE WITH THE MAIN ITEMS
- Introduction to the flexible manufacturing system: Identification of unit components.
- Introduction to pneumatics and electro-pneumatics: Identification of components.
- Configuration of a pneumatic application.
- Operation of pneumatic system: Introduction to vacuum technology and pneumatic actuators.
- Study of sensor detection.
- Manual control of a rotary table.
- Automatic control of a rotary table.
- Industrial application example.
- Industrial application tuning.
- Fault inserted analysis and diagnosis.
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