Modular Production System(MPS)

OPERATION MANUAL

Module：MPS05

A.r.t Pneumatic Systems

MPS05 Operation Manual １
 CONTENT
1. Product Overview ........................................................................................................................................................... ４
2. Technical Specification and Safety: ............................................................................................................................... ６
2.1. Technical Specification： ................................................................................................................................... ６
2.2. Safety： ............................................................................................................................................................... ６
3. Product Composition ...................................................................................................................................................... ７
4. Equipment operation flow .............................................................................................................................................. ９
4.1. Equipment Operation Safety Procedure .............................................................................................................. ９
4.2. Button and tower light ..................................................................................................................................... １０
4.3. MPS05 Full-Stations Cooperate Work Startup Sequence................................................................................ １２
4.4. The introduction of each station and the work process.................................................................................... １４
4.4.1. First station: Loading Station. ............................................................................................................... １４
4.4.2. Second Station: Classification. ............................................................................................................. １６
4.4.3. Third Station: Processing Station. ........................................................................................................ １８
4.4.4. Forth Station: Transportation Station................................................................................................. ２０
4.4.5. Fifth Station: Assembly. ....................................................................................................................... ２２
4.4.6. Sixth Station: Storage Station ............................................................................................................... ２３
4.5. HMI Operation. ............................................................................................................................................... ２５
4.6. Alarm ............................................................................................................................................................... ２８
5. Pneumatic System....................................................................................................................................................... ３１
5.1. Preparation Unit........................................................................................................................................... ３１
5.2. Control Components ........................................................................................................................................ ３１
5.3. Pneumatic Actuators. ....................................................................................................................................... ３２
6. Electronic System. ...................................................................................................................................................... ３３
6.1. Power supply. .................................................................................................................................................. ３３
6.2. Control Box ..................................................................................................................................................... ３３
7. Control System Components Introduce ...................................................................................................................... ３５
7.1. PLC(Programmable Logic Controller,) ........................................................................................................... ３５
7.2. VFD (Variable-frequency Drive)..................................................................................................................... ３５
7.3. Servo Motor Driver.......................................................................................................................................... ３６
7.4. Stepping Motor Driver ..................................................................................................................................... ３６
7.5. HMI (Human Machine Interface) .................................................................................................................... ３７
8. Troubleshoot. .............................................................................................................................................................. ３８
9. Appendix .................................................................................................................................................................... ４１
9.1. Pneumatic Diagram ......................................................................................................................................... ４１
9.2. Electrical Diagram ........................................................................................................................................... ４４
9.3. I/O List ............................................................................................................................................................. ４７
9.4. Assembly Diagram .......................................................................................................................................... ５０
9.5. Pneumatic Equipment Introduce ...................................................................................................................... ５３
MPS05 Operation Manual ２
 9.6. Sensor operation manual.................................................................................................................................. ６４
9.7. Sensors’s type and function ............................................................................................................................. ６９

MPS05 Operation Manual ３

1. Product Overview
Modular Production System (MPS)—Combining the manufacturing technique of industrial
production and the specific design of teaching.
It is able to automatically and practically controlling and also a typical combination of gas and electricity
training device.
The system includes a variety of automatic control techniques, as suitable for students majoring in
engineering. And it also suitable for the training and teaching of the general vocational schools and
universities.
The equipment is designed in modular. Main body adopts industrial aluminum profile design,
equipped with industrial standard terminal and stainless steel button control panel. The actuator and
control use DC24V voltage can guarantee the safety. We designed a HMI (Human Machine Interface)
installed on the last station and it can improve the convenience of Monitoring and control.
The system consists of six workstations：
Station 1(Loading)、Station 2(Classification)、Station 3(Machinating)、
Station 4(Transportation)、Station 5(Assembling)、Station 6(Storage).
There is one individual PLC system for each station. When each basic unit is trained completely, and
connected to the neighboring one until the whole system is connected. Also, it can be used to learn the
control method of complicated system, programming, installing，and technology of adjustment.
We can run learning training independently, after eared of each single station, it can be combine with
another two or three station, until whole system are connected. Learn complex control system included
programming、installing adjustment...etc

MPS Main Feature:

Flexibility:
MPS improves flexibility by modularity and is much closer to the actual production process.

MPS05 Operation Manual ４

Comprehensiveness: (integrity)
MPS has common and advanced technologies in the present factory automation production, including
PLC(Programmable Logic Controller) programming , Electric control technology, Pneumatic technology,
Sensor technology and Robot Technology...etc

Extendibility:
Due to the modular design, user can add his own idea in it, making the modification. The product
has more fun and ability to change.

MPS05 Operation Manual ５

2. Technical Specification and Safety:

2.1. Technical Specification：

1、Voltage：200~240VAC (Single phase) 50/60 Hz；

2、Operating Air pressure：0.4MPa-0.7MPa；
3、Operating temperature ：0℃~55℃；Environmental humidity：50~95%（25℃）
4、Overall Size ：Single station: L×W×H=600mm×900 mm×1600mm
Whole system: L×W×H=3600mm×900mm×1600mm

2.2. Safety：

In this manual we divide security into "Danger" and "Warning".

● In case of Maintenance or detection, please be sure the Power is "OFF" to

prevent the accident.
● Do Not use Wet Hand to touch it, When the power is on.
Do not operate by wet hand
● Do Not use broken conductor or broken unit in experiment.
● PLEASE be sure to have well-trained staff (professional teacher and well-trained
students) to operate the equipment.
● Please make sure the Voltage and Pressure are set to the operating range.

● Before opening machine, please Check The Power to avoid short or missing phase to broke the
equipment.
● Please make sure the power is “OFF”, when the work is finished.

MPS05 Operation Manual ６

Sixth Station (Storage):

3. Product Composition
The system consist of six working stations:

First Station (Loading):

This station consist of Loading mechanism, pushing mechanism, detecting mechanism, and transport
mechanism. electronic control system consist of PLC, control box, power, (photoelectronic for the color
detect, Material sensor to detect material) , solenoid valve ,magnetic sensor and alarm light...etc. In this
station, the major mission is to move the item from storage and detection if it is the correct side, then
passing it to the next station.

Second Station (Classification):

This station can consist of manipulator mechanism, waste material mechanism, PLC, control box,
power, pneumatic cylinder. The major mission is to remove the waste and transport the correct items to the
next station.

Third Station (Machining) ：

This station can consist of Machining mechanism, Indexing Plate, locate mechanism, sensor, power
PLC, control box, pneumatic cylinder. The major mission is to move the items to forth station after
indexing plate and simulating the electric screwdriver to screw up.

Fourth Station ( Transportation ):

This station consists of rotating mechanism, conveyor, power, PLC, pneumatic cylinder, control box,
solenoid valve. The major mission is to take the item from previous station, rotate it to the correct angle,
then transport to next station.

MPS05 Operation Manual ７

Fifth Station ( Assembling)：
This station consists of assembling mechanism, pushing mechanism, charging mechanism,
transpiration mechanism, PLC, Power system, control box, pneumatic cylinder. The major mission is to
select the item which is correct one, take it from storage, assemble it and transport to the next station.
This station consists of storage mechanism, warehouse mechanism, power system, PLC, HMI,
control box, solenoid valve, pneumatic cylinder. Major mission is to classify the item and storage it
into warehouse.

MPS05 Operation Manual ８

4. Equipment operation flow

4.1. Equipment Operation Safety Procedure

Please check the power before turning on the equipment to avoid short or damage and make sure
there is no obstacle on the equipment. Before you turn on the power, please connect air supply and set up
the pressures (Following Fig), please make sure the pressures are setted on (Station 1 0.3MPa, else
Stations set on 0.5Mpa).

Fig.4.1.1 Filter

MPS05 Operation Manual ９

4.2. Button and tower light

Button Status
Start button: click - clear alarm

start the station

step move(when stepping mode is on)

Reset button: click - clear alarm

Hold three seconds - initialize

Special button: click - switch stepping mode or continuous mode

Man/Auto switch: point to man - manual mode

point to auto - automatic mode

S/C switch: point to S - single mode

point to C - cooperation mode

Stop button: click - stop working after a circle

Power on: click - power on

EMS: emergency

Button Light
Start light: blink - can be started

on - can be started

Reset light: blink - alarm

not complete initialization

Special light: on - stepping mode

off - continuous mode

Stop light: on - stopped

Power on light: on - power is on

MPS05 Operation Manual １０

 Tower Light
First Station:

Green light: equal to the start light

Yellow light: equal to the reset light

Red light: lack of items(cube)

Fifth Station:

Green light: equal to start light

Red light: Lack of items(cylinder)

Sixth Station:

Green light: equal to start light

Red light: one kind of items(cube) is full

MPS05 Operation Manual １１

4.3. MPS05 Full-Stations Cooperate Work Startup Sequence

Six stations cooperation

1.The connection of the device: Use the inner hexagon spanner with 5mm to fasten the link blocks
owned by the device and be careful if the T nuts are in the right places.

2.The connection of the air tube: Separately connect the air tubes behind each work station and
ensure the reliable connection.

3.The connection of the communication cables: There are the communication cable of Ethernet line
(Profinet) beside the PLC in each station and please respectively check the connecting condition
between each joint and ensure the reliable connection.

4.The turn-on of the electricity: Check the connecting condition of the power supply socket in the
opposite side of the backward station of the device. There are total 7 devices requiring the power supply,
six work stations. Turn on the power supply for the air compressor after making sure that all the power
supply sockets have been connected. Notice: Turn on the power supply for the six work stations after the
completion of building up the air source of the air compressor.

5.The placement of the workpiece: Please take out the big and small workpiece from the
three-dimensional warehouse of the sixth station and respectively put them into the storage bin of the
first station and the fifth station. Notice: Do not stand the workpiece when putting the big one into the
storage bin of the first station, otherwise it will stick the storage bin. But the workpiece can be placed
back. Besides, check if there is place for each workpiece in the first station to the fifth station, if so,
please take out all the workpiece and put them into the belonged storage bin.

6.The operations for each station: Firstly pull out the emergency stop knob and make sure that the
white locations of the knobs of “manual/automatic” and “single station/cooperating ” respectively
point to “automatic” and “cooperating”. Then keep pressing the reset button about three seconds,

MPS05 Operation Manual １２

and the tower light of the reset will be off after the completion of the reset of system reset. Press the start
button at this time and the tower light of the start button will be on, which means that the work station
has already finished the starting. Start each work station as above and the device will start to work. It
means that there is no workpiece in the storage bin for the small workpiece when the yellow alarm lamp
is on and it needs to supply the small workpiece. Also it means that there is no workpiece in the storage
bin and it needs to supply the big workpiece. Check the storage bins on the touch screen to see which
one is full, and take away the workpiece at this time and press the clear/reset button.

MPS05 Operation Manual １３

4.4. The introduction of each station and the work process

4.4.1. First station: Loading Station.

The test cylinder 3#MK.

The Shifting Cylinder

1#STWS
The pusher cylinder 2#MI

The Pusher Cylinder 4#TN.

The work process in the first station:

Start 2# Push Out. 3# Push Out 3# Retract 2# Retract

4# Push Out

Trans signal to next station Type detect by sensor. 1# Movement 4# Retract

Press the start button at the state of reset; The feeding cylinder stretches out to send the material
of the storage bin to the slideway; The test cylinder stretches out to check if the material is in the heads
or tails, then the test cylinder retracts and the feeding cylinder retracts again, also the pusher cylinder
stretches out to push the material to the bottom of the slideway and then retracts; The slide cylinder
transposes to replace different storage bins to send the material; When the material at the bottom of the

MPS05 Operation Manual １４

slideway has been detected for the nature, deliver these information to the next station and inform the
next station to pick up the material.

The process of the actions is divided into three work models, namely the manual operation, the
automatic single station, and the automatic networking. The model of the manual operation is generally
used for the debugging or the testing, and the state of the corresponding cylinder can be debugged or
tested when the manual pin for the electromagnetism is touched. Under the model of the automatic
single station, the module operates from the first step to the final step and steps into the state of stop
after pressing the start button once.. Under the model of the automatic networking, the module
operates from the first step to the final step after pressing the start button, then send the information of
the material quality and color,etc. to the next station and inform the next station to pick up the
workpiece.Until the next station takes away the workpiece and returns the picking information, the
module operates again from the first step or waits for pressing the stop button,

MPS05 Operation Manual １５

4.4.2. Second Station: Classification.

The twin-rod cylinder

4#TN

The magnetic coupling

rodless cylinder 1#RMS
The pneumatic finger 2#HFZ

The pusher cylinder 3#MK

The work process in the Second station:

Yes
Correct
Start 4# Push Out. 2# Clamp 4# Retract.
Side?
No
1# move to middle.

3# Retract. 3# Push Out. 4# Push Out. 1# move to right.

4# Retract. 2# Release. 4# Push Out.

Send signal to
1# Move to lift. 4# Retract. 2# Release.
next station.

Press the start button and the biaxial cylinder stretches out; The air claw clamps the grabbed
material; The biaxial cylinder retracts; The rodless cylinder opposite to the material stretches to the
middle and place the material in the reject bin; The rodless cylinder in the forward direction to the

MPS05 Operation Manual １６

material stretches to the right and place in the work location of the next station, also send the material
information to the next station; Finally the rodless cylinder returns to the left initial place.
The process of the actions is divided into three work models, namely the manual operation, the
automatic single station, and the automatic networking. When pressing the start button, the module
operates from the first step after receiving the starting information sent from the last station; After
grabbing the material from the last station, send the information to the last station allowing it to continue
to send the material; When it operates to place the material to the work location of the next station,
it cannot place the material until receiving the information of allowing to place the material from the
next station; Send the information of the material quality, color and so on to the next station and inform
the next station to start; Finally the rodless cylinder returns to the left initial place and operates from the
first step again or waits to press the stop button.

MPS05 Operation Manual １７

4.4.3. Third Station: Processing Station.

The electric screwdriver

#ES Turntable
The three axle cylinder 1#TCL

The stepper motor #M

The clamping cylinder 2#PB

The work process in the Third station:

#ES On.
Start Detect Workpiece Turntable turn 90 degree 2# Push Out
1# Push Out.

Send signal to Turntable turn 90

2# Retract. #ES Off. 1# Retract.
next station. degree

Press the start button at the initial state, and the clamping cylinder retracts. The pneumatic dial
rotates 90 degrees, and the clamping cylinder stretches out again. The jacking cylinder stretches out to
firm the workpiece and the three axle cylinder drives the electric screwdriver to imitate the processing,
also the cylinder rises to reset after the completion. The jacking cylinder and the clamping cylinder both
retract and the dial rotates to the next work location. At the same time, send the information to the next
station to come to pick up the material, and repeat the above actions after the next work location moving
away the workpiece..
The process of the actions is divided into three work models, namely the manual operation, the
automatic single station, and the automatic networking. Under the models of both the manual operation
and the automatic single station, the operation mode is similar as the one in the second station. Under

MPS05 Operation Manual １８

the model of the automatic networking, when pressing the start button, the module operates from the
first step to the final step after receiving the starting information sent from the last station; Send the
information of the workpiece color as well as the material to the next station and inform to come to pick
up the material. At the same time, inform the last station to allow the material placing and then return to
the first step to operate again, or wait to press the stop button.

MPS05 Operation Manual １９

4.4.4. Forth Station: Transportation Station.

The Twin-rod cylinder 2#TN

The multi-position mounting
cylinder 4#MK

The rotary cylinder 1# HRQ

The pneumatic finger 3#HFY The conveyor belt

The stepping motor #SM

The work process in the fourth station：

Start 2# Push Out Detect Workpiece 4# Push out 3# Clamp

4# Retract.
#SM On.
2# Retract.

1# To Left 4# Retract. 3# Release. 4# Push Out 1# To Right

Press the start button at the initial state, and the rotary cylinder moves to the left to the
workpiece position of the last station; The biaxial cylinder stretches out and then the multi-position
fixed cylinder stretches out. The pneumatic finger clamps the grabbed material, the multi-position
fixed cylinder retracts and the biaxial cylinder retracts again; The rotary cylinder moves to the right,
the multi-position fixed cylinder stretches out and then release the material by hand; After the
retracting of the multi-position fixed cylinder, electrically drive the conveyor belt to send the
workpiece to the next station; Stop the motor after the workpiece receiving of the next station.
The process of the actions is divided into three work models, namely the manual operation, the
automatic single station, and the automatic networking. Under the models of both the manual operation

MPS05 Operation Manual ２０

and the automatic single station, the operation mode is similar as the one in the third station. Under the
model of the automatic networking, when pressing the start button, the module operates from the first
step after receiving the starting information sent from the last station, and until taking away the
material from the last station, send the information to the last station to allow the continuous material
sending; Then operate to the final step as procedures, and the module returns to the first step to operate
again after the receiving of the workpiece and the returning of the confirmed information, or waits to
press the stop button.

MPS05 Operation Manual ２１

 4.4.5. Fifth Station: Assembly.
The vacuum chuck 2#

The jacking cylinder 2 7#PB2

The jacking cylinder 1 6#PB1 The swing cylinder 1#HRQ

The pusher cylinder 3#MD

The air cushion 5# AR

The three -rod cylinder 4#TCL

The work process in the fifth station：

Start 5# On 7# Push Out 4# Push Out 6# Push Out 1# HRQ turn

4# Retract Next station ok signal Send signal to next station 3# Push Out

1# Back

6~7# Retract 1# Back 2# Off 1# HRQ Turn 3# Retract 2# On

Press the start button, and ventilate the air cushion to slide the workpiece to the assembling
platform. The jacking cylinder 1 stretches out to vertically clamp the workpiece, and the three axle
cylinder stretches out to lift the workpiece. The jacking cylinder 2 stretches out to horizontally clamp
the workpiece and the swing cylinder swings out. The pusher cylinder pushes out the small workpiece
in the storage bin and the swing cylinder swings back the swinging arm. Assemble the small workpiece
to the workpiece after the stop of the chuck; Send the information to the next station when the swing
cylinder swings back the swinging arm. Before the manipulator from the next station comes to clamp,
release the jacking cylinder both 1 and 2. When the next station takes away the workpiece and the
three axle cylinder falls, the work cycle stops.

MPS05 Operation Manual ２２

 4.4.6. Sixth Station: Storage Station
The pneumatic finger 3#HFZ
The stretching cylinder 2#TN

The swing cylinder1#HRQ

HMI

The lifting cylinder 4#TCL

The electric cylinder #EC

The work process in the sixth station:

Start 1# turn left 2# Push Out 4# Retract 3# Clamp 4# Push out

2# Retract
Aluminum #EC Move to storage 1 Yes
Storage Full? Alarm
White
1# Turn right Type #EC Move to storage 2 No Yes

Black #EC Move to storage 3 Upper Full? 4# Retract

No
2# Push out

#EC to initial position 4# Push out 2# Retract 3# Release

Press the start button and the swing cylinder swings to the left. The stretching cylinder stretches
out and the lifting cylinder falls and then wait for the reset of the jacking cylinder from the last
station.The pneumatic finger clamps the workpiece and the lifting cylinder rises.The stretching
cylinder retracts and the swing cylinder swings to the right. Move the electric cylinder to the
corresponding position according to the material quality and color of the workpiece. If the upper layer
of the storage bin is full, the lifting cylinder falls, if not, the lifting cylinder does not fall. The
stretching cylinder stretches out and the pneumatic finger releases, then the stretching cylinder retracts
and the manipulator and the electric cylinder separately return to the initial state.

MPS05 Operation Manual ２３

 There are three work models in this station, namely the manual operation, the automatic single
station, and the automatic networking. Under the models of both the manual operation and the
automatic single station, the operation mode is similar as the last four stations. Under the model of the
automatic networking, when pressing the start button, the module operates from the first step and send
the confirmed information to the last station after receiving the starting information sent from the last
station. Then send to the corresponding storage bin according to the material quality and color. Finally
return to the initial state and wait for the coming of the next job, or wait to press the stop button,
There is a Human-Machine-Interface(HMI )the touch screen in this station. It has inlaid the
company introduction, the real time monitoring for each station of MPS05, the independent control to
each station, the monitoring of the cylinders from each station, and the workpiece number of each
storage bin in the sixth station and the clear button as well as the function of the full quotation and so
on into the touch screen.

MPS05 Operation Manual ２４

4.5. HMI Operation.

In this section, we will introduce about HMI operation, HMI support more convinces operation way and show

the alarm status to help user debugging the bug.

Frist, when we open the MPS05. We’ll see the screen just like the following figure.

By pressing the button ”Enter System”, we can see the following screen (Home Page).

There are eight buttons in this screen, each one point to a different screen. Besides, each of the function buttons

MPS05 Operation Manual ２５

(physical buttons F1 ~ F8) which are under these virtual buttons equals to the button upon it. All the other screens are

as following.

Figure S1~S6

There are three buttons in every single station screen.

”Start” - equal to the start button of the station

”Reset” - equal to the reset button of the station

”Stop” - equal to the stop button of the station

MPS05 Operation Manual ２６

 Figure monitor

There are five buttons in Monitor screen.

”Start All” - the same function as pressing all the start button of the six stations

”Reset All” - the same function as pressing all the reset button of the six stations

”Aluminum Clear” - clear the count of the aluminum items

”White Clear” - clear the count of the white items

”Black Clear” - clear the count of the black items

We can see the alarms in this screen.

MPS05 Operation Manual ２７

4.6. Alarm

In this section, we will introduce the alarms of the system and tell how to deal with the alarms. Alarms shows as

the table. Almost all the alarms will be showed in the HMI before cleared.

Alarm text Station Alarm description How to Solve

No.

S1_1#STWS_ALARM S1 1#STWS alarm Check the cylinder and the sensors of it

S1_2#MI_ALARM S1 2#MI alarm Check the cylinder and the sensors of it

S1_3#MK_ALARM S1 3#MK alarm Check the cylinder and the sensors of it

S1_4#TN_ALARM S1 4#TN alarm Check the cylinder and the sensors of it

S1_Lack_Of_Items S1 Lack of Items(cube) Put in the items

The location detect sensor

S1_Sense_No_Items S1 Check whether the item is fallen off
can not sense the item

The location detect sensor

S1_Sensor_ALARM S1 sense the item before Take off the item

starting the station

Emergency is pressed
S1_Emergency S1 Pull out the emergency
down

S2_1#RMS_ALARM S2 1#RMS alarm Check the cylinder and the sensors of it

S2_2#HFZ_ALARM S2 2#HFZ alarm Check the cylinder and the sensors of it

S2_3#TR_ALARM S2 3#TR alarm Check the cylinder and the sensors of it

S2_4#ACQ_ALARM S2 4#ACQ alarm Check the cylinder and the sensors of it

Emergency is pressed
S2_Emergency S2 Pull out the emergency
down

S3_1#TCL_ALARM S3 1#TCL alarm Check the cylinder and the sensors of it

S3_2#PB_ALARM S3 2#PB alarm Check the cylinder and the sensors of it

The product detect sensor

S3_Sensor_ALARM S3 IN/OUT sense the item Take off the item

before starting the station

MPS05 Operation Manual ２８

 Emergency is pressed
S3_Emergency S3 Pull out the emergency
down

S4_1#HRQ_ALARM S4 1#HRQ alarm Check the cylinder and the sensors of it

S4_2#TN_ALARM S4 2#TN alarm Check the cylinder and the sensors of it

S4_3#HFY_ALARM S4 3#HFY alarm Check the cylinder and the sensors of it

S4_4#MK_ALARM S4 4#MK alarm Check the cylinder and the sensors of it

The product detect sensor

S4_No_Items_ALARM2 S4 IN can not sense the item Check whether the item is fallen off

after moving

The product detect sensor

S4_Sensor_ALARM S4 IN/OUT sense the item Take off the item

before starting the station

Emergency is pressed
S4_Emergency S4 Pull out the emergency
down

S5_1#HRQ_ALARM S5 1#HRQ alarm Check the cylinder and the sensors of it

S5_3#MK_ALARM S5 3#MK alarm Check the cylinder and the sensors of it

S5_4#TCL_ALARM S5 4#TCL alarm Check the cylinder and the sensors of it

S5_6#PB1_ALARM S5 6#PB1 alarm Check the cylinder and the sensors of it

S5_7#PB2_ALARM S5 7#PB2 alarm Check the cylinder and the sensors of it

The cube item do not get

S5_Item1_Not_To_Bottom S5 Check whether the item is fallen off
to the bottom

S5_No_Items0_ALARM S5 Lack of Items(cylinder) Put in the items

The product detect 1 can Check whether the item is fallen off or
S5_No_Items1_ALARM S5
not sense the item(cube) to other place

The item has not be

S5_Not_Be_Picked_ALARM S5 Check whether the item is fallen off
picked by the sixth station

The pressure sensor do

S5_Pressure_Sense_Failure S5
not give the signal to PLC

MPS05 Operation Manual ２９

 The Product detect 1/2/3

S5_Sensor_ALARM S5 sense the item before Take off the item

starting the station

Emergency is pressed
S5_Emergency S5 Pull out the emergency
down

S6_1#HRQ_ALARM S6 1#HRQ alarm Check the cylinder and the sensors of it

S6_2#TN_ALARM S6 2#TN alarm Check the cylinder and the sensors of it

S6_3#HFZ_ALARM S6 3#HFZ alarm Check the cylinder and the sensors of it

S6_4#TCL_ALARM S6 4#TCL alarm Check the cylinder and the sensors of it

Press the "Aluminum Clear"button in

S6_Aluminum_Full S6 Aluminum Full
screen monitor

Press the "Black Clear"button in screen

S6_Black_Full S6 Black Full
monitor

Press the "White Clear"button in screen

S6_White_Full S6 White Full
monitor

Press reset button to clear the servo

S6_Servo_Motor_ALARM S6 Servo Motor alarm alarm and then initialize the sixth

station

Emergency is pressed
S6_Emergency S6 Pull out the emergency
down

MPS05 Operation Manual ３０

5. Pneumatic System.

5.1. Preparation Unit

Each station have one filter-regulator, can adjust the pressure independently.

Hand-Slide Valve

Filter-Regulator

Single station filter and regulate unit.

5.2. Control Components

In order to wiring and tube connecting more convenient and more easily, the solenoid are set in
guide-rail at every stations. We have used single air control 5/2 way solenoid valve、double air
control 5/2 way solenoid valve、5/3 way solenoid valve...etc. Example in a 5/3 way valve remold to
3/2 solenoid valve.

Solenoid valve modular

MPS05 Operation Manual ３１

5.3. Pneumatic Actuators.

We used many type of cylinder in this equipment to learn different cylinder and control method.
include pen-size cylinder、compact cylinder、Mini cylinder、Multi-mount cylinder、Adjustable stroke
cylinder、Twin-rod cylinder、Tri-rod cylinder、Rotary table cylinder、Rodless cylinder、Air-gripper
cylinder、Vacuum Generator...etc.

MPS05 Operation Manual ３２

6. Electronic System.

6.1. Power supply.

The power supply system are set under the each station and it can supply 24DC Voltage to
equipment with breaker controlling the power on/off.

6.2. Control Box

The Control Box

Input（I） Output（Q）
Part
Name Label Address Name Label Address

Start Button START I0.0 Start Light(Green) L1 Q0.0

Reset Button RESET I0.1 Reset Light(Yellow) L2 Q0.1

Special Button SP I0.2 Special Light(Blue) L3 Q0.2

C
o
m
m
o
n Manual/Auto Switch M/A I0.3
p
a
Signal/Cooperate Switch S/N I0.4
r
t

Stop Button STOP I0.5 Stop Light（Red） L6 Q0.5

Power Button POWER I0.6

Control Box Function list.

MPS05 Operation Manual ３３

 Label Function Color

1 Start Start working and clear alarm Green light button.

2 Reset Reset, Initialize the equipment and clear alarm. Yellow light button.

3 SP Select Stepping mode or Continuous mode. Blue light button

4 M/A Select Manual mode or Automatic mode. Black switch

5 S/C Select Single mode or Cooperation mode Black switch

6 Stop Finished working cycle and Stop the work. Red light button

7 Power On Power On Green light button

8 EMS Urgent Stop. Red button

Button and switch list.

MPS05 Operation Manual ３４

7. Control System Components Introduce

7.1. PLC(Programmable Logic Controller,)

Fig. 7.1 SIMATIC S7-1215

(source:https://www.automation.siemens.com/salesmaterial-as/catalog/en/simatic-st70-chap03-english-2015.pdf)

Model Name: SIMATIC S7-1215

Link:
https://www.automation.siemens.com/salesmaterial-as/catalog/en/simatic-st70-chap0
3-english-2015.pdf

7.2. VFD (Variable-frequency Drive)

MPS05 Operation Manual ３５

 Fig. 7.2 Sinamics v20

(source:https://cache.industry.siemens.com/dl/files/948/103599948/att_67109/v1/SINAMICS_V20_Getting_Started_072012_en-US.pdf)

Model Name: Sinamics v20

Link:
https://cache.industry.siemens.com/dl/files/948/103599948/att_67109/v1/SINAMICS_
V20_Getting_Started_072012_en-US.pdf

7.3. Servo Motor Driver

Fig.7.3 Panasonic A5-2

(Source:http://device.panasonic.cn/ac/c/motor/fa-motor/ac-servo/thumbnail/A5.png)

Model Name: Panasonic A5-2

Link:
https://industrial.panasonic.com/content/data/MT/PDF/manual/en/acs/minas-a5-2_
manu_e.pdf

7.4. Stepping Motor Driver

MPS05 Operation Manual ３６

 Fig.7.4 DC2405m
(Source:http://cn.misumi-ec.com/vona2/detail/221005091842/?CAD=01&HissuCode=DC2405M&Tab=catalog)

Model Name: DC2405m

Link:
https://jp.c.misumi-ec.com/book/VONA1_08_J/digitalcatalog.html?page_num=38

7.5. HMI (Human Machine Interface)

Fig.7.5 KTP900

Source:http://www2.ad.siemens.com.cn/download/Html/download.aspx?DownloadId=2019&TreeId=10&Url=%2Fdownload%2FUpload%2FAS%2Fcatalog%2F40

30%5B1%5D.pdf

Model Name: SIMATIC KTP900

Link:
http://www2.ad.siemens.com.cn/download/Html/download.aspx?DownloadId=2019
&TreeId=10&Url=%2Fdownload%2FUpload%2FAS%2Fcatalog%2F4030%5B1%
5D.pdf

MPS05 Operation Manual ３７

8. Troubleshoot.
Type Condition Check Method

·Reconnect.
·Wire connective.
·Change another one.
Power tower light didn't ·tower Light.
·Turn on the switch or
light up. ·Main switch.
check connective.

·Change another one and

The light indicator is on, ·Fuse. must check power and wire

but didn’t working. ·Wire connective. connective.

·Check and reconnect.

Power Supply and ·Change another one and

tower Light. The light are not working ·Tower Light must check power and wire

or dim. ·Wire Connective. connective.

·Reconnect.

·Check equipment status. ·Press “Power on” button.

Power supply without Check Leakage protector · check power and wire

output. and breaker. connective..

·check power supply ·change another power.

·check power supply ·check power wire.

Sensor No output signal ·check wire connective. ·check wire connective.

·check it by multimeter. ·change sensor.

MPS05 Operation Manual ３８

 ·check power and power

on button

·check power supply and

·check power supply. open air source.

·check air circuit. ·adjust the throttle to the

·check pressure right pressure.

·check Solenoid valve. ·check Solenoid valve’s

Cylinder didn’t work
·check throttle valve wire and power line.

·check leakage. ·adjust throttle valve.

Pneumatic
·check cylinder. · Whether the air leakage

part is tightened

·change cylinder/

·check power supply and

·check power system
power on
Solenoid valve didn’t ·check relay.
·change solenoid valve.
work. ·check wire connection.
·check wire connection.
·check output.
·check PLC output.

·check program · check Programmer's

PLC error LED are
· make sure the power Reference to debug.
blinking
supply is right status. ·check Hardware manual

· check communication ·select correct com port

PLC protocol and parameter.

·check download line. ·software’s version is too

Can’t download.
·check PLC compiler old.

·check the other program ·fix the program

have used the com port. ·quit the program.

MPS05 Operation Manual ３９

 ·check code. ·fix the PLC program.

PLC output point didn’t ·check overload. ·check wire connection.

work. ·check the output point. ·change PLC.

·check power supply and

·check power
power on.
·check cable connection.
Communication. HMI can’t connect. · make sure cable are
· check comport and
connected.
parameter.
·fix the parameter.

·check the sensor are be

setting on right place

and no obstacle on the ·remove the obstacle.

way . ·adjust the position of the

Station abnormal
Others · check the cylinder is sensor.
stopping.
fully-push out or fully · make workpiece more

retract. close the sensor.

· check detect sensor is

detected the workpiece.

·check previous station is

done.
Station is not working · press the next station
· check next station is
when the automatic is on. reset button.
already reset.

MPS05 Operation Manual ４０

9. Appendix

9.1. Pneumatic Diagram

Station 1 Pneumatic Diagram.

Station 2 Pneumatic Diagram.

MPS05 Operation Manual ４１

 Station 3 Pneumatic Diagram.

Station 4 Pneumatic Diagram.

MPS05 Operation Manual ４２

 Station 5 Pneumatic Diagram.

Station 6 Pneumatic Diagram.

MPS05 Operation Manual ４３

9.2. Electrical Diagram

Station 1 Electrical Diagram.

Station 2 Electrical Diagram.

MPS05 Operation Manual ４４

 Station 3 Electrical Diagram.

Station 4 Electrical Diagram.

MPS05 Operation Manual ４５

 Station 5 Electrical Diagram.

Station 6 Electrical Diagram.

MPS05 Operation Manual ４６

9.3. I/O List

Input（I） Output（Q）
Part
Name Label Address Name Label Address

Start Button START I0.0 Start Light（Green） L1 Q0.0

Reset Button RESET I0.1 Reset Light（Yellow） L2 Q0.1

Special Button SPECIAL I0.2 Special Light（Blue） L3 Q0.2

C
o
m
m
o
n Manual/Automatic Switch MAN/AUTO I0.3 Stop Light（Red） L6 Q0.5
p
a
Single/Cooperate Switch S/C I0.4
r
t

Stop Button STOP I0.5

Emergency Switch EMS I0.6

1#STWS Left Side 1B1 I1.0 1#STWS To The Left Side 1Y1 Q1.0

1#STWS Right Side 1B2 I1.1 1#STWS To The Right Side 1Y2 Q1.1

2#MI Back 2B1 I1.2 2#MI Out 2Y1 Q8.0

2#MI Out 2B2 I1.3 3#MK Out 3Y1 Q8.1

F
3#MK Back 3B1 I1.4 4#TN Out 4Y1 Q8.2
i
r
s
t
s
t 3#MK Out 3B2 I1.5 Green Light LG Q8.3
a
t
4#TN Back 4B1 I8.0 Yellow Light LY Q8.4
i
o
n
:
L
o 4#TN Out 4B2 I8.1 Red Light LR Q8.5
a
d
Color Detect Sensor BA I8.2
i
n
g
Material Detect Sensor BB I8.3

Location Detect Sensor BC I8.4

Position Sensor V+ IW64

VIA
Position Sensor COM
C
1#RMS Left Side 1B1 I1.0 1#RMS To the Left Side 1Y1 Q8.0
l
a
s s
t
s a
i
1#RMS Middle Position 1B2 I1.1 1#RMS To the Right Side 1Y2 Q8.1
f t
i
i
c o
a n
:
1#RMS Right Side 1B3 I1.2 2#HFZ Release 2Y1 Q8.2
t
i
o

MPS05 Operation Manual ４７

 2#HFZ Release 2B1 I1.3 2#HFZ Clamp 2Y2 Q8.3

2#HFZ Clamp 2B2 I1.4 3#TR Out 3Y1 Q8.4

3#TR Back 3B1 I8.0 4#ACQ Out 4Y1 Q8.5

3#TR Out 3B2 I8.1

4#ACQ Back 4B1 I8.2

4#ACQ Out 4B2 I8.3

T Turntable Position Sensor BC I0.7 Stepping Motor Pulse PULS Q0.6

h
1#TCL Back 1B1 Stepping Motor Direction DIR
i
r
d I1.0 Q0.7
S
1#TCL Out 1B2 I1.1 Stepping Motor Enable EN Q8.0
t
a
t
i
2#PB Back 2B1 1#TCL Out 1Y1
o
n
: I1.2 Q8.1
P
2#PB Out 2B2 I1.3 2#PB Out 2Y1 Q8.2
r
o
c
e
s
s
i Product Detect Sensor IN BA I8.0 Electric Screwdriver ES Q8.3
n
g
Product Detect Sensor OUT BB I8.1

1#HRQ Left Side 1B1 I1.0 1#HRQ To the Left Side 1Y1 Q0.6

F 1#HRQ Right Side 1B2 I1.1 1#HRQ To the Right Side 1Y2 Q0.7
o
r
t
h 2#TN Back 2B1 I1.2 2#TN Back 2Y1 Q1.0
S
2#TN Out 2B2 2#TN Out 2Y2
t
a
t I1.3 Q1.1
i
o
n
: 3#HFY Release 3B1 I1.4 3#HFY Release 3Y1 Q8.0
T
3#HFY Clamp 3B2 3#HFY Clamp 3Y2
r
a
n I1.5 Q8.1
s
p
4#MK Back 4B1 I8.0 4#MK Out 4Y1 Q8.2
o
r
t
a
4#MK Out 4B2 VFD On S
t
i
o I8.1 Q8.3
n
.
Product Detect Sensor IN P1 I8.2 Frequency 1 S1 Q8.4

Product Detect Sensor OUT P2 I8.3 Frequency 2 S2 Q8.5

F
i 1#HRQ Front 1B1 I1.0 Green Light LG Q0.3
f
t
h 1#HRQ Back 1B2 I1.1 Red Light LR Q0.4
S
t
2#Pressure Sensor 2B1 1#HRQ To The Front Side 1Y1
a
t
i I1.2 Q0.6
o
n
:
3#MD Back 3B1 I1.3 1#HRQ To The Back Side 1Y2 Q0.7
A
s
3#MD Out 3B2 2#Vacuum Generator On 2Y1
s
e
m I1.4 Q1.0
b
l
4#TCL Back 4B1 I8.0 3#MD Out 3Y1 Q8.0
y

MPS05 Operation Manual ４８

 4#TCL Out 4B2 I8.1 4#TCL Out 4Y1 Q8.1

6#PB1 Back 6B1 I8.2 5#Air Rail On 5Y1 Q8.2

7#PB2 Back 7B1 I8.3 6#PB1 Out 6Y1 Q8.3

Product Detect 1 PD1 I8.4 7#PB2 Out 7Y1 Q8.4

Product Detect 2 PD2 I8.5

Product Detect 3 PD3 I8.6

Servo Zero Point BS0 I1.0 Green Light LG Q0.3

Servo Left Limit Sensor BS1 I1.1 Red Light LR Q0.4

Servo Right Limit Sensor BS2 I1.2 Servo Motor Pulse. PULS Q0.6

Servo Driver Alarm BS3 I1.3 Servo Motor Direction. DIR Q0.7
S
1#HRQ Left Side 1B1 I1.4 Servo Motor Enable EN Q1.0
i
x
t
h
S
t 1#HRQ Right Side 1B2 I1.5 Servo Driver Alarm Clear AC Q1.1
a
t
2#TN Back 2B1 I8.0 1#HRQ To The Right Side 1Y1 Q8.0
i
o
n
:
S
t 2#TN Out 2B2 I8.1 1#HRQ To The Left Side 1Y2 Q8.1
o
r
3#HFZ Release 3B1 I8.2 2#TN Out 2Y1 Q8.2
a
g
e
3#HFZ Clamp 3B2 I8.3 3#HFZ Clamp 3Y1 Q8.3

4#TCL Back 4B1 I8.4 3#HFZ Release 3Y2 Q8.4

4#TCL Out 4B2 I8.5 4#TCL Out 4Y1 Q8.5

4#TCL Back 4Y2 Q8.6

MPS05 Operation Manual ４９

9.4. Assembly Diagram

Station 1 Assembly Diagram.

Station 2 Assembly Diagram.

MPS05 Operation Manual ５０

 Station 3 Assembly Diagram.

Station 4 Assembly Diagram.

MPS05 Operation Manual ５１

 Station 5 Assembly Diagram.

Station 6 Assembly Diagram.

MPS05 Operation Manual ５２

9.5. Pneumatic Equipment Introduce

9.5.1. ACQ Series (Compact Cylinder)

Fig. 9.5.1.1 ACQ series Introduce.

Table 9.5.1.1 ACQ Series Feature.

MPS05 Operation Manual ５３

9.5.2. HFY Series（Air Gripper - Angular Style）

Fig. 9.5.2.1 HFY Series Introduce.

Table. 9.5.2.1 HFY Series Specifical.

MPS05 Operation Manual ５４

9.5.3. HFZ Series（Air Gripper - Parallel Style - Ball Bearing）

Fig 9.5.3.1 HFZ Introduce and Specificate.

MPS05 Operation Manual ５５

9.5.4. HRQ Series (Rotary Table Cylinder )

Fig. 9.5.4.1 HRQ Series Introduce.

Table. 9.5.4.1 HRQ Feature.

Table. 9.5.4..2 HRQ Specificate.

MPS05 Operation Manual ５６
9.5.5. MA Series (Stainless Steel)

Fig. 9.5.5.1 MA Series.

Table 9.5.5.1 MA Series Feature.

Table 9.5.5.2 MA Series Specific.

MPS05 Operation Manual ５７
9.5.6. MD/MK Series (Multi-Mount Cylinder)

Fig 9.5.6.1 MD/MK Series.

Table 9.5.6.1 MD/MK Series Feature.

Table 9.5.6.2 MD/MK Series Specificate.

MPS05 Operation Manual ５８

9.5.7. PB Series(Pen Size Cylinder)

Fig. 9.5.7.1 PB Series.

Table 9.5.7.1 PB Series Feature.

Table 9.5.7.2 PB Series Specification.

MPS05 Operation Manual ５９

9.5.8. RMS Series (Rodless Magnetic Cylinder)

Fig. 9.5.8.1 RMS Series Introduce.

Table 9.5.8.1 RMS Series Feature.

Table. 9.5.8.2 RMS Series Specificate.

MPS05 Operation Manual ６０

9.5.9. STW Series (Slide Table Cylinder)

Fig 9.5.9.1 STM Series Introduce.

Table 9.5.9.1 STM Series Feature.

Table 9.5.9.2 STM Series Specification.

MPS05 Operation Manual ６１

9.5.10. TCL Series(Tri-Rod Cylinder)

Fig.9.5.10.1 TCL Series Introduce.

Table 9.5.10.1 TCL Series Introduce.

MPS05 Operation Manual ６２

9.5.11. TN/TR Series(Twin-Rod Cylinder)

Fig 9.5.11.1 TN/TR Series Introduce.

Table 9.5.11.1 TN/TR Series Feature.

Table 9.5.11.2 TN/TR Series Specification.

MPS05 Operation Manual ６３
9.6. Sensor operation manual

Fig 9.6.1 CS1-J Specification

Fig. 9.6.2 CS1-J

MPS05 Operation Manual ６４

 Fig.9.6.3 CS1-J Mounting

Fig.9.6.4 CS1-M Specification.

MPS05 Operation Manual ６５
 Fig 9.6.5 CS1-M

Fig.9.6.6 CS1-M Mounting

MPS05 Operation Manual ６６

 Fig.9.6.7 CS1- G Specification.

Fig.9.6.8 CS1-G

MPS05 Operation Manual ６７

 Fig. 9.6.9 CS1-G Mounting

MPS05 Operation Manual ６８

9.7. Sensors’s type and function

Station Sensor-type Function

PR18 Detect Color
PR18, LR12, CR12, CS1-J, CS1-G,
1 LR12 Detect material
CS1-M
CR12 detect workpiece’s position
LR12 Detect Rod-less cylinder’s
2 LR12, CS1-G
position.
PR18 Detect workpiece’s position
3 PR18, LR12, CS1-G, CS1-M
LR12 Detect the turntable’s position
4 FU-77F, CS1-J, CS1-G FU-77F Detect workpiece’s position
PR12, CR12, PR18, CS1-J, CS1-G, PR12, CR12, PR18 Detect
5
CS1-M workpiece’s position
6 SX674, CS1-J、CS1-G SX674 Detect servo motor’s position
Sensor’s function on each station.
Notice: other sensors are cylinders’sensors, which detect cylinders’position.

MPS05 Operation Manual ６９

MPS05 Operation Manual ７０