MANUAL MODULAR PRODUCT SYSTEM

1 Modular Production System

1.1 Overview

The system integrates a variety of industrial equipments for the basic

process of the production automation, including distribute, transport, test,
process and sort. The application varies depending on the operating
scenarios.

The purpose of the system is to apply various mechanisms and control

options to the development, implementation and improvement of
processes and the automation system, and to educate and train the
system engineers with the skills and expertise in designing,
manufacturing, operating, maintaining and managing the automation
system.

The system consists of pneumatic controls, electric controls, PLC

controls, sensor controls and robot controls to provide the workplace
practice and the acquisition of knowledge in the mechatronics and
automation.

Emerging from a basic concept of engineering, the system allows a

variety of skills necessary for entire processes from design to
maintenance and teamwork.

Fig. 1. MPS Training Equipment

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1.2 Introduction

MPS (Modular Production System) is a basic step to learn the advanced

technologies for the FMS, and a training equipment to develop the
mechatronics experts.

Fig. 2. Global Educational Solution in Mechatronics

What does MPS stand for?

MPS = Modular Production System

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MANUAL MODULAR PRODUCT SYSTEM

MPS has been selected as an official equipment in mechatronics at the

International Youth Skill Olympics.

MPS consists of module components, so as to be used for the practice

of assembly/disassembly. MPS is expandable equipment that allows the
trainees realistically simulating the industrial field increasingly
complicated.

MPS allows the reconfiguration of process and system in steps from a

simple and basic operation to the complicated operation to suit the ability
of trainees.

A variety of workplace practices in the production system, including

design, assembly, programming, operation, maintenance and repair, are
available in MPS.

In addition to the expertise of mechatronics, MPS provides the system to

develop a project based integrated personal abilities, including teamwork,
cooperation, education, unique design and comprehensive analysis.
Work Plan

Assembling Machines and Systems

Programming

Control and Operation

Maintenance

Defect Tracking

It is most important for trainees to make an effort to practice the skills

and acquire the knowledge.

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1.3 Processes

MPS includes processes with different operating conditions and

scenarios.
Distribution Station
Sequentially distributes the workpieces stored in a magazine.

Testing Station
Determines the material, color and height of workpieces.

Processing Station
Uses index table to process the workpieces, and test the processing
condition.

Handling Station
Pneumatic actuators arranged on orthogonal axis delivers the
workpieces to the next process.

Buffer Station
Controls the flow of workpieces for a flexible operation between the
stations based on the waiting time and operating time.

Robot station
Robot assembles and sorts workpieces.

Sorting Station
Sorts and stores the workpieces into slider or magazine based on the
information of workpieces.

Handling Station by Robotics

Uses a vertical multi-joint robot or a horizontal multi-joint robot to sort
the workpieces, or perform a specific operation.

Assembly Station by Robot

Uses a robot to assemble and sort the workpieces and parts.

A variety of configurations and combinations of processes are available

to meet the user’s needs. It is possible to customize the practice
equipment from module and a single process to the integrated
processes.

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 Processes of MPS Equipment

Fig. 3. Various Processes

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1.4 Components of Equipment

Equipment consists of mechanical parts and electrical parts.

The course varies depending on the components of the equipment.

A station includes a mechanical part and an electrical part.

Mechanical Part
Mechanical understanding on the assembly and the operating
principle of module
Designing the circuit with the pneumatic operating component
(actuators) and the directional control component (valves)
Structure, installation and operation of sensors

Electrical Part
Preparation and modification of PLC program with additional
conditions
Electrical understanding on the wiring and the relay control system

Fig. 4. Structure of Station

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1.4.1 Structure of Mechanical Part

All modules and components are simply bolted on an aluminum profile in

2.5 mm pitch.

There are additional components, including actuators, valves, sensors

and terminals in mechanical part.

Fig. 5. Structure of Mechanical Part

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MANUAL MODULAR PRODUCT SYSTEM

Service Unit
Distribution Unit

Aluminum Profile Rotary Transport Module

Panel

Solenoid Valve
Signal Transfer
Terminal Block

Switch Console Relay

Fig. 6. Example of Mechanical Part (Distribution Station)

Most stations that can be used to acquire a variety of the following skills
are assembled in the similar formation as shown above.
Mechanical Skills
Understanding and utilization of mechanical parts
Implementation of automation system using a profile
Assembly and disassembly of mechanical parts
Planning and designing the mechanical interfaces in the system

Pneumatic Skills
Understanding and utilization of pneumatic parts, including cylinders,
valves, and others
Analysis and preparation of pneumatic circuit
Understanding and utilization of vacuum control skills
Optimization and correction of pneumatic circuit (speed, shock and
safety)
Piping and maintenance of pneumatic circuit, and a defect tracing of
the system

Electric/Electronic Skills
Wiring and testing of electrical parts
Analysis and preparation of electric circuit
Understanding on electric circuit and the utilization of each component

Understanding on electric machines

Planning and understanding the electric interfaces
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MANUAL MODULAR PRODUCT SYSTEM

Sensor Skills
Understanding and utilization of limit switches and sensors
Understanding on various types of sensor
Position control with sensors and limit switches

PLC Skills
Understanding on the structure and the operating principle of PLC
Basic programming of PLC (Ladder, Mnemonic, and Function Block)
Application and special functions of PLC

1.4.2 Structure of Electrical Part

Electrical part consists of components for power supply and signal

transfer, centering on the PLC controlling the system.

Fig. 7. Structure of Electrical Part

PLC (Programmable Logic Controller)

PLC is a main controller that can integrate various component options
to control the system.

DC Power Supply
Converts AC 220V into DC 24V to supply the power to the system.

Breaker
Supply or cut the power to PLC and other equipment to protect the
electrical parts from the electrical surge.

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MANUAL MODULAR PRODUCT SYSTEM
Noise Filter
Isolates the noise to stabilize the power supply.

Signal Cable
Transfers the control signal and the power supply.

Signal Terminal
Connects the control signal from controller to component.

Common Terminal
Distributes the power supply.

Control Panel
Collects the control components.
Coated with paint to prevent a short circuit of the power supply.

Cable Duct
Installed along the wiring to protect and sort the cables.

Use the control panel with care. There is a risk of electric shock from the
control panel that uses the alternating voltage AC 220-110V.

PLC on the control panel can be customized with user’s needs.

For further information, please refer to the circuit diagram attached.

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1.5 Operating Console

Uses buttons and switches to input the operating requirements, and

uses lamps to display the system conditions during the operation of the
system.

User can optionally integrate the switches to reflect various additional

conditions during the preparation and modification of the PLC program.

Fig. 8. Operating Console Module

Start Button
Starts or restarts the operation.
With a built-in green lamp that indicates the normal operation
Self-return pushbutton switch

Stop Button
Stops or pauses the operation.
With a built-in red lamp that indicates the operation stop
Self-return pushbutton switch

Auto / Manual Switch

Auto or manual is selectable.
A blue switch with a built-in lamp
Self-holding 2-stage rotary selector switch

Function Button
Adds the additional conditions to each process.
With a built-in white lamp

Self-Return Pushbutton Switch

Network switch
Allows the internetworking with other process.
A blue switch with a built-in lamp

Reset Button
Initiates the system.
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With a built-in yellow lamp that indicates the operation stop

Self-return pushbutton switch

Alarm Lamp
Indicates the abnormal condition or error.
Red lamp

Emergency Stop Switch

Immediately stops the operation at an emergency.
Turn the knob to release the self-holding pushbutton switch.
With a built-in red lamp

For the detailed assignment and wiring of each switch, please refer to the
circuit diagram attached.

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1.6 Workpieces

The workpieces different in material, color and height (dimension) are

used to create various virtual scenarios for the system.

Materials include aluminum and MC nylon in two colors. Uses an

induction type sensor detecting metals, and a photoelectric sensor
detecting colors to determine the material and color of workpieces.

Fig. 9. Workpieces

There is a drill hole in a workpiece to meet a virtual condition of drilling

process.

A workpiece is used up side down to set the condition without drilling.

Fig. 10. Dimension of Workpiece

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There are three different heights of workpieces: Low, Mid and High.

The workpiece 25 mm high is determined as a normal, and the

workpiece over/under 25 mm high is rejected as a defective item.

Fig. 11. Three Heights of Workpieces

Various information of workpiece allows a variety of user-defined

scenarios with various control conditions.

Utilizing the Characteristic Information of Workpieces

Dimension
Color
Material
Processing Condition

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