18
Book of exercises TP 1110 Festo Didactic 566924 EN Sensors for object detection 24 V 0V 10 -30 30 20 -20 10 40 30 20 mm 40 50 mm -40 -50

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Book of exercises

TP 1110

Festo Didactic

566924 EN

Sensors for object detection

24 V

0 V

10

-30

30

20

-20

10 403020 mm

40

50mm

-40

-50

Sens

ors

for o

bjec

t det

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Boo

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10

Festo worldwide

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Use for intended purpose

The training system for sensors for object detection may only be used:

• For its intended purpose in teaching and training applications

• When its safety functions are in perfect condition

The components included in the training package are designed in accordance with the latest technology as

well as recognised safety rules. However, life and limb of the user and third parties may be endangered, and

the components may be impaired if they are used improperly.

The training system from Festo Didactic has been developed and produced for training and vocational

education in the field of automation technology. The respective training companies and/or trainers must

ensure that all trainees observe the safety precautions which are described in this workbook.

Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company

and/or any third parties, which occur during use of the equipment in situations which serve any purpose

other than training and/or vocational education, unless such damages have been caused by Festo Didactic

due to malicious intent or gross negligence.

Order No.: 566924

Edition: 09/2009

Authors: Frank Ebel, Markus Pany

Graphics: Doris Schwarzenberger

Layout: 11/2009, Frank Ebel

© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2009

Internet: www.festo-didactic.com

e-mail: [email protected]

The copying, distribution and utilization of this document as well as the communication of its contents to

others without expressed authorization is prohibited. Offenders will be held liable for the payment of

damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design

registration.

© Festo Didactic GmbH & Co. KG 566924 III

Table of contents

Preface ______________________________________________________________________________ IV

Introduction _____________________________________________________________________________ VI

Work instructions and safety precautions ____________________________________________________ VII

Equipment set, sensors for object detection (TP 1110) _________________________________________ VIII

Exercises

Exercise 1: Detecting the speed of a gear _______________________________________________________ 1

Exercise 2: Sensing the position of a valve slide _________________________________________________ 9

Exercise 3: Inspecting food tins _____________________________________________________________ 19

Exercise 4: Sorting washers ________________________________________________________________ 25

Exercise 5: Measuring the thickness of steel discs _____________________________________________ 30

Exercise 6: Sorting flat seals _______________________________________________________________ 38

Exercise 7: Controlling a dip at a belt tensioner ________________________________________________ 45

Exercise 8: Monitoring an electrically operated gate ____________________________________________ 55

Exercise 9: Feeding crown caps _____________________________________________________________ 63

Exercise 10: Sorting workpieces ____________________________________________________________ 72

Exercise 11: Detecting ladder rungs _________________________________________________________ 80

Exercise 12: Monitoring fill levels ___________________________________________________________ 88

Exercise 13: Detecting variously coloured transport cases _______________________________________ 97

Exercise 14: Checking for the presence of threads_____________________________________________ 102

Exercise 15: Monitoring material feed at a press ______________________________________________ 106

IV © Festo Didactic GmbH & Co. KG 566924

Preface

Festo Didactic’s training system for automation and technology is geared towards various educational

backgrounds and vocational requirements. The training packages are therefore broken down as follows:

• Technology training modules

• Mechatronics and factory automation

• Process automation and control technology

• Robotino® – training and research with mobile robots

• Hybrid learning factories

The technology modules deal with various technologies including pneumatics, electro-pneumatics,

hydraulics, electro-hydraulics, proportional hydraulics, programmable logic controllers, sensor technology,

electrical engineering and electric drives.

The modular design of the training system makes it possible to focus on applications above and beyond

those covered in the individual modules, such as, for example, PLC actuation of pneumatic, hydraulic and

electrical drives.

© Festo Didactic GmbH & Co. KG 566924 V

All training modules have the same structure:

• Hardware

• Courseware

• Software

• Seminars

The hardware is comprised of industrial components and systems that are specially designed for training

purposes.

The structure of the courseware corresponds to that of the training hardware. It includes:

• Textbooks (with exercises and examples)

• Workbooks (with practical exercises, supplementary instructions and solutions)

• Books of exercises (with practical exercises and supplementary explanations)

• Transparencies and videos (for dynamic instruction)

The teaching and learning media are available in several languages. They’re intended for use in classroom

instruction, but are also suitable for self-study.

Where software is concerned, computer training programs, as well as simulation, visualisation, project

engineering, design engineering and programming software, are made available.

A wide range of seminars covering the contents of the training packages round off the programme for

training and vocational education.

If you have suggestions or comments about this manual,

send us an e-mail at [email protected].

The authors and Festo Didactic look forward to your feedback.

VI © Festo Didactic GmbH & Co. KG 566924

Introduction

This book of exercises is part of the training system for automation and technology from

Festo Didactic GmbH & Co. KG. The system provides a solid basis for practical training and vocational

education. Training module TP 1110 deals with the subject of sensors for object detection.

Special emphasis is placed on the design, function, connection, range of applications and selection of

sensors on the basis of the requirements for the respective application.

A permanent workstation equipped with a Festo Didactic profile plate and a short-circuit proof power supply

unit with an output voltage of 24 V DC is a prerequisite for setting up the circuits.

All the circuits for the 15 exercises are set up using the TP 1110 equipment set. The theoretical

fundamentals for understanding these exercises are included in the textbook:

• Proximity sensors (order number 093046)

Data sheets for the individual components are also available (sensors, measuring instruments etc.).

© Festo Didactic GmbH & Co. KG 566924 VII

Work instructions and safety precautions

General

• Trainees should only work with the circuits under the supervision of a trainer.

• Observe the specifications included in the data sheets for the individual components and in particular

all safety instructions!

• Faults which may impair safety must not be generated in the training environment and must be

eliminated immediately.

Mechanical setup

• Mount all the components securely onto the profile plate.

• Adhere to the instructions regarding positioning of the components.

Electrical setup

• Use low voltage only (max. 24 V DC).

• Electrical connections must only be established and interrupted in the absence of voltage!

• Only use connecting cables with safety plugs for electrical connections.

• Only pull the plug when disconnecting connecting cables – never pull the cable.

Mounting technology

The mounting boards for the components are equipped with mounting variant A, B or C:

• Variant A, snap-in system

Lightweight components that are not load-bearing (e.g. directional control valves and sensors). Simply

clip the component into the slot on the profile plate. Release the component from the slot by turning the

blue lever.

• Variant B, bolt system

Components with medium load capacity (e.g. pneumatic cylinders). These components are clamped

onto the profile plate using T-head bolts. The blue, knurled nut is used for clamping and loosening.

• Variant C, screw system

For components with high load capacity and components which are seldom removed from the profile

plate (for example on-off valve with filter regulator). The components are secured with socket head

screws and T-head bolts.

Recommended accessories

A ruler and a digital multimeter are required in order to evaluate the circuits which have been set up.

• Layout dimensions and scanning widths are measured with the ruler.

• Operating voltages, output voltages and output current values are measured with the digital

multimeter.

VIII © Festo Didactic GmbH & Co. KG 566924

Equipment set, sensors for object detection (TP 1110)

The equipment set is used to convey knowledge about the basic principles and the use of magneto-resistive,

inductive, capacitive and optical proximity switches. It includes all the components that are necessary for

mastering the specified learning objectives and can be supplemented with any other equipment sets. A

profile plate, a power supply unit and a digital multimeter are also required in order to set up functional

circuits.

Component Order no. Quantity

Indicator unit and distributor, electrical 162244 1

Proximity switch, inductive, M12 548643 1

Proximity sensor, inductive, with analogue output, M12 548644 1

Proximity switch, inductive, M18 548645 1

Through-beam sensor, receiver 548647 1

Through-beam sensor, transmitter 548648 1

Retro-reflective sensor 548649 1

Reflector (triple mirror), 20 mm 548650 1

Proximity switch, capacitive, M12 548651 1

Fibre-optic unit 548655 1

Diffuse sensor with background suppression 548656 1

Fibre-optic cable 548659 1

Set of objects 549830 1

Positioning slide 549842 1

Proximity switch, magneto-resistive 566199 1

© Festo Didactic GmbH & Co. KG 566924 IX

Graphic symbols, equipment set

Component Graphic symbol Component Graphic symbol

Indicator unit and distributor,

electrical

Retro-reflective sensor 1

3

4

Proximity switch, inductive,

M12 1

3

4

Proximity switch, capacitive,

M12 1

3

4

Proximity sensor, inductive,

with analogue output, M12 U

I

1

3

4

2

Fibre-optic unit 1

3

4

2

Proximity switch, inductive,

M18 1

3

4

Diffuse sensor with

background suppression 1

3

4

2

Through-beam sensor,

receiver 1

3

4

Proximity switch,

magneto-resistive 1

3

4

Through-beam sensor,

transmitter 1

3

2

X © Festo Didactic GmbH & Co. KG 566924

© Festo Didactic GmbH & Co. KG 566924 1

Exercise 1:

Detecting the speed of a gear

Learning objectives

After completing this exercise:

• You’ll be familiar with the setup and function of a magneto-resistive proximity switch.

• You’ll be familiar with the switching performance of a magneto-resistive proximity switch.

• You’ll be familiar with the basic principles of connection technology and circuit technology for

proximity switches.

Presentation of the problem

The use of a contactless proximity switch has been planned in order to record the speed of a non-metallic

gear. A magnet is mounted on one of the gear’s teeth to this end. Reliable switching must be ensured. The

proximity switch’s characteristic switching curve needs to be determined. The influence of the orientation of

the magnetic axis must also be examined.

Layout

Magnetic proximity switch for recording speed

Exercise 1 – Detecting the speed of a gear

2 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 566924

Project assignment

1. Describe the setup and function of a magneto-resistive proximity switch.

2. Examine the switching performance of the magneto-resistive proximity switch.

3. Examine the influence of the orientation of the magnetic axis.

Work tools

• Data sheets

• Textbook, proximity switches

Note

Do not switch electrical power supply on until all the connections have been completed and inspected.

After completing this exercise, switch the electrical power supply back off again before dismantling the

components.

Exercise 1 – Detecting the speed of a gear

© Festo Didactic GmbH & Co. KG 566924 Name: __________________________________ Date: ____________ 3

Description of the function

– Describe the function of the magneto-resistive proximity switch.

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

– Complete the circuit symbol for the magneto-resistive proximity switch.

Requirements

• The proximity switch is contactless,

• reacts when a magnet approaches it, and

• its switching output has a normally open function.

1

3

4

– Complete the table below. The required data are included in the data sheet for the magneto-resistive

proximity switch.

Parameter Value

Operating voltage (DC)

Switching current

Switching frequency

Switching output

Switching status display

Switching point reproducibility

Exercise 1 – Detecting the speed of a gear

4 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 566924

Determine switching performance

– Mount the indicator unit, the positioning slide and the magneto-resistive proximity switch on the profile

plate.

– Mount the magneto-resistive proximity switch, leaving a space of one slot from where the positioning

slide is mounted.

0V

0 10 20 30 40 50

24

VQ

1Q

2Q

3

Setup

– Connect the 24 V power supply unit and the magneto-resistive proximity switch to the indicator unit.

Complete the circuit diagram.

24 V

1

3

4

24 V

0 V

Q1

B

Electrical circuit diagram

Exercise 1 – Detecting the speed of a gear

© Festo Didactic GmbH & Co. KG 566924 Name: __________________________________ Date: ____________ 5

– Complete the equipment list. Enter all the components you’ll require in order to examine switching

performance.

Quantity Component

1

1

1

1 Power supply unit, 24 V DC

Item Part

1 Workpiece holder

2 Magnet 1, on support plate

3 Magnet 2, on support plate

Individual parts from the set of objects

Experiment 1

– Insert the workpiece holder from the set of objects into the workpiece receiver on the positioning slide.

– Take magnet 1 from the set of objects and insert it into the workpiece holder.

– Push the workpiece receiver on the positioning slide all the way up to the limit stop (scale value:

“0 mm”). Position the proximity switch and the positioning slide so that the distance between the

magnet and the proximity switch is as small as possible.

– Move the magnet along the longitudinal axis of the proximity switch. Add the points at which the

proximity switch reacts to the magnet to the diagram. You’ll know when the proximity switch responds,

because the integrated LED lights up at. The LED integrated in the indicator also lights up.

– The distance between the magnet and the proximity switch is increased in steps of 2 mm each. The

magnet carrier is moved 50 mm relative to the middle of the active surface of the proximity switch

(blue dot). Travel must be fully completed for each measurement.

Exercise 1 – Detecting the speed of a gear

6 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 566924

Note

While performing measurements, make sure that the switch-on and switch-off points for the proximity

sensor do not coincide. If the unactuated proximity switch is approached by the magnet from, for

example, the left until its switching status changes, the switch-on point is detected. If the magnet

continues to move to the left until the proximity switch changes from the actuated to the unactuated

state, the switch-off point is detected. The distance between these two points is known as hysteresis.

10

-30

30

20

-20

10 403020 mm

40

50

mm

-40

-50

Switching curve, magnet 1

Exercise 1 – Detecting the speed of a gear

© Festo Didactic GmbH & Co. KG 566924 Name: __________________________________ Date: ____________ 7

Experiment 2

– Using magnet 2 from the set of objects, repeat the above described procedure.

– Add the points at which the proximity switch reacts to this magnet to the diagram.

10

-30

30

20

-20

10 403020 mm

40

50

mm

-40

-50

Switching curve, magnet 2

Exercise 1 – Detecting the speed of a gear

8 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 566924

Influence of the orientation of the magnetic axis

– Describe the influence of the orientation of the magnetic axis.

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

Answer the following questions.

– Describe two further possibilities for substantiating the presence of a magnetic field. Briefly explain how

these proximity switches function.

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

– Explain the term magneto-resistive.

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________

_________________________________________________________________________________________