Changes in industrial production driven by digitalization make stronger networking and more relevant information necessary on all production levels. With this model, these digitalization activities can be simulated, learned, and applied on a small scale before they are implemented on a large scale.
This 24V simulation model that consists of factory modules including storage and retrieval stations, a Vacuum Gripper robot, High-Bay Warehouse, Multi-Processing Station with Oven, a Sorting Line with Color Detection, an environmental sensor, and a pivoting camera. It is especially designed for exploring and understanding industry 4.0 applications in vocational schools and training as well as for research, teaching and development at universities, in companies, and IT departments.
The set contains all of the components found in four different models.
Vacuum Gripper Robot:
- 4 DC motors, including 2 with integrated magnetic encoder (max. pulse frequency 1kHz)
- 4 Limit switches
- 2 Pulse sensors for path measurement
- 8 Digital inputs
- 8 Outputs, 24V: 4 motors clockwise/counterclockwise rotation
- Relay board for motor polarity reversal
- Port: PCB with relays to reverse polarity of motor, multi-pin connector (34 pin ST1 connection) and additional PCB terminals with push in connection for all I/O.
Automated High Bay Warehouse:
- 2 encoder motors
- 2 mini motors
- 4 push buttons (limit switch)
- 2 phototransistors
- 2 lens tip lamps
- Workpiece carriers
- Various colored workpieces (6 pieces)
- Port: PCB with relays to reverse polarity of motor, multi-pin connector (34 pin ST1 connection) and additional PCB terminals with push in connection for all I/O.
Multi-Processing Station with Oven:
- 4 mini motors
- 6 push buttons (limit switch)
- 2 phototransistors
- 2 lens tip lamps
- 4 solenoid valves
- 1 compressor
- Port: PCB with relays to reverse polarity of motor, multi-pin connector (34 pin ST1 connection) and additional PCB terminals with push in connection for all I/O.
Sorting Line with Color Detection:
- 2 mini motors
- 5 phototransistors
- 5 lens tip lamps
- 3 solenoid valves
- 1 compressor
- 1 optical color sensor
- Port: PCB with relays to reverse polarity of motor, multi-pin connector (34 pin ST1 connection) and additional PCB terminals with push in connection for all I/O.
IMPORTANT NOTE: for proper control of the 24V model, the PLC used must be able to support the following number of I/O’s:
Digital inputs: 28
Counter inputs: 14
Analog inputs: 2
Outputs: 43
Outputs PWM (optional): 12
Dimensions: 39 x 31 x 16 inches
The digitally driven change in industrial production requires stronger networking and more intelligent information at all levels of production. With the fischertechnik Training Factory 4.0, these digitization activities can be simulated, learned and applied on a small scale before they are implemented on a large scale. This makes it a highly flexible, modular and cost-effective and robust training and simulation model.
The fischertechnik learning environment is used for learning and understanding a variety of applications in vocational school and training and for use in research, teaching and development at universities, in companies and IT departments. The simulation depicts the ordering process, the production process and the delivery process in digitized and networked process steps.
The following topics can be implemented with the fischertechnik Training Factory 4.0:
- Training and simulation on a realistic production image
- Deepening learning through haptic comprehension
- Optical and sensory applications
- Digital traceability with NFC/RFID
- Customer-specific production in lot size 1
- Integrated cloud connection, control via smart devices
- Use and operation of dashboards
- Web-based remote monitoring
- Linking of production and disposition data
- Connection of upstream/downstream logistics processes
- High-bay warehouse operates according to FIFO industry standard
- 24V sample program as structured text (ST) for Siemens PLC S7-1500 already included, own program creation possible
Factory environment
This consists of the factory modules storage and retrieval station, vacuum suction pads, high-bay warehouse, multi-processing station with furnace, a sorting line with color recognition, an environmental sensor and a swiveling camera. After ordering in the dashboard, the workpieces pass through the respective factory modules and the current status is immediately visible in the dashboard.
The integrated environmental sensor reports values for temperature, humidity, air pressure and air quality. Due to the vertical and horizontal swivel range, the camera can see the entire plant and can thus be used for web-based remote monitoring.
The individual workpieces are tracked by NFC (Near Field Communication): each workpiece receives a unique identification number (ID). This enables the current status of the workpieces in the machining process to be tracked and made visible.
Control with 24V
The Training Factory 4.0 24V is controlled by a PLC (brand independent, not included in the scope of delivery) and comes with a ready-made sample program as structured text (ST). The program was created on the basis of a Siemens S7-1500 (see www.fischertechnik.de/simulation).
The newly developed 24V adapter boards as interface to the PLC are pre-assembled in the Training Factory and are connected to the PLC via terminals. Among other things, this latest generation of adapter boards allows
- the encoder motors are controlled in speed via PWM, and
- push/pull output stages for phototransistors and buttons
A fischertechnik TXT controller is also installed in the Training Factory 4.0 24V. This is supplied with power via the adapter board and provides the connection to the fischertechnik cloud. The TXT Controller also communicates in MQTT to the IOT gateway (Raspberry Pi) which in turn translates in OPC-UA to the PLC controller. In this way, the 9V-based components such as the environmental sensor, the USB camera, the brightness sensor and the NFC reader can be addressed via the MQTT interface and read out by the PLC. Even more interesting, however, is another function of the IOT Gateway, namely the possibility of an optional connection to a separate cloud. Thus, Training Factory 4.0 offers maximum flexibility for the individual user.
Software
The PLC sample program for controlling fischertechnik Training Factory 4.0 was created based on a Siemens S7-1500 and can be viewed, used free of charge and downloaded from Github:
https://github.com/fischertechnik.
Of course, the Training Factory can also be controlled with other PLC models and brands and individual solutions can be programmed and implemented by the user. It may be necessary to make small adjustments to the sample program, which can be implemented independently.
AR/VR, Digital Twin
The fischertechnik training and simulation models are also ideal for digital applications and demonstrators. We will be happy to provide you with the necessary CAD data.
fischertechnik Cloud, 2 Dashboards, Raspberry Pi and Node-RED
The connection to the fischertechnik cloud is established via the WLAN router which is integrated in the Training Factory. The use of the Chrome or Firefox web browsers is recommended. The
cloud can be used via a personal access which is created once (www.fischertechnik-cloud.com).
The servers of the cloud are located in Germany and ensure that the strict European requirements apply for the storage of data. Personal data is protected in an account with password access, which uses the very secure "OAuth2" industry standard. All data sent to the cloud is encrypted with certificates (https standard).
Two dashboards
The fischertechnik dashboard in the cloud can be called up and operated via mobile devices such as tablet and smartphone as well as on laptop and PC. In addition, a local dashboard, created with Node-RED, is implemented on the Raspberry Pi (IOT gateway), and own dashboards can also be created via Node-RED.
The dashboards included in Training Factory 4.0 allow the presentation of platforms from three different perspectives:
- Customer view
- Supplier view
- Production view
The Customer View shows a web-shop interface with a shopping cart, where you can order a workpiece and follow the current status of the order in the shopping cart. This history is displayed on the interface for the customer, so that he is informed about the status of his order.
In the Supplier View, the process for ordering the raw material is displayed and visualized.
In the Production View, the factory status, the production process, the inventory, the NFC/RFID
reader and the sensor values can be queried. In addition, the camera that monitors the production line can also be controlled here. All these functions are controlled within one window and can be switched via the menu.
In the Factory Status, the status of the respective module is visualized via a traffic light display. If a fault occurs in production, it is acknowledged by a button after the cause has been eliminated and production is continued.
In the Production Process view, the individual production steps are visually simplified by connected nodes. The respective active node (=production module) lights up green or red if the respective process step is being processed live or if there is an error and is waiting for remedy.
The Production View Stock level visualizes the current stock level of the workpieces including minimum and maximum stock. A reorder point procedure is stored. This production view is for visualization purposes only.
The Production View of the NFC/RFID reader displays the data of the workpiece and can be used to read or delete workpieces manually. The raw data of the NFC tags can be read with a standard NFC app from mobile devices with NFC reader. Each workpiece has its own unique ID and displays the following data: Status, color and time stamp from delivery to dispatch.
The camera is also controlled via the production view and the read-out values of the environmental sensor can also be viewed here.
Accompanying Booklet:
In addition to all technical documents available at www.fischertechnik.de, the fischertechnik eLearning portal also contains a didactic accompanying booklet with detailed operating instructions as well as vital and helpful training and teaching content specially developed for this model. The technical specifications and explanations for the individual modules of the learning factory are also listed. The accompanying booklet can be viewed at www.fischertechnik.de/en/service/elearning.
REQUIRED—VERY IMPORTANT: Please note that model requires a PLC (not included) for all operation, as well as all cabling from the model to the PLC. In addition, one 9V power adaptor (for powering the TXT Controller) is all required—sold separately. We suggest the Condor 9V Supply: Condor 9V power supplies for controllers | Studica
Service Offers
Contact:
If you need any consultation or have any questions, you can contact fischertechnik in Germany Monday to Friday by phone (Tel. +49 74 43/12-42 93) and by email ([email protected]). Their service consultants will be glad to help you quickly. You can also go through the FAQs on fischertechnik.de for further information.
Delivery:
All fischertechnik training and simulation models are delivered in a particularly sturdy shipping carton, which guarantees a safe delivery across the world. In addition, all deliveries are insured against transport damage at our expense.
Maintenance:
You can request for a maintenance service for all training and simulation models to be able to use the full range of functions reliably over many years. If needed, please contact fischertechnik directly for more information. We will be happy to make you an all-inclusive offer.
Spare Parts:
Each fischertechnik component can be purchased and replaced individually even years after your model purchase. In this way it is guaranteed that you always have a fully functional model in operation. The complete overview of individual parts can be found at www.studica.com/FischertechnikSpareParts.
Fully Assembled
fischertechnik training models are delivered pre-assembled as compact functional models. For this purpose, they are fixed onto wooden boards using screws to increase stability, so that mobility to carry the models with you for projects, exhibitions or trade fairs is guaranteed at all times. The screws can be easily loosened to take advantage of the flexibility and modular design of fischertechnik, if an independent conversion and extension of further models is required at any time.
fischertechnik has been a "Made in Germany" brand for over 50 years and continues its manufacturing in Germany. Profit from the excellent high quality which makes fischertechnik models extremely durable and well-known.
