The AT-205 system has been designed based upon the training requirements of industries with a medium to high level of automation.

Its cutting-edge and attractive design allows for simulation of the operations taking place in a real factory hence making it possible to study different scenarios.

The state-of-the-art technologies used in production processes are integrated in this didactic system with the aim of responding to the needs of sectors as diverse as automotive, semiconductors, food, pharmaceuticals, etc. The technologies used and the situations reproduced are in accordance with the requirements of each industry.

An AT-205 system covers field, controller, operator and management levels in its automation pyramid. Using this system, the student will have an integrated and motivating context to become familiar with technologies such as electro-pneumatics, sensors, motors and PLCs. The system has an appealing and inspiring design while all the components used are completely industrial ones.

The AT-205 allows the user to manufacture different products. The raw materials include containers which can be filled by two types of raw material: P.V.C. color granules and metallic balls. Production lines can be programmed at a managing level to fill containers with different volumes and weights of raw material. The ASRS warehouse which is designed to be the final station to store containers based on their cap material (P.V.C. or metallic) and/or color (red or blue).

The feeding station picks up and feeds empty containers into the production line. Up to 20 containers placed on the rotary feeding disk simulate one of the most usual methods of feeding in the industry. This functional module feeds containers to the line at a constant speed. In an investigation module which is located immediately after the disk, all feed containers inspect for proper positioning on the line. If there is any bottom-up condition detected, the container will be removed from the line.

Special Technology:

• Stepper Motor drive and control technology.

The most important components:

• 1x 2-Phase Stepper Motor
• 1x Stepper Motor Drive
• 1x SIMATIC S7-300 PLC (CPU 314C-2DP) – with Profi-bus connection
• 1x SIMATIC S7-300 Stabilized Power Supply
• 2x Pneumatic Jack
• 1x Air treatment and pressure regulator
• 2x 3/2 Electro-pneumatic Valve
• 1x Capacitive Proximity Sensor

Time-based filling is one of most common methods used in the industry. The “filling station 1” simulates a scenario with a storage tank filled with PVC granules and equipped with a special funnel that opens and closes with a pneumatic linear actuator. The opening time of the funnel can be programmed and controlled by a PLC. Therefore, students may learn principles and applications by the filling methodology.

Special Technology:

• Innovative handling system

The most important components:

• 1x Retro-reflective Optical Sensor
• 1x 5/2 Electro-pneumatic Valve
• 1x SIMATIC S7-300 PLC (CPU 314C-2DP) – with Profi-bus connection
• 1x SIMATIC S7-300 Stabilized Power Supply
• 3x Pneumatic Jack
• 1x Air treatment and pressure regulator
• 2x 3/2 Electro-Pneumatic Valve
• 1x Capacitive Proximity Sensor

The “Filling Station 2” demonstrates the principles of weight measurement and their applications in industrial automation with a properly installed load-cell under the belt conveyor. Containers filled up in “Filling station 1” are carried to the weighing locations. Then, the conveyor stops to be filled up with metallic balls and allows a silent measurement in parallel with the filling process.

Special Technology:

• Load cell transducer with display and analog interface to PLC

The most important components:

• 1x Retro-reflective Optical Sensor
• 1x Load Cell Sensor
• 1x SIMATIC S7-300 PLC (CPU 314C-2DP) – with Profi-bus connection
• 1x SIMATIC S7-300 Stabilized Power Supply
• 2x Pneumatic Jack
• 1x Air treatment and pressure regulator
• 2x 3/2 Electro-Pneumatic Valve
• 1x Capacitive Proximity Sensor
• 1x Inductive Proximity Sensor
• 1x Load Cell Transducer with 0..10V Analog output

The containers’ cap will be put and closed in two stages in the “Capping Station”. Four types of caps with different colors and materials are placed in the magazines. An index table takes a container from the belt conveyor, puts the cap, closes the cap by a pushing mechanism and finally delivers it to the next station.

Special Technology:

• 3-phase AC motor drive technology

The most important components:

• 1x 3-Phase AC Motor
• 1x Motor Inverter
• 1x Optical Photo-Gate Sensor
• 1x 5/2 Electro-Pneumatic Valve
• 1x SIMATIC S7-300 PLC (CPU 314C-2DP) – with Profi-bus connection
• 1x SIMATIC S7-300 Stabilized Power Supply
• 2x Pneumatic Jack
• 1x Air treatment and pressure regulator
• 1x 3/2 Electro-Pneumatic Valve
• 1x Incremental Rotary Encoder

Special Technology:

• DC motor drive
• Color sensing technology

The most important components:

• 1x Permanent Magnet DC Motor
• 1x Industrial Color-Marking Sensor
• 1x Inductive Proximity Sensor
• 1x 5/2 Electro-pneumatic Valve
• 1x SIMATIC S7-300 PLC (CPU 314C-2DP) – with Profi-bus connection
• 1x SIMATIC S7-300 Stabilized Power Supply
• 4x Pneumatic Jack
• 1x Air treatment and pressure regulator
• 2x 3/2 Electro-Pneumatic Valve
• 1x Capacitive Proximity Sensor

All modern automated factories are equipped with properly designed HMI and Monitoring units. The “Monitoring Station” displays manufacturing lines schematically and enables operators to check the status of the sensors and actuators at every station. This station will connect to all the other stations via a Profi-Bus industrial network link.

Special Technology:

• Field-Bus industrial network technology
• HMI programming

The most important components:

• 1x Desktop PC
• 1x SIMATIC CP-5611 Profi-Bus PCI card
• 1x SIMATIC Step7 Professional Edition
• 1x WinCC Flex 2008
• 1x SIMATIC S7-300 PLC (CPU 314C-2DP) – with Profi-bus connection
• 1x SIMATIC S7-300 Stabilized Power Supply