LABORATORY STAND

AUTOMATED PRODUCTION LINE

USER MANUAL
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CONTENTS
1 INTRODUCTION ................................................................................................................5
2 OVERVIEW .......................................................................................................................5
3 SAFETY REQUIREMENTS ...................................................................................................6
4 HARDWARE AND SOFTWARE ...........................................................................................7
4.1 Stand hardware ................................................................................................................. 7
4.2 Additional hardware requirements .................................................................................. 8
4.3 Software requirements ..................................................................................................... 8
5 Architecture of system .....................................................................................................8
6 HARDWARE DESCRIPTION ................................................................................................9
6.1 Magazine module .............................................................................................................. 9
6.2 Changer module ................................................................................................................ 9
6.3 Turntable and machine vision module ........................................................................... 10
6.4 Belt conveyer module ..................................................................................................... 10
6.5 Sorting gate module. Sorting box transfer module ........................................................ 11
7 Software installation and setup ...................................................................................... 11
7.1 Software Installation ....................................................................................................... 11
7.2 Setup ............................................................................................................................... 14
8 Getting started ............................................................................................................... 14
8.1 Required background knowledge and skills ................................................................... 14
8.2 Powering up and preparations ....................................................................................... 14
8.3 Running the software and getting started ...................................................................... 15
9 HANDS-ON EXPERIMENTS .............................................................................................. 16
9.1 Manual mode .................................................................................................................. 16
9.2 Programming mode ........................................................................................................ 19
9.3 Automatic Sequential mode ........................................................................................... 25
9.4 Automatic Parallel mode ................................................................................................ 30

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1 INTRODUCTION
The laboratory stand Automated Production Line can be used by research groups for the
development of production line automation systems and for hands-on study of Automation
Control Systems and computer programming disciplines.
Due to the flexible construction, the stand essentially reduces the time and resources required for
the development of production line automation systems. The experimental setup enables the user
to control and program all units, either in series or parallel mode of operation. Wireless sensor
network for transmission of information from the sensors are installed in the stand. The lab
software has a simple and intuitive user interface. You may choose the desired lab from the menu
and work according to our step-by-step instructions provided the lab manual.
The laboratory stand Automated Production Line is based on the NI cRIO hardware platform of
National Instruments. Course software has been developed in the NI LabVIEW Graphical
Programming Environment.

2 OVERVIEW
The laboratory stand Automated Production Line has been developed as a tool for the study of
production line automatic control and monitoring.
Automation of production is a process in which the control and monitoring functions, previously
performed by humans, are transferred to instruments and automatic devices. Automation of
production is the base for the development of modern industry. Its goal is to improve the
efficiency of labor and the quality of manufactured products, creation of conditions for the
optimum utilization of all production resources.
Automation can be partial, comprehensive, and complete.
Partial automation is the automation of specific production operations. It is used when human
control is practically impossible due to complexity or rapidity of the process, and where simple
automatic devices can effectively replace human labor. This production equipment can be
partially automated.
When comprehensive automation is utilized, the manufacturing area, production shop, plant, or
power station operates as a unified interdependent automated complex. Comprehensive
automation is only feasible in the case of highly developed production based on modern
technology and utilizing highly reliable production equipment. Human function is limited to
overall monitoring and control of the entire complex.
Total automation is the ultimate stage of automation, when all functions involving control and
monitoring of complex automated production are performed by automatic control systems. Total
automation is instituted when the production line is profitable and stable, production conditions
remain practically unchanged, and possible deviations can be taken into account beforehand.
Total automation is also used in situations when conditions are hazardous to human health or life,
or when no human access is possible.
When determining, which type of automation to utilize in a particular case, first of all are to be
considered factors of cost and feasibility under specific production conditions. Human labor
acquires new qualitative nuances, becoming more complex and meaningful.
On the laboratory stand Automated Production Line WSN nodes that receive the information from
the sensors and transmit by Gateways on the cRIO are mounted. The use of wireless sensors gives
ample opportunity to control and monitor remote objects and systems in real time.

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The laboratory stand consists of the following modules:
1. Magazine module
2. Changer module
3. Turntable module
4. Belt conveyer module
5. Sorting gate module
6. Sorting box transfer module
Machine vision is implemented based on the of the NI 1772C Smart Camera by National
Instruments. Special algorithms are utilized for work piece recognition and analysis. The color of
the work piece is determined, the attached label is identified, and defects are detected, if present.
A set of three circular work pieces of various colors is included. During the hands-on sessions the
user will control and program all the units on the production line, in series or in parallel.
Four modes of system control are possible:
1) Manual mode
2) Programming mode
3) Automatic sequential mode
4) Automatic parallel mode

3 SAFETY REQUIREMENTS
Carefully read the safety instructions before connecting the hardware, before starting the work
over the hands-on experiments, or before any technical maintenance. Technical maintenance
shall only be provided by qualified personnel.
The laboratory stand can only be used indoors, in the absence of electrical shock risk factors, such
as extreme humidity, condensation, lack of grounding, etc.
The body of the laboratory stand should be connected to a proper grounding network. Any
maintenance operations can only be performed when the laboratory stand is disconnected from
the mains.
In case of failure of the device or if a burning smell of wires or components is detected please turn
OFF the workstation immediately, disconnect the power cord from the socket, and seek a
qualified service from an appropriate agency.

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4 HARDWARE AND SOFTWARE
4.1 Stand hardware
Stand table with the following modules installed:

1. Magazine module QTY 1

2. Changer module QTY 1

3. Turntable module QTY 1

4. Belt conveyer module QTY 1

5. Sorting gate module QTY 2

6. Sorting box transfer module QTY 3

7. Work pieces 1 SET

Standard equipment of stand also includes User's Manual.

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4.2 Additional hardware requirements
The following hardware is required for the Course:
1. NI TPC-2212 12 in. LabVIEW Touch Panel Computer With Windows Embedded QTY 1
2. NI WSN-3226 4 Ch, 20-Bit, Programmable Voltage/RTD Combination Node QTY 4
3. NI 1772C Smart Camera High-Performance, 640x480 (VGA), 65 fps, Color QTY 1
4. NI cRIO-9075 Integrated 400 MHz Real-Time Controller and LX25 FPGA QTY 4
5. NI 9912 DIN Rail mounting kit for 4-slot CompactRIO chassis QTY 4
6. NI 9472 8- Ch 24V Logic, 100 µs, Sourcing Digital Output Module QTY 4
7. NI 9421 DSUB, 24 V, 100 µs, Sinking Digital Input, 8 Ch Module QTY 3
8. NI 9201 DSUB, ±10 V, Analog Input, 500 kS/s, 8 Ch Module QTY 1
9. Power cord, 240V, EuroClass QTY 5
10. NI 9795 C Series Wireless Sensor Network (WSN) Gateway QTY 4
11. IP67 M12 Connector Cap and Plug QTY 1
12. Computar M1214-MP, 12mm, F1.4, Megapixel QTY 1
13. Starter Kit for NI 177xx Smart Cameras QTY 1
14. NI 177xx Smart Camera Light Bracket for AI RL4260 and RL127 lights QTY 1
15. RL4260 Bright Field Ring Light QTY 1
16. NI PS-10 Desktop DC Power Supply QTY 5
4.3 Software requirements
1. MS Windows 7 (installed on Personal computer)
2. LabVIEW Run-Time Engine 2013

5 ARCHITECTURE OF SYSTEM
The overall system architecture is shown in Fig. 5-1.

3 3 3 3 3

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4
4

Fig. 5-1
The system includes:

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 1. Platform
2. Compressor
3. The power supply PS-10
4. WSN (Wireless sensor network)

6 HARDWARE DESCRIPTION
6.1 Magazine module
The Magazine module consists of a work piece magazine and a double-acting pneumatic actuator.
Insert the work pieces into the vertical magazine module (Fig. 6-1). The double-acting piston
pushes the lower work piece off the magazine (logical “1”), and then returns to the initial position
(logical “0”). This is required in order to cause no hindrance to further movements of the work
piece. The piston position is determined by reed switches. Information about the position of the
piston of the air cylinder is transferred via the first WSN node to the gateway that is installed in
the first cRIO (units and modules on the bench are numbered).
When the Magazine module is activated, the piston will pushing the work pieces off the magazine
and, when it is turned OFF, the piston will move in backwards direction (returning to the initial
position).

Fig. 6-1 Magazine module

6.2 Changer module
The Changer module is a pneumatic manipulator (Fig. 6-2) with a vacuum relay. The vacuum
gripper picks up the work pieces and, using a part-turn actuator, places them at a controlled
rotation angle (from 0° to 180°).

Fig. 6-2 Changer module

The operating principle of vacuum ejector (Fig. 6-3) is based on the phenomenon of the drop of
pressure when a gas flows through a narrowed section of the pipe.
The vacuum relay (Fig. 6-4) is a mechanical relay with an adjustable switch point and direction
indicator LEDs.
When the Changer module is activated, the pneumatic manipulator rotates by 180° clockwise and
the vacuum gripper stops above the work piece surface. Then the vacuum is turned on, and the

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gripper picks up the work piece. A digital display on the vacuum relay indicated the vacuum level
achieved. When the Changer module is turned OFF, the pneumatic manipulator rotates by 180°
counterclockwise (the manipulator returns to the initial position) and the gripper stops over the
turntable module. Then the vacuum is turned off and the work piece appears in one of the
turntable notches. Information about the position of the Changer module is transferred via the
second WSN node to the gateway that is installed in the second cRIO (units and modules on the
bench are numbered).

Fig. 6-3 Vacuum ejector Fig. 6-4 Vacuum relay

6.3 Turntable and machine vision module
The turntable module is equipped with a position sensor. It has six notches for the placement of
work pieces (Fig. 6-5).

Fig. 6-5 Turntable module

The turntable module is driven by a geared DC motor. Upon activation the turntable starts to turn
and stops when the position sensor detects that it has turned by one segment. When the table
turns by two segments, the work piece will appear in the field of vision of a smart camera.
The smart camera analyses the work piece and determines its color. Then the command to
activate the turntable is issued and it rotates by one more segment. As a result, the work piece
appears in front of the belt conveyer module.
6.4 Belt conveyer module
The Belt conveyer module consists of a conveyer, a diffusion type light detector and a double-
acting pneumatic actuator.
When the light detector (presence sensor) detects a work piece, the belt (Fig. 6-6) is activated,
and the piston of the pneumatic actuator will place the work piece on the belt. The work piece is
then driven ahead by the belt. The piston position is determined by reed switches. Information
about the position of the piston of the air cylinder is transferred via the third WSN node to the
gateway that is installed in the third cRIO (units and modules on the bench are numbered).

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 Fig. 6-6 Belt conveyer module
6.5 Sorting gate module. Sorting box transfer module
The Sorting gate module sorts the work pieces into different storing boxes (Fig. 6-7). Machine
vision determines into which of the two sorting gate modules should be activated, and the work
piece will follow into the corresponding sorting box. If none of the sorting gate modules is
activated, the work piece will be directed to the last sorting box. Information about the position
of the piston of the air cylinder of Sorting gate module is transferred via the fourth WSN node to
the gateway that is installed in the fourth cRIO (units and modules on the bench are numbered).

Fig. 6-7 Sorting gate module Fig. 6-8 Sorting box transfer module
The sorting box transfer module is used for inertial transfer of work pieces from belt conveyer to
storage gates (Fig. 6-8).

7 SOFTWARE INSTALLATION AND SETUP

7.1 Software Installation
For operation of the laboratory stand the software supporting the operation of NI hardware along
with the lab software has to be installed on the personal computer connected to the laboratory
stand.
To install the software please follow the steps described below:
1. Log in as an administrator or a user with administrator’s rights.
2. Insert the Automated Production Line installation disc into the optical drive of your
computer. If the installation wizard does not open automatically, open it by double clicking on
the file setup.exe in the folder Installer\Volume on the disc. Follow the instructions of the
Setup wizard.

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 Wait while the installer initializes.
3. In the open dialogue window select the primary installation directory for the lab software
installation and for the required NI Device Drivers. The folders C:\Program Files\Automated
Production Line\ and C:\Program Files\National Instruments\ will be selected by default,
respectively:

Click Next.
4. You must accept the National Instruments License Agreement displayed below to proceed:

Choose the I accept the License Agreement radio button and click Next.
5. The Automated Production Line hands-on course software will be installed on the PC:

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 Click Next to proceed.
6. Wait until all the required files are installed completely:

7. Click Finish to exit the software installation wizard.

When finished, reboot the computer.

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7.2 Setup
Launch the lab software by double clicking on the Automated Production Line shortcut on the
desktop or through the Windows start menu: Start -> Programs -> Automated Production Line.
The following dialog window will open (Fig. 7-1).

Fig. 7-1 Fig. 7-2

Click the Settings button (Fig. 7-1) and set the cRIO and the Smart camera IP addresses. The
Hardware settings window will open (Fig. 7-2).
Enter the IP address of cRIO 1 (192.168.0.6), cRIO 2 (192.168.0.8), cRIO 3 (192.168.0.7), cRIO 4
(192.168.0.9) into the corresponding fields of cRIO IP adress. Enter the IP address of Smart
camera (192.168.0.5) - in the Smart Camera IP address field. Choose the camera resolution in the
Camera resolution field. Click Save to store the settings.

8 GETTING STARTED
8.1 Required background knowledge and skills
Before starting the hands-on experiments the student must:
1. Get acquainted with the safety requirements (please refer to section 3. SAFETY
REQUIREMENTS of this manual).
2. Have basic understanding of the operating principles of the system hardware.
3. Get acquainted with the materials of this Manual.
8.2 Powering up and preparations
Powering ON
4. Insert the key into the keyhole of the lock and turn it clockwise.
5. The laboratory stand start button will start flashing.
6. Push the button and hold it for 5 seconds.
7. Wait until the computer is turned on and booted.
8. Fill the magazine module with multicolor work pieces from the work piece magazine.
9. Start the compressor by following the instructions Bambi Air Compressor's handbook.
10. Set the pressure 4-5 bar.
Before starting the work make sure that there are no work pieces on the Production Line.

Powering OFF
1. Power OFF the computer.
2. Insert the key into the lock and turn it counterclockwise.
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3. Switch off the compressor using the on/off control on top of the pressure switch (set to off
state).
8.3 Running the software and getting started
Launch the lab software by double clicking on the Automated Production Line shortcut on the
desktop or through the Windows start menu: Start -> Programs -> Automated Production Line.
The following dialog window will open (Fig. 7-1).
The list of hands-on labs is available as a drop-down menu. Choose the lab and click the Start
button to proceed. Detailed instructions for each lab are given in corresponding sections of
chapter 9. HANDS-ON EXPERIMENTS.
Stand stops its work when there is no work pieces in magazine or when there is work piece on
turntable opposite of Changer module. For restarting work of stand click Restart.

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9 HANDS-ON EXPERIMENTS
9.1 Manual mode
Lab objectives
Study of operating principles of the Automated Production Line in manual mode and making sure
that the manual mode allows an overall control over the work piece processing cycle.
Hands-on procedure
In this lab we shall study the processing of several work pieces through a full processing cycle in
manual mode. This means that the modules will be activated only upon the receipt of
corresponding command for this or that action.
The following elements are available on the user Interface (Fig. 9-1):
 Magazine
 Changer module
 Turntable
 Sorting gate module
First, the Magazine module is activated and the pneumatic actuator pushes the lower work piece
off the magazine. Then the magazine should be turned off to return the piston to the initial
position. Then the Changer module is activated to take the correct position over the work piece,
the vacuum is turned on and the Changer module picks up the work piece. Next, the Changer
module is activated again to place the work piece in one of the turntable notches. Next, the
turntable is activated and shall be rotated by required number of segments, until the work piece is
detected by the Smart camera. The Smart camera requires one second in order to determine the
work piece. Then, upon receipt of corresponding command, the turntable is activated again, until
the work piece will appear in front of the belt conveyer module. Then the pneumatic piston
pushes off the work piece onto the belt conveyer module. The run command is then issued to the
conveyer and, at the same time, the command to activate the corresponding sorting gate module,
so that the work piece is driven into the corresponding sorting box.
Only one work piece will appear in the sorting gate module after one cycle. It is essential that,
after each operation, each module must return to its initial position, otherwise the elements of
the modules or the whole module can be damaged due to subsequent operations.
Step-By-Step Instructions
1. Turn ON the laboratory stand (see 8.2 Powering up and preparations).
2. Launch the Automated Production Line lab software.
3. From the Dialogue window choose the Manual mode. Lab window will open (Fig. 9-1). The
Manual mode window contains all the instruments required for the laboratory stand control.
All the commands will be issued manually.

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 Fig. 9-1
4. A mouse click on the On/Off Magazine button in the Magazine control field will activate the
Magazine module, i.e. the pneumatic actuator will run directly.
5. When the pneumatic actuator completes its motion, and the work piece is in front of the
magazine, the Finish indicator will turn ON.
6. A click on the On/Off Magazine button will stop the magazine, i.e. the pneumatic actuator will
rotate in backwards direction and will return to the initial position. The Start indicator will
turn ON.
7. In the Changer module control field, click On/Off, wait until the module appears above the
item, and click the Turn On/Off vacuum button. When the vacuum is established, i.e. the
piston will pick up the work piece, click On/Off and wait until the Changer module returns to
the initial position.
8. When the turntable module takes the correct position for receiving a work piece, click Turn
On/Off vacuum. The Changer module will release the work piece and it will appear in the
special notch.
9. In the Turntable (Rotary indexing table) control field click the On/Off table button - the
turntable will turn by one segment and stop. The work piece will not appear on the field of
vision of the Smart camera yet, therefore it is required to click the On/Off table button again.
Wait until the Turntable module turns by one more segment and stops. Thus, the work piece
will appear in the field of vision of the Smart Camera.
10. The Smart Camera will determine the color of the work piece within approximately one
second. After detection, click the On/Off table button. The Turntable module will turn by one
segment and stop. The work piece will appear in front of the belt conveyer module.

When the work piece color is determined, the Turntable module must be rotated by one
segment, otherwise it may be damage due to collision of the work piece with the pushing
mechanism.

11. Click the Pusher button in the Sorting block field to advance the work piece onto the belt
conveyer.
12. Click the Pusher button in the Sorting block field to return the pneumatic piston to the initial
position.
13. Click the Conveyor button in the Sorting block field and assign a direction by clicking Sorting
Gate A or Sorting Gate B. Thus, the first or the second sorting gate will be activated and the
work piece will be delivered to a respective sorting gate. If no sorting gate is selected, the
work piece will be delivered to the last sorting box.
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14. Turn OFF the Sorting gate module by clicking Sorting Gate A or Sorting Gate B, to return the
respective sorting gate module to the initial position.
15. Turn OFF the Belt conveyer module by clicking on the Conveyor button.
If, through all the steps above, the work piece was transferred from the Magazine to the Sorting
boxes, the lab was performed correctly.
16. Close the Software panel.
17. Turn OFF the Laboratory Stand (see 8.2 Powering up and preparations).
Test Questions:
1. Which modules constitute the Automated Production Line?
2. Describe the Manual mode of the Automated Production Line.

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9.2 Programming mode
Lab objectives
Study of operating principles of the Automated Production Line in programming mode of
operation.
Hands-on Procedure
In the previous lab we studied the manual mode: a certain sequence of operations allowing
picking up the work piece and transferring it into the sorting boxes. In this lab we shall study the
basic programming principles for some modules on the laboratory stand, providing for correct
operation sequence of the modules.
When the lab is launched, a window will open with empty fields connected in series. These fields
represent the series of operations that will be followed in one cycle. You will have to fill in these
fields, assigning an operation to each one, then set up each module for correct operation.
Step-By-Step Instructions
1. Turn ON the laboratory stand (see 8.2 Powering up and preparations).
2. Launch the Automated Production Line lab software.
3. Choose Programming mode from the lab list. Lab window will open (Fig. 9-2).

Fig. 9-2
4. Click on the Initialization field and choose the START module (11). Click OK to confirm the
selection.
5. Click on the field #1 and choose the Magazine module (1), Fig. 9-3. Click OK to confirm the
selection.

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 Fig. 9-3
6. Click on the following fields and assign appropriate modules, as suggested in the table below.
Click OK to confirm each selection.
Field # Module Module #
2 Changer module 4
3 Turntable module 7
4 Smart Camera 10
5 Presence sensor 2
6 Belt conveyer module 8
7 Pneumatic actuator 5
8a Sorting gate module А 3
8b Sorting gate module В 6
8c Sorting gate module С 9

7. Click on the Finish field and choose the FINISH module (12). Click OK.
8. When finished, the sequence should look like it is shown in Fig. 9-4:

Fig. 9-4
We shall now set up the operations sequence for each module.

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 If the specified sequence does not coincide with fig. 9-4, then correct the error as follows:
double-click the module in the dialog box, select Delete Component; follow the directions given
in paragraphs 4-8.
9. Double click on the Magazine module. The following window will open (Fig. 9-5).

Fig. 9-5
10. On the Actions tab choose Turn On Magazine for the first action and Turn Off Magazine for
the second action (Fig. 9-5).
11. On the Conditions A tab choose Changer is Turned Off for the first condition and Magazine is
Turned On for the second condition (Fig. 9-6).

Fig. 9-6
12. Click Save to store the settings.
13. Set up the remaining modules based on the requirements in Table 9-1.

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Table 9-1
Step Action Condition A Condition B Condition C ELSE Description
(Module)
Initialization
Turn Off Magazine Turn off the Magazine and the Changer, i.e. return them to the
their initial positions. Other actions may be applied, if needed.
Turn Off Changer
1 (Magazine module)
Turn On Magazine Changer is Turn On the Magazine while the Changer is turned Off, otherwise
Turned Off the Changer may be damaged.
Turn Off Magazine Magazine is Turn Off the Magazine only when the work piece is fully pushed
Turned On out the Magazine module.
2 (Changer module)
Turn On Changer Magazine is Turn On the Changer after the Magazine is turned Off, otherwise
Turned Off the Changer may be damaged.
Turn Off Changer Changer is Turn Off the Changer and return it to the initial position.
Turned On
3 (Rotary indexing Table)
Forward Rotary Work piece isn't Table has Turn the Table by one segment if the previous turn has completed
indexing Table detected on the finished the and no work piece is detected in front of the Pusher (pneumatic
Table rotation actuator). Otherwise the work piece may damage the Pusher.
Forward Rotary Work piece isn't Table has Turn the Table by one segment if the previous turn has completed
indexing Table detected on finished the and no work piece is detected in front of the Pusher (pneumatic
Table rotation actuator). Otherwise the work piece may damage the Pusher.
4 (Smart Camera)
Detect the color of Determine the color of the work piece using the smart camera.
work piece

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5 (Work piece detector)
Detect work piece Detect work piece existence in front of the Pusher
existence on Table
6 (Conveyor)
Turn On Conveyor Conveyor is Turn On the Conveyer
Turned Off
7 (Pusher)
Turn On Pusher to - Turn On the Pusher to bring the work piece onto the Conveyor
bring the work piece
on Conveyor
Turn Off Pusher Pusher is Turned Turn Off the Pusher if the work piece reaches the end point
On
8a (Sorting Gate A)
Turn On Sorting Gate - Turn On the Sorting Gate A (later this will be a conditional action)
A
8b (Sorting Gate B)
Turn On Sorting Gate - Turn On the Sorting Gate B (later this will be a conditional action)
B
8c (Sorting Gate C)
Turn Off Sorting Turn Off the Sorting Gates (later this will be a conditional action)
Gates
Finish
Turn Off Conveyor Turn Off the Conveyer and turn Off the Sorting Gates to reset the
stand to the initial state (other actions may be applied, if needed)
Turn Off Sorting
Gates

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14. Click Run (Fig. 9-4). If the settings were right (selected settings will not damage the laboratory
stand), the window shown in Fig. 9-8 will open. Otherwise the wrong module and settings will
be displayed in the Error reports field (Fig. 9-7).

Fig. 9-7
15. Click Start in the Automated Production Line-Control window (Fig. 9-8). The laboratory stand
operation will start according to the assigned mode.
In case of wrong operations click Stop, close the window and resume from step 9.
16. Repeat several full cycles. When finished, click Stop. The laboratory stand will be stopped.
If you want to run the experiment after the system was stopped, click the Restart button in the
Automated Production Line-Control window (Fig. 9-8).
17. Close the software window (Fig. 9-8). Click Save File (Fig. 9-4) to save the settings in the file
Sequential_Programming.aplconfig file in the user folder.
18. Close the software panel.
19. Turn OFF the laboratory stand (see 8.2 Powering up and preparations).
Control:
Start - Start the system
Stop - Stop the system
Reset work piece counter - Resets
counter to zero
Restart - Restarts the program
Color detection: Displays camera output
in real-time. Special algorithms identify
the work piece and identify the color
which is the displayed under the Color
detection field.
Readiness of modules: Indicates the
readiness state for all modules. Indicators
of ready modules will be green.
Work pieces in sorting block: Indicates
Fig. 9-8 User Interface the number of processed work pieces for
each color.
Test Questions:
1. Describe the Programming mode of the Automated Production Line system.
2. Why do you need to be careful when setting up individual modules?
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9.3 Automatic Sequential mode
Lab objectives
Study of operating principles of the Automated Production Line in automatic sequential mode.
Work piece color recognition and sorting.
Hands-on procedure
In this lab we shall set up each module on the automated production line. The sequence is the
same as in the previous lab. In serial automatic mode no new work piece will enter the cycle
unless the whole processing cycle of the previous work piece has completed.
Step-By-Step Instructions
1. Turn ON the laboratory stand (see 8.2 Powering up and preparations).
2. Launch the Automated Production Line lab software.
3. Choose the Automatic Sequential mode from the lab list. Lab window will open (Fig. 9-9).

Fig. 9-9
4. Click Open File (Fig. 9-9) and choose the Sequential_Programming.aplconfig file from user
folder (Fig. 9-10).

Fig. 9-10
5. Set the sequence of operations of each module as in the previous lab. Sequentially select
each module by double clicking on it and set the modules based on the data in Table 9-2.
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Table 9-2
Step Action Condition A Condition B Condition C ELSE Description
(Module)
Initialization
Turn Off Magazine
Turn Off Changer
1 (Magazine module)
Turn On Magazine Changer is
Turned Off
Turn Off Magazine Magazine is
Turned On
2 (Changer module)
Turn On Changer Magazine is
Turned Off
Turn On vacuum Changer is (Action). Turn On vacuum upon fulfillment of the condition in
Turned On column A (the Changer is turned On, i.e. it is above the work piece)
Turn Off Changer Vacuum is Turned A: Turn Off (Action) Turn Off the Changer, if the vacuum is turned On
On Vacuum (Condition A) and the work piece is picked up by the vacuum
gripper. If not, (Else Action A) turn Off the vacuum (the Changer will
B: Skip current
return to initial position) and (ELSE Action B) skip current operation
sequence
Turn Off vacuum Changer is B: Skip current (Action) Turn Off the vacuum if the work piece has been picked up
Turned Off sequence by the Changer and the Changer has returned to the initial position
for placing the work piece in one of the turntable notches,
otherwise (ELSE Action B) skip the operation.

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3 (Rotary indexing Table)
Forward Rotary Work piece isn't Table has finished
indexing Table detected on the the rotation
Table
Forward Rotary Work piece isn't Table has finished
indexing Table detected on the rotation
Table
4 (Smart Camera)
Detect the color of
work piece
5 (Work piece detector)
Detect work piece Table has finished
existence on Table the rotation
6 (Conveyor)
Turn On Conveyor Work piece is (Action) Turn On the Conveyer if (Condition A) the work piece is
detected on the detected on the Rotary indexing Table.
Table
7 (Pusher)
Turn On Pusher to Conveyor is A: Skip current (Action) Turn On the Pusher if (Condition A) the Conveyer is turned
bring work piece to turned on sequence On and ready to transfer the work piece, otherwise (ELSE Action A)
Conveyor skip current action, as the work piece is not detected for further
transfer, or the Conveyer is faulty.
Turn Off Pusher Pusher is Turned
On
8a (Sorting Gate A)
Turn On Sorting Gate Color of work A: Continue (Skip (Action) Turn On the Sorting Gate A, if (Condition A) the color of
A piece is Red command) work piece is Red, otherwise (ELSE Action A) skip the command
and continue.

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8b (Sorting Gate B)
Turn On Sorting Gate Color of work A: Continue (Skip (Action) Turn On the Sorting Gate B, if (Condition A) the color of
B piece is Gray command) work piece is Gray, otherwise (ELSE Action A) skip the command
and continue.
8c (Sorting Gate C)
Turn Off Sorting Color of work A: Continue (Skip (Action) Turn Off the Sorting Gates if (Condition A) the color of work
Gates piece is White command) piece is White, otherwise (ELSE Action A) skip the command and
continue.
Finish
Turn Off Conveyor Sorting complete Turn Off the Sorting Gate and Conveyer if the work piece appears in
relevant place and complete sorting.
Turn Off Sorting Sorting complete
Gates

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6. Click Run.
7. In the Automated Production Line-Control window (Fig. 9-11) click Start.

Fig. 9-11
8. Follow the operation of the line. Make sure that the work pieces are passing through all
modules without any hindrance and finally appear in corresponding boxes.
9. Click Stop (Fig. 9-11).
10. Close the software panel.
11. Turn OFF the laboratory stand (see 8.2 Powering up and preparations).
Test Questions:
1. Describe the Automatic Sequential mode of production line automation systems.
2. What is the difference between the Programming and Automatic Sequential modes of
automation systems?

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9.4 Automatic Parallel mode
Lab objectives
Study of operating principles of the Automated Production Line in automatic parallel mode.
Sorting the work pieces by color.
Hands-on procedure
In this lab the laboratory stand will be programmed for operation of the modules in parallel mode.
In this mode the Magazine module will continue supplying new work pieces whilst the first work
piece has not completed the full processing cycle.
This operation mode is represented schematically in Fig. 9-12. You can see that the modules are
grouped in two groups and for each group the modules work sequentially. Upon completion of
the operation of the first group, the modules of the second group are activated, and the modules
of the first group are reactivated in parallel to this.
Consider, that among modules 8a, 8b, 8c in the second group only one module is activated at a
time (depending on work piece color). Therefore both cycles process the work piece in equal time.
Upon completion of the lab verify that only work pieces of definite color are placed in each sorting
box.
Step-By-Step Instructions
1. Turn ON the laboratory stand (see 8.2 Powering up and preparations).
2. Launch the Automated Production Line lab software.
3. Choose the Parallel automatic mode hands-on lab from the lab list. Lab window will open:

Fig. 9-12
4. Click on the Initialization field and choose the START module (11).
5. Click on the field #1 and choose the Magazine module (1), Fig. 9-13. Click OK to confirm the
selection.

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 Fig. 9-13
6. Click on the following fields and assign appropriate modules, as suggested in the table below.
Click OK to confirm each selection.
Field # Module Module #
2 Changer module 4
3 Turntable module 7
4 Smart Camera 10
5 Presence sensor 2
6 Belt conveyer module 8
7 Pneumatic actuator 5
8a Sorting gate module А 3
8b Sorting gate module В 6
8c Sorting gate module С 9

7. Click on the Finish field and choose the FINISH module (12).
8. When finished, the sequence should look like it is shown in Fig. 9-14:

Fig. 9-14
9. Set the sequence of operations of each module as in the previous lab. Sequentially select
each module by double clicking on it and set the modules based on the data in Table 9-3.
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Table 9-3
Step Action Condition A Condition B Condition C ELSE Description
(Module)
Initialization
Turn Off Magazine
Turn Off Changer
1 (Magazine module)
Turn On Magazine Changer is
Turned Off
Turn Off Magazine Magazine is
Turned On
2 (Changer module)
Turn On Changer Magazine is
Turned Off
Turn On vacuum Changer is
Turned On
Turn Off Changer Vacuum is Turned A: Turn Off (Action) Turn Off the Changer if (Condition A) the vacuum is turned
On Vacuum On (gripper picks up the work piece), if not (ELSE Action A)
immediately turn Off the vacuum (the Changer returns to the
initial position).
Turn Off vacuum Changer is
Turned Off
3 (Rotary indexing Table)
Forward Rotary Work piece isn't Table has finished In contrast to previous mode, turn the table by one segment only,
indexing Table detected on the the rotation as the next work piece will be placed in the next notch.
Table
4 (Smart Camera)
Detect the color of
work piece

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5 (Work piece detector)
Detect work piece Table has finished
existence on Table the rotation
6 (Conveyor)
Turn On Conveyor Workpiece is A: Skip current
detected on sequence
Table
7 (Pusher)
Turn On Pusher to Conveyor is A: Skip current
bring the work piece turned on sequence
on Conveyor
Turn Off Pusher Pusher is Turned A: Continue (Skip
On command)
8a (Sorting Gate A)
Turn On Sorting Gate Color of work Conveyor is A: Continue (Skip
A piece is Red turned On command)
8b (Sorting Gate B)
Turn On Sorting Gate Color of work Conveyor is A: Continue (Skip
B piece is Gray turned On command)
8c (Sorting Gate C)
Turn Off Sorting Color of work Conveyor is
Gates piece is White turned On
Finish
Turn Off Conveyor Sorting complete
Turn Off Sorting Sorting complete
Gates

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10. When finished, the following window will open (Fig. 9-14).
11. Click Run (Fig. 9-14).
In the open window (Fig. 9-15) click Start.

Fig. 9-15
12. Watch the operation of the system and note that several work pieces are simultaneously
involved in processing cycle.
13. Check the contents of Sorting boxes. Each module should only contain work pieces of definite
color.
14. Click Stop.
15. Close the software panel.
16. Turn OFF the laboratory stand (see 8.2 Powering up and preparations).
Test Questions
1. Describe the Automatic Parallel mode of the Automated Production Line.
2. What is the difference between the Sequential and Parallel Automatic modes of
operation?
3. Under which condition only a single work piece will be present on the line during the
processing cycle in Parallel mode?

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Laboratory stand Automated Production Line
Serial No. VT-APL301

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