Teaching training system based on smart factory application scene

Abstract

The invention discloses a teaching training system based on a smart factory application scene, and the system achieves the adaptation of flexible training and stepped teaching: through the flexible design of the independent actions of all units and the online actions of multiple units, not only is the basic skill training of a single unit satisfied, but also the complex system joint debugging among multiple units is supported, and the training efficiency is improved. The system meets the full-process teaching requirements from entry to advance, and is suitable for teaching and training of multiple majors such as mechanical manufacturing and automation thereof, mechatronics and the like.

Description

Technical Field

[0001] This invention belongs to the field of teaching and training technology, and relates to a teaching and training system based on a smart factory application scenario. Background Technology

[0002] With the increasing demands on vocational education for the training of opto-mechatronics professionals, practical teaching, skills assessments, and vocational competitions have placed higher standards on the comprehensiveness, flexibility, and safety of training equipment. Currently, existing training equipment has many shortcomings and is insufficient to meet the actual needs of teaching and practical training. Existing training equipment is mostly designed for single functions, enabling only basic training in a single skill point. It cannot handle complex system control, programming, and debugging training involving multiple interconnected units, making it difficult to meet the needs of tiered teaching from beginner to advanced levels. Furthermore, different institutions purchase PLCs and automation equipment from various brands, and the communication protocols of these brands are incompatible, resulting in poor scalability of the training systems and an inability to interface with existing teaching equipment, thus increasing teaching costs.

[0003] To address the aforementioned technical challenges and meet the teaching, assessment, and skills competition needs of the opto-mechatronics major, developing a training system that integrates flexible training, multi-technology integration, safety, reliability, and remote control has become an urgent technical issue. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, this invention provides a training and education system based on smart factory application scenarios.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A training system based on a smart factory application scenario includes a training device and a control system. The training device includes a training platform and a feeding unit, a conveying unit, a processing unit, an assembly unit, and a sorting unit set on the training platform. The feeding unit, conveying unit, processing unit, assembly unit, and sorting unit are each equipped with the control system. The control system includes a communication module and a PLC. Multiple PLCs in the control system form a communication network through the communication module.

[0006] Furthermore, the communication module includes an industrial switch and a wireless communication gateway, wherein the industrial switch is used to construct a Profinet network.

[0007] Furthermore, the control module also includes a frequency converter, a servo system, a touch screen connected to the PLC via a Profinet network, and a monitoring layer connected to an external computer via a wireless communication gateway.

[0008] Furthermore, the training platform includes a tabletop for installing the feeding unit, conveying unit, processing unit, assembly unit, and sorting unit, and a table frame disposed below the tabletop. The bottom of the table frame is equipped with casters, and the interior of the table frame...

[0009] Furthermore, the feeding unit, conveying unit, processing unit, assembly unit, and sorting unit each adopt independent power supplies and filter pressure reducing valves, and the feeding unit, conveying unit, processing unit, assembly unit, and sorting unit are connected by communication cables for signal interaction and air pipes for air supply.

[0010] Furthermore, the feeding unit 3 includes a vertical material cylinder, a top material cylinder, a push material cylinder, a material detection sensor component, a material detection device, and a terminal block with protection. The top material cylinder is arranged directly below the vertical material cylinder and is used to move inside the vertical material cylinder and push the material. The push material cylinder is located on one side of the vertical material cylinder, and the axis of the push material cylinder is perpendicular to the axis of the vertical material cylinder.

[0011] Furthermore, the conveying unit includes a robotic arm and an auxiliary positioning cylinder; the robotic arm performs grasping with the set area, and the auxiliary positioning cylinder is disposed around the set area.

[0012] Furthermore, the processing unit includes a sliding table, a simulated punch, a punch press bracket, and a synchronous belt drive mechanism; the sliding table is disposed on the synchronous belt drive mechanism and moves between at least two positions through the synchronous belt drive mechanism; the simulated punch is mounted on the punch press bracket and moves toward the sliding table in one of the positions.

[0013] Furthermore, the assembly unit includes a feeding mechanism, a rotary feeding unit, an assembly robotic arm, and a discharging platform; the feeding mechanism includes an auxiliary material cylinder and an auxiliary material ejecting cylinder for ejecting material from the auxiliary material cylinder; the rotary feeding unit includes a rotary table and a stepper motor for driving the rotary table to rotate; the feeding mechanism, the assembly robotic arm, and the discharging platform are respectively arranged on the periphery of the rotary table.

[0014] Furthermore, the sorting unit includes a conveyor belt, a sorting pneumatic assembly, and a hopper; the sorting pneumatic assembly includes three sorting cylinders arranged sequentially along the length of the conveyor belt on one side; the hopper is configured as multiple hoppers, each corresponding to one of the sorting cylinders; and the hopper is fixed to the outside of the conveyor belt by a bracket.

[0015] In summary, the advantages of this invention are: This invention achieves flexible training and tiered teaching adaptation: through the flexible design of independent actions in each unit and multi-unit online actions, it not only meets the basic skills training of a single unit, but also supports the complex system integration between multiple units, covering the entire teaching process from beginner to advanced, and is suitable for teaching and training in multiple majors such as mechanical manufacturing and automation, mechatronics, etc.

[0016] Through the multi-interface structure design of the wireless communication gateway, it is compatible with a variety of industrial communication protocols, enabling seamless connection of equipment from different brands, supporting a large number of slave stations to communicate concurrently, adapting to existing teaching equipment in schools and colleges, reducing equipment upgrade costs, and reserving expansion interfaces to facilitate future function upgrades.

[0017] The equipment adopts a multi-layered safety protection structure, including an independent grounding structure, an integrated leakage protection design, high-insulation sockets, and insulated wire arrangement, which meets national standards. The mechanical structure is assembled with industrial aluminum and steel profiles, reinforced with triangular ribs, and fixed with positioning holes to ensure stable equipment load-bearing capacity and secure installation, effectively avoiding electrical and mechanical safety risks.

[0018] The monitoring layer enables remote control through a layered communication structure, allowing real-time display of equipment operating status, parameter modification, and recording of training data. The three-phase power monitor enables real-time monitoring of all electrical parameters and fault warnings through a dedicated communication interface, facilitating teachers to accurately grasp the progress of training, trace teaching data, and improve teaching management efficiency.

[0019] The training platform adopts an industrial-grade aluminum profile assembly structure with high load-bearing capacity. The bottom casters facilitate equipment movement. The perforated plate drawers are designed with pre-set threaded holes and adjustable guide rails, allowing for flexible equipment arrangement. Each unit base plate is firmly connected to the tabletop through positioning holes, ensuring stable equipment operation and adapting to the layout requirements of different training scenarios.

[0020] Each unit constructs a real-time communication structure through a Profinet network or Profibus network. The collaborative control logic ensures precise action timing, and the collaborative fault handling responds quickly through the signal transmission structure, reducing training interruption time. The integrated design of the structure, which integrates technologies from multiple fields such as mechanics, pneumatics, PLC, and sensors, allows students to master comprehensive skills in practical operation, meeting the requirements of vocational ability assessment and skills competition.

[0021] The modular structure design allows each unit to be repaired independently, reducing overall equipment downtime; the unified use of standardized interfaces and universal connection structures facilitates equipment maintenance and parts replacement; the multi-protocol compatible structure design avoids duplicate equipment purchases, significantly reducing the overall cost of teaching and maintenance. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the training device of the present invention.

[0023] Figure 2 for Figure 1 A structural diagram from another perspective.

[0024] Figure 3 This is a structural block diagram of the training system of the present invention.

[0025] The diagram is labeled as follows: 11. Tabletop; 12. Table frame; 13. Perforated panel drawer; 2. Conveying unit; 3. Feeding unit; 4. Processing unit; 5. Distributing unit; 6. Assembly unit. Detailed Implementation

[0026] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that, unless otherwise specified, the following embodiments and features described therein can be combined with each other.

[0027] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Therefore, the drawings only show the components related to the present invention and are not drawn according to the actual number, shape and size of the components. In actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0028] In this embodiment of the invention, all directional indicators (such as up, down, left, right, front, back, lateral, longitudinal, etc.) are only used to explain the relative positional relationship and movement of each component in a specific posture. If the specific posture changes, the directional indicator will also change accordingly.

[0029] Due to installation errors and other reasons, the parallel relationship referred to in the embodiments of the present invention may actually be an approximate parallel relationship, and the perpendicular relationship may actually be an approximate perpendicular relationship.

[0030] This invention provides a training system based on smart factory application scenarios, comprising a training platform, a material feeding unit 3, a collaborative robotic conveying unit 2, a processing unit 4, an assembly unit 6, and a classification unit. The control system uses a PLC for control, which has good flexible control. Each unit has its own independent PLC control system. After the basic unit module training is completed, two, three, or even five adjacent units can be connected together to learn the control, programming, assembly, and debugging techniques of complex systems.

[0031] This training device was developed and manufactured based on the actual needs of colleges and universities in training students in opto-mechatronics control theory, assessing professional abilities, and conducting skills competitions. It is a practical opto-mechatronics training device that aligns with automated teaching and practice. This device encompasses a wide range of electrical control technologies involved in mechatronics and related majors, including mechanics, transmission, pneumatics, sensors, PLC, variable frequency speed control, human-machine interfaces, and network communication. It is a typical mechatronics training product specifically designed for vocational colleges, technical schools, and vocational education and training institutions. It is suitable for teaching and training in mechanical manufacturing and automation, mechatronics, mechatronics engineering, electrical engineering and automation, automation engineering, control engineering, and computer control technology. This highly practical experimental equipment, designed to improve students' hands-on abilities and practical skills, is an ideal device for mechatronics professional education and training.

[0032] The training system is also equipped with a three-phase power monitoring instrument, which has overcurrent, overload, overvoltage, undervoltage, and leakage current monitoring and protection measures. It supports 4-channel PT100 high-precision temperature measurement, 4-channel opening and closing and expandable status input detection, 2-channel digital actionable output, and the set values ​​can be set locally via menu or remotely via PC. It has the function of remotely monitoring the voltage, current, power, power factor, 25th harmonic, sub-metering, and 4-quadrant power metering of each experimental device in real time, and supports standard Modbus RTU 485 and Ethernet communication.

[0033] It also includes a wireless communication gateway module, which supports PLC protocol acquisition from Siemens, Mitsubishi, Omron, Delta, Xinje, Schneider, and other manufacturers; supports mainstream protocols such as S7, FX, and FINS; supports Modbus RTU Master, Modbus TCP Master, DL / T645, open source or standard IEC protocols, BACnet IP, BACnet MS / TP, and other protocols; after acquisition, it can be converted to Modbus TCP, MQTT, BACnet IP, and other protocols for forwarding, supporting ≥32 slave stations for concurrent communication; the product is developed using an embedded Linux system and has high stability; structurally, the module provides 4 serial port inputs (1 RS232 serial port plus 3 RS485 / RS232 serial ports which can be configured via jumpers or software), 2 Ethernet ports (WAN and LAN ports), 2 USB interfaces, 1 main power supply and 1 backup power supply input.

[0034] The control system used in each unit of the training system includes a core layer, a control layer, a field layer, and a monitoring layer. The core layer includes an industrial switch and a wireless communication gateway, which are responsible for data aggregation and core communication. The control layer uses a Siemens S7-1200 PLC and builds a Profinet network or Profibus network through the industrial switch to realize real-time communication between devices. The field layer includes devices such as frequency converters, servo systems, and touch screens, which are connected to the PLC through Profinet. The monitoring layer uses MES software and configuration software running on a computer and realizes remote monitoring through a wireless gateway or wired connection. It can display the operating status of each unit in real time (such as cylinder extension and retraction, motor start and stop, sensor detection results), modify PLC parameters (such as cylinder action delay, motor speed), and record training data (such as the number of unit actions and fault alarm information).

[0035] Specifically, the training platform includes a tabletop 11 and a table frame 12 below the tabletop 11. The tabletop 11 and the table frame 12 are assembled from 20*80 industrial aluminum profiles, and the corners are fixed with triangular strong reinforcing ribs to ensure that the table frame 12 is stable and does not wobble. The bottom of the table frame 12 is equipped with four nylon casters with brakes. The casters are connected to the aluminum profile of the table frame 12 with M10 bolts, so that it can bear a weight of more than 300kg. The tabletop 11 is equipped with a 50mm high protective baffle around its perimeter to prevent materials from falling or tools from slipping during training.

[0036] The table frame 12 has an internal power control box, which integrates a three-phase leakage current protector (rated current 63A, leakage current ≤30mA), an air switch (each unit is independently equipped with a 10A single-phase air switch), power indicator lights, and terminal blocks. The training system is powered by AC power, with specifications of three-phase five-wire AC 380 V±10% 50Hz, and has grounding protection and leakage protection functions, and its safety meets relevant national standards. It uses high-insulation safety sockets and high-strength safety experimental wires with insulating sheaths.

[0037] The table frame 12 features four drawers on both sides, each made of perforated metal. The drawers utilize three-section silent guide rails, allowing for flexible equipment installation. The perforated metal drawers 13 come in two types, A and B. Type A drawers are used to install small control devices such as PLC modules and sensor junction boxes, while type B drawers are used to store cylinder parts, tools, etc. Label slots are provided on the outside of the drawers for labeling the contents. M4 threaded holes are pre-drilled in the perforated metal panels, allowing for bolt mounting of the equipment bracket or direct installation of the equipment.

[0038] The five units of the training system each use an independent power supply and a filter pressure reducing valve, enabling them to complete the experimental process independently. The units are connected to each other through dedicated communication cables and air pipes to achieve signal interaction and air supply during online operation.

[0039] I. The feeding unit 3 includes a vertical material cylinder, a top-feeding cylinder, a pusher cylinder, a material detection sensor component, a mounting bracket platform, a material detection device component, and a terminal block with protection, etc. The vertical material cylinder has an 80mm diameter outlet at its bottom and is fixed to the mounting bracket platform with four M5 bolts. The mounting bracket platform is welded to a designated position on the base plate. The top-feeding cylinder is installed directly below the vertical material cylinder, and its cylinder body is fixed to the base plate with an L-shaped bracket. A circular top-feeding plate is installed at the top of the cylinder piston rod for moving within the vertical material cylinder and pushing material. The pusher cylinder is horizontally installed on the right side of the vertical material cylinder, with its axis perpendicular to the vertical material cylinder's axis. The cylinder body is fixed to the base plate with a U-shaped bracket. An L-shaped pusher plate is installed at the end of the pusher cylinder piston rod, with a 2mm gap between the pusher plate and the upper surface of the top-feeding plate to prevent material jamming.

[0040] The material detection sensor component includes three photoelectric sensors. One is installed in the middle of the vertical material cylinder and fixed by a clamp to detect whether there is material in the material cylinder. Another is installed directly above the top material plate and fixed to the mounting bracket platform by an L-shaped bracket to detect whether the top material plate has pushed the material into position. The third is installed at the end of the piston rod of the pusher cylinder and fixed to the cylinder body by a bracket to detect whether the pusher plate has pushed the material to the gripping position of the conveying unit 2. The material detection device component is a capacitive sensor installed at the end of the pusher path and fixed to the base plate by a bracket to distinguish the material material.

[0041] The base plate of the feeding unit 3 is made of 380mm*310mm*15mm steel plate, which ensures the stability and levelness of the equipment. There are four positioning holes with a diameter of 7mm on the base plate for connecting with the table 11, which ensures that the feeding unit 3 is installed firmly and stably. Four M4 threaded holes are set on the edge of the base plate (located at the four corners of the base plate, 10mm away from the edge) for fixing the air pipe clamp and cable clamp to avoid the pipeline from being messy.

[0042] The feeding unit 3 can operate independently or in multi-station connection. It uses 24V DC power and is powered by the DC24V switching power supply of the training platform. The power cord is connected through a protected terminal block unit. It includes one solenoid valve (installed on the right side of the base plate and fixed by a bracket), two double-acting cylinders (top material cylinder and push material cylinder), one air source switch (installed at the outlet of the filter pressure reducing valve for manual air supply cut-off), two magnetic switch sensors (installed at both ends of the cylinder body of the top material cylinder and the push material cylinder respectively for detecting the cylinder piston position), a PLC module (installed in the drawer 13 of the type A perforated plate and connected to the sensors and solenoid valve on the base plate through a dedicated cable), three photoelectric sensors, and a multi-functional integrated interface (installed on the front side of the base plate and can be directly connected to the interface of the conveying unit 2 through a dedicated cable, or connected by a single terminal block to realize the interaction of sensor signals and control signals).

[0043] Single-station operation flow of feeding unit 3: Manually turn on the air source switch and adjust the pressure of the filter pressure reducing valve to 0.5MPa; the PLC sends a signal to the solenoid valve of the top material cylinder, the solenoid valve is energized, the piston rod of the top material cylinder extends, and lifts the material at the bottom of the cylinder to the pushing position; the magnetic switch at the end of the top material cylinder detects that the piston rod has extended to the correct position and sends a signal to the PLC; after receiving the signal, the PLC sends a signal to the solenoid valve of the pushing cylinder, the piston rod of the pushing cylinder extends, and pushes the material to the gripping position of conveying unit 2; the magnetic switch at the end of the pushing cylinder detects that the piston rod has extended to the correct position, and at the same time the photoelectric sensor detects that the material has reached the gripping position and sends a signal to the PLC; the PLC controls the solenoid valve of the pushing cylinder to de-energize, the piston rod retracts, and then the solenoid valve of the top material cylinder de-energizes, the piston rod retracts, completing one feeding action; if the material detection device detects that the material is abnormal, the PLC controls the alarm light to flash.

[0044] II. Conveying Unit 2 includes a six-degree-of-freedom robotic arm, a solenoid valve assembly, an auxiliary positioning cylinder, an air source switch, a magnetic switch sensor, a PLC module, a terminal block unit with protection, and a robotic arm controller. The six-degree-of-freedom robotic arm is fixed to the robotic arm mounting base (the mounting base has four positioning holes at the bottom that match the positioning holes on the base plate) by four M10 bolts. The mounting base is welded to the middle of the base plate. A two-finger pneumatic gripper is installed at the end of the robotic arm, and a photoelectric sensor is installed on the gripper to detect whether the gripper has grasped the material.

[0045] The auxiliary positioning cylinder is installed below the gripping position of the robotic arm, at the corresponding position of the pushing end of the feeding unit 3. The cylinder body is fixed to the base plate by an L-shaped bracket, and a positioning block is installed at the top of the piston rod for auxiliary positioning during material gripping to prevent material deviation. A magnetic switch sensor is installed next to the positioning cylinder to detect the position of the piston rod of the positioning cylinder.

[0046] The solenoid valve assembly (containing three solenoid valves) is installed in the middle right side of the base plate and fixed by a bracket. One of them controls the auxiliary positioning cylinder, and the other two control the clamping and releasing of the pneumatic grippers (the grippers are double-acting, requiring two solenoid valves to control the clamping and releasing actions respectively). The air source switch is installed at the outlet of the filter pressure reducing valve, with the same structure as the feeding unit 3. The terminal block with protection is installed in the middle front side of the base plate and includes power terminals, signal terminals, and communication terminals. The power terminals are connected to DC24V, the signal terminals are connected to the sensors and solenoid valves, and the communication terminals are connected to the interface modules of the feeding unit 3 and the processing unit 4 via Profinet cables.

[0047] The six-degree-of-freedom robotic arm has a payload capacity of ≥3kg and a working radius of ≥600mm, covering the gripping position of the feeding unit 3, the feeding position of the processing unit 4, and the feeding position of the assembly unit 6. It has ≥6 rotary joints (including base rotary joint, shoulder swing joint, elbow swing joint, wrist rotary joint, wrist swing joint, and gripper rotary joint). Its I / O port parameters include: digital input (DI) ≥2 (connected to gripper photoelectric sensor signals and auxiliary positioning cylinder magnetic switch signals respectively), digital output (DO) ≥2 (controlling gripper clamping indicator and robotic arm running indicator respectively), analog input (AI) ≥1 (connected to robotic arm end force sensor signals, optional), and analog output (AO) ≥1 (controlling the rotation speed of the robotic arm end gripper).

[0048] Conveying unit 2 can operate independently or in multi-station tandem, using 24V DC voltage; it includes three solenoid valves (solenoid valve group), one auxiliary positioning cylinder, one air source switch, two magnetic switch sensors (installed at both ends of the auxiliary positioning cylinder respectively), and a PLC module (installed in drawer 13 of type A perforated plate, communicating with the robotic arm controller via Profinet to realize robotic arm motion control, and equipped with a protected terminal block unit); the connection between conveying unit 2 and feeding unit 3 and processing unit 4 is achieved through a multi-functional integrated interface, wherein the interface with feeding unit 3 transmits material arrival signal and gripping completion signal through a dedicated cable, and the interface with processing unit 4 transmits material arrival at processing position signal and processing completion signal.

[0049] The online operation flow of conveying unit 2 is as follows: Feeding unit 3 sends a material arrival signal to the PLC of conveying unit 2; upon receiving the signal, the PLC controls the robotic arm base to rotate to the gripping position of feeding unit 3, and the shoulder and elbow swing until the gripper aligns with the material; simultaneously, the PLC controls the auxiliary positioning cylinder solenoid valve to energize, the cylinder piston rod extends, and the positioning block lifts the bottom of the material; the robotic arm end gripper descends to 5mm above the material, and the PLC sends a signal to the gripper solenoid valve, causing the gripper to clamp the material; the photoelectric sensor on the gripper detects the material and sends a successful gripping signal to the PLC; the PLC controls the auxiliary positioning cylinder piston rod to retract, and the robotic arm carries the material to the feeding position of processing unit 4; processing unit 4 sends a feeding position idle signal to the PLC of conveying unit 2; the robotic arm adjusts its posture and places the material on the sliding platform of processing unit 4; the gripper releases, the photoelectric sensor detects that the material has been released, and sends a placement completion signal to the PLC; the PLC controls the robotic arm to return to the initial position and simultaneously sends a material arrival signal to processing unit 4, completing one conveying operation.

[0050] III. Processing Unit 4 includes a sliding table, a simulated punch, a punch press bracket, a unit with protective terminals, a synchronous belt drive mechanism, a servo motor, etc.; the sliding table is mounted on two parallel linear guide rails, and a material positioning groove is opened on the top of the sliding table; the synchronous belt drive mechanism includes a synchronous belt, a driving synchronous pulley, and a driven synchronous pulley. The driving synchronous pulley is connected to the output shaft of the servo motor by a key, the driven synchronous pulley is fixed to the right side of the base plate by a bearing seat, and the synchronous belt is connected to the bottom of the sliding table by a synchronous belt clamp to realize the left and right movement of the sliding table.

[0051] The simulated punch is mounted on the slide of the punch press bracket. The slide is connected to the base of the punch press bracket via two guide columns. A linear bearing is installed between the guide columns and the slide to ensure smooth up-and-down movement of the slide. The punch press bracket is fixed on the right side of the base plate, located at the end of the sliding table's movement path. The punch axis is aligned with the center of the sliding table's positioning groove. A double-acting cylinder is installed on the top of the bracket to drive the punch's up-and-down movement. The cylinder piston rod is connected to the top of the slide via a floating joint to prevent cylinder jamming caused by installation errors.

[0052] The base plate of processing unit 4 is made of 380mm*400mm*15mm steel plate, which ensures the stability and levelness of the equipment. There are four positioning holes on the base plate for connecting to the table 11 with bolts, which ensures that the processing unit 4 is installed firmly and stably. A servo motor driver is installed in the middle of the left side of the base plate, and a power filter is installed next to the driver to suppress power interference. An air pipe and cable routing groove is set on the rear side of the base plate, and pipe clamps and wire clamps are installed in the groove to fix the pipeline.

[0053] Processing unit 4 can operate independently or in multi-station connection, using 24V DC voltage; it includes one solenoid valve (installed on the left side of the punch support to control the punch cylinder), one double-acting cylinder (punch drive cylinder), one air source switch (installed at the outlet of the filter pressure reducing valve), two magnetic switch sensors (installed at the upper and lower ends of the punch cylinder body respectively to detect whether the punch has reached the "to be processed position" and "processing completed position"), a PLC module (installed in type A perforated plate drawer 13, connected to the servo motor driver, sensors, and solenoid valve), two synchronous pulleys (drive pulley and driven pulley) and a multi-functional integrated interface (installed on the left side of the front of the base plate, connected to the interface of conveying unit 2 and assembly unit 6 through a dedicated cable to transmit material arrival signal, processing completed signal, and assembly request signal).

[0054] The online operation flow of processing unit 4 is as follows: Conveying unit 2 sends a signal that the material has arrived at the processing position to the PLC of processing unit 4; after receiving the signal, the PLC controls the servo motor driver to drive the synchronous belt transmission mechanism, and the sliding table carries the material to move towards the punch to the processing position; after the sliding table moves into place, the servo motor driver sends a position completion signal to the PLC; the PLC sends a signal to the solenoid valve of the punch cylinder, the solenoid valve is energized, the cylinder piston rod extends, and the punch moves downward to simulate processing of the material (such as punching and drilling); the magnetic switch at the lower end of the punch cylinder detects that the piston rod has extended into place (processing is complete) and sends a signal to the PLC; the PLC controls the solenoid valve of the punch cylinder to de-energize, the piston rod retracts, and the punch returns to the waiting position; the magnetic switch at the upper end of the punch cylinder detects that the piston rod has retracted into place, the PLC controls the servo motor to reverse, and the sliding table returns to the initial position; the PLC sends a processing completion signal to conveying unit 2 and assembly unit 6, waiting for conveying unit 2 to convey the processed material to assembly unit 6.

[0055] IV. Assembly unit 6 includes a feeding mechanism (including auxiliary material cylinder and auxiliary material lifting cylinder), a rotary feeding unit (including rotary table and stepper motor), a robotic arm assembly unit 6 (including assembly robotic arm and assembly gripper), a feeding platform, a unit with protective wiring terminals, and a fiber optic sensor calibration bracket, etc. The feeding mechanism is installed on the left side of the base plate, the auxiliary material cylinder is fixed to the base plate by the bracket, the auxiliary material lifting cylinder is vertically installed directly below the cylinder to lift the material inside the auxiliary material cylinder, and a photoelectric sensor is installed next to the auxiliary material lifting cylinder to detect whether the auxiliary material has been lifted into place.

[0056] The rotary feeding unit is located in the middle of the base plate. The rotary table is mounted on the base plate through a bearing seat. The bottom of the rotary table is connected to the output shaft of the stepper motor through a coupling. The stepper motor is mounted under the base plate and is used to drive the rotary table to rotate clockwise or counterclockwise. A photoelectric sensor is installed on the edge of the rotary table to detect whether the rotary table has rotated to the correct position. The feeding mechanism, assembly robot arm and unloading platform are respectively set on the periphery of the rotary table.

[0057] The robotic arm assembly unit 6 is installed on the right side of the base plate. The assembly robotic arm is a four-degree-of-freedom robotic arm, which is fixed to the base plate by a mounting base. An assembly gripper is installed at the end of the robotic arm to grab auxiliary materials and assemble them onto the processed materials. A fiber optic sensor is installed next to the assembly robotic arm on a calibration bracket. The height of the calibration bracket is adjustable and is used to detect the assembly accuracy, such as the coaxiality and fit between the auxiliary materials and the processed materials.

[0058] The surface of the feeding platform has a positioning groove, which is installed in the middle of the back side of the base plate. A weight sensor is installed at the bottom of the feeding platform to detect whether there are assembled materials on the feeding platform. A three-color indicator light is installed next to the feeding platform to indicate the status of "to be assembled", "in assembly" and "assembly completed".

[0059] The base plate of assembly unit 6 is made of steel plate with a diameter of not less than 370mm*390mm*15mm, which ensures the stability and levelness of the equipment. The base plate has positioning holes for connecting to the table 11 with bolts, which ensures that the assembly unit 6 is installed firmly and stably. Three pipeline fixing seats are set on the base plate (located next to the feeding mechanism, the rotary feeding unit, and the robot assembly unit 6, respectively) to fix the air pipes and cables and prevent the pipelines from getting tangled.

[0060] Assembly unit 6 has two assembly methods: horizontal and vertical. Horizontal assembly: The assembly robot arm horizontally grasps the auxiliary material and presses it horizontally onto the processed material on the rotary table, which is suitable for flat materials. Vertical assembly: The assembly robot arm vertically grasps the auxiliary material and inserts it vertically into the assembly hole of the processed material, which is suitable for columnar auxiliary materials. The two assembly methods are achieved by switching PLC programs without changing the mechanical structure, ensuring the flexibility and versatility of the equipment.

[0061] Assembly unit 6 can operate independently or in multi-station connection, using 24V DC voltage; it includes one solenoid valve (controlling the auxiliary material lifting cylinder), one double-acting cylinder (auxiliary material lifting cylinder), one air source switch (installed at the outlet of the filter pressure reducing valve), two magnetic switch sensors (installed at both ends of the auxiliary material lifting cylinder), a PLC module (installed in type A perforated plate drawer 13, connected to the stepper motor driver, assembly robot arm controller, and sensors), one fiber optic sensor, three-color indicator lights, and a multi-functional integrated interface (installed in the middle of the front side of the base plate, connected to the interface of processing unit 4 and material sorting unit 5 through a dedicated cable, transmitting assembly request signals, assembly completion signals, and sorting request signals).

[0062] Assembly Unit 6 Online Operation Flow: Processing Unit 4 sends a processing completion signal, while Conveying Unit 2 transports the processed material to the positioning hole of the rotary table in Assembly Unit 6; the rotary table photoelectric sensor detects the material and sends a material arrival signal to the PLC; the PLC controls the auxiliary material lifting cylinder to extend, lifting the auxiliary material to the gripping position, and the auxiliary material photoelectric sensor sends an auxiliary material arrival signal; the PLC controls the assembly robotic arm to grip the auxiliary material and adjust its posture according to the preset "horizontal / vertical assembly" program; the rotary table rotates to the assembly position under the drive of the stepper motor, and the PLC controls the robotic arm to assemble the auxiliary material onto the processed material; the fiber optic sensor detects the assembly accuracy, and if it is qualified, it sends an assembly qualified signal; if it is unqualified, it controls the three-color indicator light to flash yellow; after the assembly is qualified, the robotic arm returns to the initial position, the rotary table rotates to the unloading position, and places the assembled material on the unloading platform; the weight sensor detects the material and sends a unloading completion signal to the PLC; the PLC controls the three-color indicator light to light up green, and simultaneously sends an assembly completion signal to the material distribution unit 5, waiting for the material distribution unit 5 to receive the material.

[0063] V. The material sorting unit 5 includes a conveyor belt mechanism, a three-phase motor power unit, a sorting pneumatic assembly (including a sorting cylinder and a pusher plate), a sensor detection unit (including a material sensor and a size sensor), a high-precision feedback and positioning mechanism (including an encoder and a positioning photoelectric switch), a unit with protective wiring terminals, a hopper support, etc.; wherein, the conveyor belt mechanism is installed in the middle of the base plate, and the two ends of the conveyor belt are equipped with a drive roller and a driven roller. The drive roller is connected to the three-phase motor power unit through a coupling.

[0064] The three-phase motor power unit includes a three-phase asynchronous motor, a reducer, and a frequency converter. The motor and reducer are fixed to the lower right side of the base plate by a motor bracket. The frequency converter communicates with the PLC through Profinet to realize the speed adjustment of the conveyor belt.

[0065] The sorting pneumatic assembly includes three sorting cylinders, which are installed at three sorting positions on the left side of the conveyor belt. The cylinder body is fixed to the base plate by a U-shaped bracket. A sorting pusher plate is installed at the top of the piston rod (a rubber pad is pasted on the surface of the pusher plate to prevent the material from being scratched). A magnetic switch sensor is installed next to each sorting cylinder to detect whether the pusher plate has extended into place.

[0066] The sensor detection unit is installed at the conveyor belt inlet and includes a material sensor (for distinguishing between metal and non-metal materials) and a size sensor (installed 50mm directly above the conveyor belt via a bracket for detecting material size and distinguishing between large, medium, and small sizes). The high-precision feedback and positioning mechanism includes an encoder (connected to the drive roller via a synchronous belt for detecting the conveyor belt running distance) and three positioning photoelectric switches (installed on the right side of the conveyor belt at the corresponding positions of the three sorting cylinders for locating the material position).

[0067] The hopper support is installed on the left side of the base plate, corresponding to the positions of the three sorting cylinders. Three hoppers are placed on the hopper support, and a material inlet is set at the bottom of the hopper. The height difference between the material inlet and the surface of the conveyor belt is 10mm to ensure that the sorting pusher plate can push the material smoothly into the hopper.

[0068] The base plate of the material distribution unit 5 is made of 740mm*300mm*15mm aluminum plate, which ensures the stability and levelness of the equipment. The base plate has positioning holes for connecting to the table 11 with bolts, which ensures that the material distribution unit 5 is installed firmly and stably. Four support feet are installed under the base plate for fine adjustment of the levelness of the base plate.

[0069] The material sorting unit 5 can operate independently or in multi-station connection, using 24V DC voltage; it includes one geared motor, one conveyor line, one material blocking solenoid valve (installed at the conveyor belt inlet to control the material blocking plate and prevent material accumulation), three sorting cylinders, three hoppers, three photoelectric sensors, six magnetic switch sensors (two are set for each sorting cylinder to detect the extension and retraction positions), a PLC module (installed in type B perforated plate drawer 13, connected to the frequency converter, sensors, and solenoid valve), one encoder, and a multi-functional integrated interface (installed on the front right side of the base plate, connected to the assembly unit 6 interface via a dedicated cable, transmitting material arrival and sorting completion signals).

[0070] The operation flow of the material sorting unit 5 is as follows: Assembly unit 6 sends an assembly completion signal, and simultaneously conveying unit 2 transports the assembled material to the conveyor belt inlet of material sorting unit 5; the material blocking solenoid valve is energized, the material blocking plate retracts, and the material enters the conveyor belt; the sensor detection unit performs material and size detection on the material and sends the detection results to the PLC; the encoder detects the conveyor belt running distance in real time, and when the material reaches the first positioning photoelectric switch position, the PLC determines whether sorting is required based on the detection results: if it is a large metal material, the PLC... The first sorting cylinder solenoid valve is energized, extending the pusher plate and pushing the material into the first hopper. For non-metallic medium-sized materials, the material continues to move with the conveyor belt. When it reaches the second positioning photoelectric switch, the second sorting cylinder activates, pushing the material into the second hopper. For small-sized materials, the third sorting cylinder activates when the material reaches the third positioning photoelectric switch, pushing the material into the third hopper. The magnetic switch of the sorting cylinder detects the pusher plate's extension and sends a signal to the PLC. The PLC de-energizes the sorting cylinder solenoid valve, retracting the pusher plate and simultaneously sending a sorting completion signal to the monitoring layer MES software to record the sorting data. If the material detection result shows no matching hopper, the PLC controls the alarm light at the end of the conveyor belt to flash, and the conveyor belt stops running, awaiting manual handling.

[0071] VI. Five-unit online collaborative control logic Communication and Collaboration: The five PLC units form a Profinet network through an industrial switch to ensure real-time signal transmission; the wireless communication gateway connects to the Profinet network, converts the data from each PLC unit into MQTT protocol, and uploads it to the monitoring layer configuration software to achieve remote monitoring.

[0072] Action sequence coordination: A master-slave control mode is adopted, with the PLC of conveying unit 2 as the master PLC and the PLCs of other units as slave PLCs. The master PLC sends action instructions through Profinet. After receiving the instructions, the slave PLCs execute the corresponding actions and feed back action status signals. For example: feeding unit 3 (slave control) → conveying unit 2 (master control) → processing unit 4 (slave control) → assembly unit 6 (slave control) → distributing unit 5 (slave control). After each unit completes its action, it must feed back a completion signal before the master PLC can send the action instructions for the next unit to avoid action disorder.

[0073] Collaborative Fault Handling: When any unit malfunctions (e.g., sensor fails to detect material, cylinder timing out), the unit's PLC immediately sends a fault signal to the main control PLC and the monitoring layer. Upon receiving the fault signal, the main control PLC immediately stops all units and sends a fault interlock signal to prevent other units from starting. The monitoring layer's KingSCADA software displays the faulty unit, fault type, and fault code, and simultaneously issues an audible and visual alarm. After the fault is cleared, a manual fault reset signal is sent via the touchscreen. Upon receiving this signal, the main control PLC releases the interlock, and all units return to their initial state and resume online operation.

[0074] Parameter Coordination Adjustment: The monitoring layer MES software can uniformly set key parameters for each unit, such as the action delay of the top cylinder of the feeding unit 3, the moving speed of the robotic arm of the conveying unit 2, the punch pressure of the processing unit 4 (achieved by adjusting the pressure of the filter pressure reducing valve), the assembly accuracy threshold of the assembly unit 6, and the conveyor belt speed of the material distribution unit 5. After the parameters are set, they are synchronously sent to the PLC of each unit through Profinet to ensure parameter consistency.

[0075] Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention.

Claims

1. A teaching and training system based on intelligent factory application scenarios, characterized in that, The utility model provides a practical training device and control system, the practical training device includes practical training platform and set up on the practical training platform feeding unit, conveying unit, processing unit, assembly unit, classification unit, the feeding unit, conveying unit, processing unit, assembly unit, classification unit respectively set up with control system, the control system includes communication module and PLC, and the PLC of multiple control systems constructs communication network through communication module.

2. The teaching and training system based on the intelligent factory application scenario according to claim 1, characterized in that, The communication module includes an industrial switch and a wireless communication gateway. 3.The system according to claim 2, wherein, The control module further includes a frequency converter, a servo system, and a touch screen connected to the PLC through the Profinet network, and a monitoring layer connected to an external computer through the wireless communication gateway.

4. The teaching and training system based on smart factory application scenarios according to claim 1, characterized in that, The practical training platform includes a table top for installing the feeding unit, conveying unit, processing unit, assembly unit, and classification unit, and a table frame arranged below the table top.

5. The teaching and training system based on smart factory application scenarios according to claim 1, characterized in that, The feeding unit, conveying unit, processing unit, assembly unit, and classification unit each use an independent power supply and a filter pressure reducing valve, and are connected by a communication cable for signal interaction and an air pipe for air supply. 6.The system according to claim 1, wherein, The feeding unit 3 includes a vertical cylinder, a feeding cylinder, a pushing cylinder, a material detection sensor component, a material detection device, and a terminal unit with protection; the feeding cylinder is arranged directly below the vertical cylinder and is used for action in the vertical cylinder and feeding, the pushing cylinder is arranged on one side of the vertical cylinder, and the axis of the pushing cylinder is perpendicular to the axis of the vertical cylinder. 7.The system according to claim 1, wherein, The conveying unit includes a mechanical arm and an auxiliary positioning cylinder; the mechanical arm performs grabbing in a set area, and the auxiliary positioning cylinder is arranged on the side of the set area. 8.The system according to claim 1, wherein, The processing unit includes a sliding material table, a simulation punch, a punch support, and a synchronous belt transmission mechanism; the sliding material table is arranged on the synchronous belt transmission mechanism and moves between at least two positions through the synchronous belt transmission mechanism, the simulation punch is installed on the punch support, and the simulation punch moves towards the sliding material table in one of the positions. 9.The system according to claim 1, wherein, The assembly unit includes a feeding mechanism, a rotary feeding unit, an assembly mechanical arm, and a material placing table; the feeding mechanism includes an auxiliary material cylinder and an auxiliary material feeding cylinder for feeding in the auxiliary material cylinder, the rotary feeding unit includes a rotary table and a stepping motor for driving the rotary table to rotate, and the feeding mechanism, the assembly mechanical arm, and the material placing table are arranged on the side of the rotary table, respectively. 10.The system according to claim 1, wherein, The classification unit includes a conveyor belt, a sorting pneumatic assembly, and a material bin; the sorting pneumatic assembly includes three sorting cylinders arranged on one side of the conveyor belt in sequence along the length direction of the conveyor belt, the material bin is arranged in multiple and corresponds to each sorting cylinder, respectively, and the material bin is fixed to the outside of the conveyor belt through a support.

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