Educational Concept and Learning Objectives

The MPS 403-1 system is designed to provide a holistic learning experience covering the entire industrial value chain. It enables learners to understand not only individual components and technologies but also their interaction within a complex cyber-physical production system.

Students and trainees progressively acquire both theoretical knowledge and hands-on skills in the following areas:

• Design, commissioning, and operation of automated mechatronic systems
• Industrial communication and networking of distributed automation components
• Programming and debugging of PLC-based control systems
• Development and integration of modern Human-Machine Interfaces (HMI)
• Configuration and use of smart sensors based on IO-Link technology
• Implementation and use of MES systems for production control
• Integration of Industrial Internet of Things (IIoT) solutions
• Data acquisition, analysis, and visualization in production environments
• Introduction to artificial intelligence (AI) and machine learning (ML) in industrial applications
• Implementation of mass customization through digital order processing (Webshop integration)

Global Production Process

The production workflow begins with the creation of a manufacturing order through an intuitive MES user interface. This interface allows users to configure product variants, define process parameters, and initiate production runs.

Each workpiece is uniquely identified using RFID technology, which ensures full traceability and enables decentralized decision-making throughout the production process.

At the Distribution station, raw parts are automatically fed into the system and assigned digital identities. The Assembly station then reads the RFID data and performs customized operations depending on the specific production order. Finally, the Inline Sorting station verifies product quality and routes the workpieces according to predefined criteria or measurement results.

In advanced configurations, the system can be divided into multiple production cells. In such cases, a mobile robot (Robotino) can be used to transport parts between stations, simulating flexible and decentralized manufacturing environments.

Main Stations

1. Distribution Pro Station

The Distribution Pro station serves as the entry point of the production line. It is responsible for supplying raw parts and initiating the production process.

The station features three stack magazines equipped with intelligent level monitoring. A double-acting pneumatic cylinder ensures precise and reliable separation of individual workpieces. A bidirectional conveyor system then transports the parts to the next station.

• Automated part feeding from three stack magazines
• Pneumatic separation mechanism for single-part handling
• Bidirectional conveyor with integrated sensors
• Smart IO-Link sensors (laser, ultrasonic, capacitive) for level detection
• Industrial touchscreen interface for operation and monitoring
• Full integration with MES and Web-based applications (Webshop)

The station can operate both in standalone mode and in fully networked MES mode, allowing flexible use in different training scenarios.

2. Assembly Station

The Assembly station performs automated assembly operations based on product specifications and RFID data. It introduces learners to advanced handling systems, sensor technology, and industrial assembly processes.

Workpieces are first transported to a measurement position where their orientation is checked using optical sensors. Only correctly positioned parts are processed further, ensuring realistic quality control conditions.

• Pick & Place module configurable with vacuum gripper or parallel gripper
• Automated assembly of components based on production data
• Optical and analog sensors for position and orientation detection
• Introduction to pneumatic systems and vacuum technology
• Material flow monitoring using fiber-optic sensors
• Industrial Ethernet communication for system integration

The station provides a comprehensive understanding of automated assembly systems, including mechanical handling, sensor integration, and control logic.

3. Inline Sorting Station

The Inline Sorting station represents the final stage of the production line, focusing on quality control, classification, and routing of finished products.

A height-adjustable RFID read/write device identifies each workpiece and retrieves its production data. Additional sensors detect physical properties such as color and material, enabling advanced quality verification.

• RFID-based product identification and tracking
• Detection of color and material properties
• Automated sorting into multiple output channels
• Combination of inductive, optical, and diffuse sensors
• Integration of IIoT system with camera-based monitoring
• Machine learning algorithms for image analysis and decision support

This station introduces learners to modern quality assurance methods, sensor fusion, and data-driven decision-making in industrial environments.

Optional Stations

4. Measure Pro Station (Optional)

The Measure Pro station focuses on industrial metrology and in-process quality assurance. It enables precise measurement of workpiece characteristics and supports statistical process control (SPC).

• Measurement of height, level, and weight
• Load cell technology using strain gauges (DMS)
• Rotary lifting module for part handling
• Comparison of measured values with target specifications
• Automatic rejection of non-conforming parts
• Graphical visualization of measurement results

This station provides a realistic environment for learning advanced measurement techniques and quality management strategies.

5. Robotic Assembly Station (Optional)

The Robotic Assembly station introduces industrial robotics into the learning factory environment, enabling advanced automation and complex assembly operations.

It is equipped with a Mitsubishi RV-2FRB industrial robot, controlled by a CR800 controller and programmed via a teach pendant. The robot performs multi-step assembly processes, including part handling, inspection, and component integration.

• Industrial robot with high precision and repeatability
• Automated assembly of multi-component products
• RFID-based process control and traceability
• Integration with MES via industrial Ethernet
• Quality inspection using optical sensors
• Safety enclosure compliant with industrial standards

Learners gain hands-on experience in robot programming, system integration, maintenance, and optimization within a real industrial context.