Perfect for an Industry 4.0 world, Amatrol’s Smart Factory Mechatronics Training System is a multi-station automated manufacturing line that assembles a functional, two-way pneumatic valve. This system utilizes either a FANUC LR Mate robot or an Amatrol Pegasus robot, iGear Squeaks software for Smart Factory communication, Allen-Bradley and/or Siemens PLCs, and an additional cart that houses systems for Ethernet (87-EN), Wireless Communication (87-WL), and Network Security (87-NS) training. Each of the eight main stations of the Mechatronics System features a smart sensor or component for Smart Communication, including pneumatic/vacuum, ultrasonic, photoeye, stack light, electrical current, and analog pressure.
Amatrol’s Smart Factory Mechatronics Training System has as its foundation Amatrol's popular 870-series Mechatronics line. For those wishing to build up to teaching Industry 4.0 smart automation skills, Amatrol offers the Mechatronics Learning System without smart automation components. Users can then upgrade as time and funding allow to create a robust Smart Factory system. The experts at Amatrol can help you chart a course to reach your specific teaching goals.
The Mechatronics Learning System teaches learners a broad array of job-ready skills in integrated technologies as they work together in a team environment. The Mechatronics training system is compact, enabling it to fit into almost any teaching facility. Whether using one station or many, Amatrol’s Mechatronics Learning System is the ultimate team project!
This learning system teaches learners how to manufacture industrial-quality, working directional control valves. They develop skills needed to enable processes to work together, such as making precision physical adjustments. Modern industry leverages technology so that one set of equipment can make many products. Amatrol’s 870-Series Mechatronics line brings industrial realism to the classroom by allowing learners to program it to assemble a minimum of four different variations of the valve.
Individual Station Detail:
Amatrol's individual Mechatronics stations can be used in a variety of combinations (contact Amatrol for more information on specific options). All together, these stations make up a complete flexible manufacturing system. Each station is a small mechatronics system in itself with multiple, integrated technologies that can be used stand-alone or in various combinations, creating unlimited project capability.
- Station 1 – Pick and Place Feeding
- Station 2 – Gauging
- Station 3 – Orientation Processing
- Station 4 – Sorting / Buffering
- Station 5 – Servo Robotic Assembly
- Station 6 – Torque Assembly
- Station 7 – Inventory Storage
- Station 8 – CNC Mill
- Station 9 – Hydraulic Press
Amatrol's Mechatronics line can be outfitted with programmable logic controllers (PLCs) from either Allen-Bradley (870-AB53A) or Siemens (870-S715). In addition, a variety of options are available for the Mechatronics line, including:
- MechaSIM Mechatronics Simulation Learning System – AB CompactLogix L16 (87-MSSAB53A)
- Mechatronics Ethernet Learning System – AB CompactLogix L16 (87-ENAB53A)
- Mechatronics Troubleshooting Learning System (87-FTSAB53A/87-FTSS715)
- Mechatronics HMI Terminal Learning System (87-HMIAB53A/87-HMIS715)
- PLC Learning System (87-IOSAB53A/87-IOSS715)
- Mechatronics Vision Inspection Learning System (87-VS1AB53A/87-VS1S715)
Amatrol pioneered Industry 4.0 training when it transformed its popular full-scale Mechatronics line into a robust Smart Factory training system. Amatrol's Smart Factory is a fully-connected and flexible manufacturing system that links its physical systems, operational information, and human assets to control manufacturing, maintenance, inventory, and supply chain operations.
The linked Mechatronics stations incorporate all major manufacturing technologies, including electrical, mechanical, hydraulics, and pneumatics. Together, the stations comprise a fully-automated manufacturing line that teaches essential processes, such as inventory control, inspection, sorting, assembly, torqueing, testing, CNC machining, and storage.
To transform the Mechatronics line into a true Smart Factory, Amatrol added a station for networking communications equipment, along with a variety of other connected technologies:
- Smart Sensors: Smart sensors with I/O links provide flexible manufacturing, predictive maintenance, and data analytics capabilities. Featured smart sensors include pneumatics/vacuum, ultrasonic, photoeye, stacklight, electrical current, and analog position and pressure sensors.
- Smart Product ID: Smart product identification components, including barcode, vision, and RFID scanners, allow learners to track parts and see production history of sorting, acceptance, and rejection of parts, as well as inventory control.
- Network Communications: Network communications lie at the heart of Industry 4.0 systems. Amatrol adds Ethernet/PROFINET and wireless communications equipment to allow learners to utilize industrial protocols for real-time control, program transfer, data collection, and changing programs.
- Network Security: Amatrol’s network security equipment teaches learners how to protect manufacturing processes and data from outside access, provide safe data communication between factory networks and the Internet, and securely extend operational data to suppliers and customers.
- Smart Production: Smart production capabilities are achieved by adding industry-standard visual communications software that allows learners to monitor processes, enter orders, and view and analyze production trends.
- Smart Maintenance: Web-based, industry-standard manufacturing execution software provides smart maintenance capabilities. For example, the software collects system data from all the Smart Factory components to automatically trigger necessary maintenance operations via apps that can be used on smartphones, tablets, or personal computers.
Amatrol utilizes multiple Industry 4.0 smart devices on the Smart Factory that communicate via Ethernet and I/O Link protocol providing flexible manufacturing, predictive maintenance, and data analytics capabilities. The following learning systems teach communications between intelligent automation devices using PROFINET with Siemens PLCs and EtherNet/IP with Allen-Bradley PLCs in a Smart Factory environment with the specified sensors and components:
- Smart Factory Sensor Learning System, Pneumatics / Vacuum Sensor (87-SN1AB53A/87-SN1S715)
- Smart Factory Sensor Learning System, Ultrasonic Sensor (87-SN2AB53A/87-SN2S715)
- Smart Factory Sensor Learning System, Photoeye (Photoelectric Sensor) (87-SN3AB53A/87-SN3S715)
- Smart Factory Smart Device Learning System, Stack Light (87-SN4AB53A/87-SN4S715)
- Smart Factory Sensor Learning System, Electrical (Current Monitoring Devices) (87-SN6AB53A/87-SN6S715)
- Smart Factory Sensor Learning System, Analog Position Sensor (87-SN7AB53A/87-SN7S715)
- Smart Factory Sensor Learning System, Analog Pressure (Pneumatic Pressure Sensor) (87-SN9AB53A/87-SN9S715)
Smart Product ID
Amatrol’s Smart Factory incorporates Industry 4.0 smart product identification devices, such as vision systems and bar code readers, which trigger “intelligent” actions including parts tracking, production history, sorting, part accept/reject, & inventory control.
- Mechatronics Barcode Learning System (87-BR2AB53A/87-BR2S715): teaches programming and operation of barcode reading identification systems and communications with other intelligent automation devices using EtherNet/IP or PROFINET in a Smart Factory and Industry 4.0 environment.
- Smart Factory RF Identification Learning System (87-RF1AB53B/87-RF1S715): teaches programming and operation of radio frequency identification (RFID) systems and communications with other intelligent automation devices using PROFINET or EtherNet/IP in a Smart Factory and Industry 4.0 environment.
- Mechatronics Vision Inspection Learning System (87-VS1AB53A/87-VS1S715): teaches the use of machine vision systems in smart factory applications.
Amatrol’s communication system connects students with a fully functional production system using industrial protocols for real-time control, program transfer, data collection, and changing programs on the fly.
- Mobile Workstation – Smart Factory Communications (87-MS1A): provides integrated organization of Smart Factory communications modules, including but not limited to wireless communication modules, managed and unmanaged network switch modules, network security modules, and master PC.
- Mechatronics Wireless Communications Learning System (87-WLAS) [U.S. Customers Only]: teaches wireless communications in a Smart Factory environment.
- Smart Factory Ethernet Learning System (87-ENAB53B/87-ENS715): teaches communications between various intelligent automation devices in various topologies in a Smart Factory environment to efficiently control and monitor an automated manufacturing process.
Amatrol’s network security system teaches how to keep data safe and securely extend operational data to suppliers and customers. Communications security protects the smart factory from unauthorized outside access & provides secure data communications between the plant-wide network and the internet.
- Smart Factory Network Security Learning System (87-NS1AB53A/87-NS1S715): teaches network security for communications in a Smart Factory environment.
Smart Maintenance and Production
Smart Maintenance software utilizes smart device information to automatically trigger maintenance operations. Amatrol’s Smart Factory uses industry standard software to connect users directly to the automated system and each other to create a real-world environment where maintenance team members can collaborate to resolve issues quickly and effectively.
- Smart Factory Visual Communications Learning System (87-VCAB53A/87-VCS715): teaches web-based maintenance communications in Smart Factory applications.
- Smart Factory Manufacturing Execution Learning System (87-MEAB53A/87-MES715): teaches the use of web-based production control, scheduling, and monitoring in Smart Factory applications.
Amatrol’s eLearning curriculum is unique in that it thoughtfully combines in-depth theoretical knowledge with practical, hands-on skills. This powerful combination of knowledge and skills solidifies understanding and creates a strong foundation for pursuing more advanced skills. For example, Smart Factory eLearning courses cover important topics, such as:
Basic Robot Programming & Operation
Learners will study basic robot programming and operation used in a Smart Factory setting. Individual lessons include types of robot classifications, basic operation of a Servo robot, robot safety rules, types of robot grippers, and robot commands. Learners will also practice skills, such as jogging a Servo robot, teaching robot position points, running a Servo robot program, and entering a robot program that uses Pmove, Grasp/Release, and Label/Branch commands.
Introduction to Electronic Sensors
Using Amatrol’s Smart Factory eLearning course, learners will study different types of electronic sensors, and the advantages (and disadvantages) they can bring. Individual lessons include the function of the two parts of an electronic sensor, operation of transistors used in sensors, and characteristics that affect inductive proximity sensor operation. Learners will also practice skills, such as connecting and operating an inductive proximity sensor, measuring and analyzing the performance of an inductive proximity sensor, connecting and operating a capacitive proximity sensor, and measuring and analyzing the performance of a capacitive proximity sensor.
RFID Operation & Programming
Learners will study the programming and operation of radio-frequency identification, or RFID tags. Individual lessons include the function and operation of an RFID system, factors that affect RFID system operation, the operation of Rockwell Studio 5000 message instruction, and the function and operation of an IOLink Master. Learners will also practice skills, such as operating an RFID system, entering and operating a Rockwell Studio 5000 PLC program, configuring an IOLink Master in a PLC project, and operating a CompactLogix PLC project that uses an RFID function block instruction.
Introduction to Ethernet Networks
Learners will be introduced to Ethernet Networks used in a Smart Factory setting. Individual lessons include function of an industrial network, basic operation of a TCP/IP Ethernet network, components of an Ethernet network, and how to set Ethernet IP addresses of robots and PLCs. Learners will also practice skills, such as connecting an Ethernet network using an unmanaged switch, setting IP addresses of robots and PLCs, and transferring PLC programs via an Ethernet network.
Cloud-Based Data Acquisition
In this module, learners will be exposed to cloud-based data acquisition concepts. Individual lessons include operation of a cloud-based SCADA system, how to configure a cloud-based data acquisition software to retrieve production data, operation of cloud-based maintenance management, and how to send/receive a cloud-based maintenance message. Learners will also practice skills, such as operating a cloud-based data acquisition system, configuring a web-based data acquisition system to display production statistics, and configuring a cloud-based maintenance management message.
Highly-Interactive Multimedia Format Appeals to All Learning Styles
Amatrol’s Smart Factory eLearning course curriculum features a highly-interactive multimedia format. Stunning 3D animations, videos, pictures, voiceovers of all text, and interactive quizzes and exercises bring learning to life. Amatrol’s multimedia curriculum contains elements that will appeal to every learning style, keeping learners motivated and engaged.
Anytime, Anywhere Access Promotes Self-Paced Learning
In today’s fast-paced, technology-driven world, it’s more important than ever to extend the reach of industrial skill training beyond the borders of traditional classrooms. Amatrol’s eLearning meets the challenge for flexibility by offering in-depth, comprehensive technical skills training via an intuitive, easy-to-use web-based Learning Management System (LMS). With anytime, anywhere online access, Amatrol’s eLearning allows learners to set their own pace at home, on the job, in a traditional class setting, or a blended approach of these options.