SOUTHERN LUZON STATE UNIVERSITY

LUCBAN QUEZON
COLLEGE OF ENGINEERING

FESTO

PROCESSING STATION

Lustado, Johnro
Leanillo, Jommel
Padilla, Dhen-Mark Jude F.
Pionilla, Jon Felix
Paulite, Keith Aldwin

BSEE IV- GI
Engr. Meller Gonzales
Instructor

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 TABLE OF CONTENTS

i. INTRODUCTION …………………………………………………………………………………………………………………. 3
ii. PROCESSING STATION ……………………………………………………………………………………………………….. 3
iii. FUNCTION …………………………………………………………………………………………………………………………. 4
iv. DIAGRAM ………………………………………………………………………………………………………………………….. 5
v. PARTS ………………………………………………………………………………………………………………………………… 6
vi. SEQUENCE …………………………………………………………………………………………………………………………. 9
vii. LADDER DIAGRAM …………………………………………………………………………………………………………… 10
viii. HOW TO CREATE A PROGRAM …………………,……………………………………………………………………… 16
ix. HOW TO UPLOAD …………..………………………………………………………………………………………………… 20
x. REFERENCES …………………………………………………………………………………………………………………….. 23

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 I. INTRODUCTION

FESTO places great emphasis on research and development to stay ahead in the field and
consistently introduces new technologies to improve efficiency in industrial operations. The company
is also committed to environmentally friendly practices in its manufacturing processes and product
designs. FESTO’s reliable and precise products have helped many industries optimize their operations.
Additionally, FESTO provides educational resources to train workers in automation technologies,
ensuring their skills meet industry demands. With a global network of subsidiaries and distributors,
FESTO makes its products and services accessible worldwide, focusing on customer needs and
innovation to shape the future of industrial automation.
The FESTO Processing Station is an advanced tool designed for learning and training in automation.
It allows students and professionals to experience real-world industrial tasks, such as assembling,
testing, and controlling systems. This station is widely used in educational environments to teach
practical skills in handling sensors, motors, and programmable logic controllers (PLCs). With its
modular design, the station can simulate different industrial processes, making it a great platform for
hands-on learning. Users can enhance their teamwork, technical skills, and troubleshooting abilities by
working on this system. Safety is an important part of using the Processing Station. All users must
follow the guidelines in the manual to avoid accidents or damage. Only authorized and trained
individuals should operate the equipment. Regular checks and maintenance are necessary to keep the
station in good working condition and ensure safety.

II. PROCESSING STATION

FESTO’s Processing Station highlights its expertise in automation by combining advanced robotics,
sensor technology, and centralized control systems. This setup allows the station to perform tasks with
precision and reliability, making it an excellent tool for improving industrial operations. The Processing
Station is designed to simplify complex tasks, reduce manual labor, and ensure consistent productivity.
The Processing Station is a system where different tasks like checking, drilling, and transferring
workpieces are performed. It consists of several modules, such as a rotary indexing table, testing
module, and drilling module. The rotary indexing table moves the workpiece to different positions for
processing. Sensors and actuators ensure that tasks like drilling and testing are done accurately and
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safely. The station operates in a sequence, starting with detecting the workpiece, checking its
orientation, and then processing it. For example, the drilling module clamps the workpiece, drills a
hole, and releases it for the next task. Each step is controlled by a PLC, ensuring precision and
repeatability. This setup mimics real industrial environments, making it an ideal training tool.

III. FUNCTION

The Processing Station is designed to make material handling easier, faster, and more accurate
while reducing the need for manual work. It moves workpieces from one point to another using robotic
arms, and sensors ensure that the workpieces are positioned correctly during the process. The station
also inspects the quality of the workpieces to confirm that they meet specific standards. If any parts
are defective, they are removed to maintain quality control.
The station is capable of performing tasks like drilling or shaping workpieces, simulating real
manufacturing operations with precision. High-speed motors and tools ensure that every operation is
consistent and accurate. Additionally, the station can sort workpieces based on size, color, or material,
and move finished items to the next stage using conveyors or sorting mechanisms. It provides real-time
feedback to operators about its performance, making it easier to identify and fix issues quickly. Safety
features, such as interlocks and protective mechanisms, ensure that the station operates securely and
prevents accidents. By automating repetitive tasks, the Processing Station improves productivity and
accuracy, helping industries achieve higher efficiency and consistency in their processes.

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 IV. DIAGRAM

The diagram provided illustrates the various components comprising a handling station. Primarily, the

processing station is composed of the drilling module, rotary index table, clamping module, injector

module, inductive sensor, testing module.

. DRILLING MODULE

INDUCTIVE SENSOR
ROTARY INDEX
TABLE

CLAMPING MODULE

INJECTOR MODULE
TESTING MODULE

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 V. PARTS

Rotary indexing table module

The drive of the Rotary indexing table module is operated by a
DC gear motor. The 6 rotating plate positions are defined by the
positioning screws on the rotary table and sensed by means of
an inductive sensor.

Each of the 6 semi-circular workpiece retainers of the plate is provided with hole in the center to facilitate
sensing by means of a capacitive proximity sensor.

Testing module

An inserted workpiece is checked for correct positioning. If the hole points

upwards, then the armature of the testing solenoid reaches its end position.

An inductive proximity sensor is actuated via a nut at the upper end of the
armature.

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Drilling module

The Drilling module is used to simulate the polishing of the hole of the workpiece.

An electrical clamping device retains the workpiece. The feed and return actions
of the drilling machine are affected by means of a linear axis with toothed belt
drive. An electrical gear motor drives the linear axis and a relay circuit is used to
activate the motor.

The motor of the drilling machine is operated via 24 V DC and the speed is not
adjustable.

The end position sensing is affected by means of electrical limit switches.

Approaching of the limit switches causes a reversal of the direction of movement
of the linear axis.

Assembling profile plate and control console

1. Profile plate

2. T-head nut M6 x-32 (4x)

1 3. Trolley

4. Socket head screw M6x10 (4x)

2
(4x) 5. Screw 3.5x9 (2x)
3
6. Control console

5
(2x) 6

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PARTS FUNCTION
Rotary indexing table Driven by a DC gear motor, this module rotates to six predefined
module positions, detected by an inductive sensor. It features semi-circular
retainers with central holes for capacitive proximity sensing.
Testing module This module checks if the workpiece is correctly positioned. If the hole
is upwards, the armature of the testing solenoid activates an
inductive proximity sensor.
Drilling module Simulates hole polishing by securing the workpiece with an electrical
clamp. A linear axis with a toothed belt drive controls the feed and
return actions, with direction reversal managed by limit switches.
Clamping module The clamping module securely holds the workpiece in place during
processing, ensuring stability and precision throughout the
operations.
Sorting gate module This module sorts finished workpieces based on predefined criteria,
directing them to appropriate locations for further processing or
packaging.
Profile plate The profile plate serves as a structural component that supports the
arrangement of other modules and ensures proper alignment and
stability within the processing station.
Trolley The trolley is used for transporting workpieces between different
modules within the processing station, enhancing workflow
efficiency.
Control console The control console provides the user interface for operating the
processing station, allowing for monitoring and control of various
functions and processes.
PLC board The PLC (Programmable Logic Controller) board is responsible for
automating the operations of the processing station, executing
control logic, and managing the interactions between different
modules.

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VI. SEQUENCE

1. The rotary table turns 60° when the START button is pressed and the workpiece is in place.
2. The solenoid checks if the workpiece is positioned with the opening facing up. If it is correct,
the table turns 60° again.
3. The clamping device holds the workpiece, and the drilling machine turns on. The machine
moves down.
4. When the drilling machine reaches the lowest position, the linear axis moves it back up to the
top.
5. The drilling machine turns off, and the clamp releases the workpiece. The rotary table turns 60°
again.
6. The sorting gate moves the workpiece to the next station.

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VII. LADDER DIAGRAM

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SYMBOL TABLE

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 VIII. STEPS HOW TO CREATE PROGRAM

1. CREATE A FILE
- File/New project/Name/Ok

2. Insert SIMATIC 300 Station

- right click/insert new object/Simatic 300 station/double click to replace

3. Attach the V3.3 to create Program

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 - Hardware /Simatic 300/ RACK 300/RAIL /SELECT THE TABLE/CPU 300/ CPU314C-2
PN-DP/6ES7 314-6EH04/V3.3/ok/save

4. Open S7 Program
- CPU 314C-2 PN-DP/ S7 Program/ blocks/OB1

5. Set a Protection
- double click the CPU 314C-2 PN-DP/ Protection/select number 1/ok

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 6. Address the D124/DO16
- Double Click the D124-DO16/select addresses/put your group number into start/ok

7. Select Ladder Program

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 IX. STEPS HOW TO UPLOAD

1. Set Into PG/PC Interface

- Option/SET PG-PC INTERFACE

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 2. Set to Realtek RTL8821C 802.11ac PCIe Adapter. TCPIP
- Double click the Realtek RTL8821C 802.11ac PCIe Adapter. TCPIP/Ok

3. Select Target Module

- hardware/save and compile/ download module/ok

4. Select Node Address

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 - hardware/save and compile/ download module/ok

5. Run the Program

- back to ladder diagram/download/Monitor (ON-OFF)

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 X. REFERENCE

https://www.festo.com/net/hu_hu/SupportPortal/Files/767246/648813_deen_v2.0_Bearbeiten_Proces
sing_C_H4.pdf

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