Testing Station

Assembly
Instructions

EN
10/02
Intended use

This station has been developed and produced exclusively for vocational and further
training in the field of automation and communication. The training authority and/or
the instructors are to ensure that trainees observe the safety instructions described
in the manual provided.

Festo Didactic herewith rules out all liability for damage or injury to trainees, the
training authority or other third parties which may occur during the use/operation of
this equipment other than purely in a training situation, unless it can be proved that
Festo Didactic has caused such damage or injury through malicious intent or gross
negligence.

Description MONT.ANLEIT

Designation: D:MP-MA-S-PRUEF-1-GB

Status: 11/2002

Author: Frank Ebel

Graphics: Doris Schwarzenberger, Albert Sigel

Layout: 11/2002

© Festo Didactic GmbH & Co., D-73770 Denkendorf, 2002

Internet: www.festo.com/didactic

e-mail: did@festo.com

The copying, distribution and utilisation of this document, as well as the communication of its
contents to others without the express authorisation of Festo Didactic is prohibited. Offenders will be
held liable for the payment of damages. All rights reserved, in particular the right to carry out patent,
utility model or ornamental design registration

2 © Festo Didactic GmbH & Co. • Testing station

Contents

1. Notes on safety ________________________________________________ 5

2. Short description ______________________________________________ 7

3. Views and tools ________________________________________________ 9

3.1 Views ________________________________________________________ 9
3.2 Required tools ________________________________________________ 10

4. Assembling the station_________________________________________ 11

4.1 Step 1 _______________________________________________________ 11
4.2 Step 2 _______________________________________________________ 12
4.3 Step 3 _______________________________________________________ 13
4.4 Step 4 _______________________________________________________ 14
4.5 Step 5 _______________________________________________________ 15
4.6 Step 6 _______________________________________________________ 16
4.7 Step 7 _______________________________________________________ 18
4.8 Step 8 _______________________________________________________ 20

© Festo Didactic GmbH & Co. • Testing station 3

4 © Festo Didactic GmbH & Co. • Testing station
1. Notes on safety

In the interests of your own safety, please observe the following safety instructions:

General
• Trainees must only work on a station under the supervision of an instructor.
• Observe the data in the data sheets for the individual components, particularly
all safety instructions!

Electrical
• Electrical connections are to be wired-up or disconnected only when the power
supply is turned off!
• Use only extra-low-voltages of up to max. 24 V DC.

Pneumatic
• Do not exceed the maximum permissible pressure of 8 bar (800 kPa).
• Do not switch on the compressed air supply until you have established and
secured all tubing connections.
• Do not disconnect air lines under pressure.
• Particular care is to be taken when switching on the compressed air supply.
Cylinders may advance or retract as the compressed air is switched on.

Mechanical
• Attach all components securely on the mounting plate.
• No manual intervention is to take place unless the machine is at rest.

© Festo Didactic GmbH & Co. • Testing station 5

Notes on safety

6 © Festo Didactic GmbH & Co. • Testing station

2. Short description

View of the Testing station

According to VDI 2860, "testing", like "measuring", forms part of the handling
function "checking".

The major elements of a testing operation are the acquisition of information (actual)
and the comparison of specified characteristics (required), and the resulting
decision "Workpiece acceptable/rejected" or "Yes/no". An important component
part of a measuring operation is the comparison of characteristics (actual values)
with specified reference dimensions (required values).

Classic types of testing include workpiece availability checking, identity checking,

contour checking, size checking, colour checking, weight checking or orientation
checking. In automated production, in contrast to manual production, monitoring is
very important. In manual production, rejected workpieces can be separated out
immediately, while in automated production rejects may disrupt production
operations or halt these completely.

© Festo Didactic GmbH & Co. • Testing station 7

Short description of testing station

The purpose of the Testing station is as follows:

• To determine the material characteristics of a workpiece

• To check the workpiece height and either
• To reject the workpiece concerned or
• To feed the workpiece to the next station.

The Testing station consists of the following:

• Profile plate
• Sensing module
• Lifting module
• Measuring module
• Slide module
• PLC board with control panel

8 © Festo Didactic GmbH & Co. • Testing station

3. Views and tools

3.1
Views

Testing station, plan view

Testing station, r.h. side view

© Festo Didactic GmbH & Co. • Testing station 9

Views and tools

Testing station, front view

3.2 Tube spanner, 9 x 10 mm

Required tools
Open-ended spanners 6 x 7, 12 x 13, 22 x 24 mm

Slot-head screwdriver, 3.5 mm

Allen key, 5 mm

10 © Festo Didactic GmbH & Co. • Testing station

4. Assembling the station

4.1
Step 1

1 14. Nut

13.
12.
11.
10.
9.
8.
7.
6.
5.
4.
3.
2.
1.

1 Profile plate

© Festo Didactic GmbH & Co. • Testing station 11

Assembling the station

4.2
Step 2

2.1 (2x)

2.5

2.2 (4x)

2.3 (4x)
2.6 (2x)

2.7 (2x)

2.4 (4x) 2.8 (2x)

2.1 Cable duct

2.2 Socket-head screw M5 x 10

2.3 Washer B5.3

2.4 T-head nut M5-32

2.5 Mounting rail

2.6 Socket-head screw M5 x 10

2.7 Washer B5.3

2.8 T-head nut M5-32

12 © Festo Didactic GmbH & Co. • Testing station

Assembling the station

4.3
Step 3

5. 2

3.

1.

2 Mounting the electrical system

© Festo Didactic GmbH & Co. • Testing station 13

Assembling the station

4.4
Step 4

3
13.
12.

10.

7.
6. 9

8 (2x)

7 (5x)

3 I/O terminal

4 Comparator

5 Interface unit

6 CP valve terminal

7 Cable clip (5x)

8 Connectors (2x)

9 Service unit

14 © Festo Didactic GmbH & Co. • Testing station

Assembling the station

4.5
Step 5

Position of cable clips

© Festo Didactic GmbH & Co. • Testing station 15

Assembling the station

4.6
Step 6

14

13

(11) 12

11

(12)

10.

15
7.
6.

2.

2.
10

16 © Festo Didactic GmbH & Co. • Testing station

Assembling the station

10 StationLink receiver

11 Sensing module
(retro-reflective sensor to be fitted to the mounting bracket of the lifting
module)

12 Retro-reflective sensor and reflector

13 Measuring module

14 Lifting module

15 StationLink transmitter

© Festo Didactic GmbH & Co. • Testing station 17

Assembling the station

4.7
Step 7

19

18

7.

16

17

18 © Festo Didactic GmbH & Co. • Testing station

Assembling the station

16 Cable clip

17 Slide module, 210 mm

18 Air cushioned slide module

19 Cable guide
Loosen the two screws M5 x 12 on the lifting module (securing the lifting
bracket). These screws are used to secure the mounting bracket of the cable
guide and the lifting bracket to the slide of the pneumatic linear drive.

© Festo Didactic GmbH & Co. • Testing station 19

Assembling the station

4.8
Step 8

Station fully assembled

20 © Festo Didactic GmbH & Co. • Testing station