Control Technology – a classic discipline of technical training Advancing automation is increasingly conferring the monitoring and control of technical processes and production techniques to autonomous control systems. Mechanical controls are thus relieving humans from performing monotonous control and operating tasks. However technical systems often require a level of accuracy, speed and reliability that humans would not be able to fulfill. Our control technology training system employs an training panel system for basic and advanced courses. The multimedia training system, based on COM3LAB, is equally well suited to student self-help practice and experiment demonstrations with a PC beamer.
Basic Course Basic courses in control technology employ real technical controlled systems. These produce non-electrical controlled variables (fill level, temperature, flow rate, angle of heel, etc.) and therefore require sensors to convert the given quantities into electrical signals. Since here explicit results take on foreground importance, these experiments are particularly well suited for a basic introduction to this thematic.
Advanced Course Advanced courses in control technology employ pure electronic devices as controlled systems. Sensors are no longer necessary here because only electrical signals occur in the entire control circuit. Since electrical signals are easily managed, these experiments stand out as a consequence of their convincingly quantifiable results. The results assessed here also stand up to critical interpretation.
Symbols: Experiment literature included
Battery required
Software included
COM3LAB compatible
Accessories required
Bus-capable (USB, Profibus, ...)
T8.2 Equipment Set Configuration
CONTROL TECHNOLOGY
T 8.2.1.1
Temperature Control
Temperature control with DDC controller under WinFACT.
Training Objectives ➔ Temperature control with two-point controller ➔ Hysterisis of two-point controller
T 8.2.1.1 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.1.1
Temperature Control
Basic Course: Technical Systems
Some like it hot Instead of the oven model 734 38 from T 8.1.3 Process Instrumentation Technology, the thermally quicker Temperature Controlled System 734 12 is used here. This increases the dynamics of control and shortens measurement time.
Foundries must maintain exacting, prescribed, temperature profiles for the molten mass.
EQUIPMENT LIST T8.2.1.1
Temperature Control QUANTITY CAT. NO.
DESCRIPTION
1
734 01
Two Position Controller
1
734 02
Reference Variable Generator
1
734 12
Temperature Controlled System
2
734 13
Power Amplifier
1
524 016
Profi-CASSY
1
734 48
WinFACT 6-COM3LAB / CASSY-Edition
1
568 222
Book: Fundamentals of Automatic Control Technology II, Vol. 2
T 8.2.1.1 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY T 8.2.1.2 T 8.2.1.3
Liquid Level Control Flow Rate Control
Liquid level control with DDC controller under CASSYLab.
Training Objectives ➔ Control of fill level height on single tank model ➔ Control of fill level height on dual tank model ➔ Control of liquid flow rate ➔ Disturbance behavior in the Liquid Controlled System
T 8.2.1.2 T 8.2.1.3
T 8.2.1.2 T 8.2.1.3 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY T 8.2.1.2 T 8.2.1.3
Liquid Level Control Flow Rate Control
Basic Course: Technical Systems
Two in a boat Liquid level and flow can both be measured with one instrument. The illustrated experiment uses the same liquid level measurement as T 8.1.3.2 to maintain a pre-selected fill level height with a closed loop controlled system. The experiment is quite clear and demonstrates, in an instructional manner, the interrelationship between reference value and actual value in feedback loops. EQUIPMENT LIST T8.2.1.2
Basic experiment: Liquid level control on a single tank model QUANTITY CAT. NO.
DESCRIPTION
1
734 262
Liquid Controlled System
1
734 02
Reference Variable Generator
1
734 81
Differential Pressure Transducer
1
734 876
Immersion Tube
1
524 016
Profi-CASSY
1
734 48
WinFACT 6-COM3LAB / CASSY-Edition
1
568 1012
Book: Experiments with the Liquid Controlled System T 8.1/8.2
Supplementary experiment: Liquid level control on a dual tank model The basic experiment can be extended for the dual tank model. The probes listed below can also be used in the basic experiment 1
734 264
Additional reservoir
1
727 68
C/F-, L/F- and F/U-Converter
1
734 861
Capacitive Bar-Type Probe
1
734 881
Level Switch with Float
1
734 89
Capacitive Level Switch
1
734 901
Gravimetric Level Meter
1
568 1012
Book: Experiments with the Liquid Controlled System T 8.1/8.2
EQUIPMENT LIST T8.2.1.3
Flow Rate Control QUANTITY CAT. NO.
DESCRIPTION
1
734 262
Liquid Controlled System
1
734 02
Reference Variable Generator
1
524 016
Profi-CASSY
1
734 48
WinFACT 6-COM3LAB / CASSY-Edition
1
568 1012
Book: Experiments with the Liquid Controlled System T 8.1/8.2
T 8.2.1.2 T 8.2.1.3 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.1.4
Gas Flow Control
Flow Control with blower and windmill type anemometer.
Training Objectives ➔ Control of a technical system with a moderate time constant ➔ Evaluation of the step response ➔ Determination of system time constants
T 8.2.1.4 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.1.4
Gas Flow Control
Basic Course: Technical Systems
They don‘t all have the same time A system‘s responsiveness to state changes is determined by its time constants. Technical systems can exhibit significantly different time constants: temperature : very slow flow : slow rotary speed : moderately fast brightness : very fast The control techniques investigated here are used for process control and in air conditioning systems.
While wind force and direction are constantly being measured in wind power generators, the availability of wind can’t be controlled by man. EQUIPMENT LIST T8.2.1.4
Gas Flow Control QUANTITY CAT. NO.
DESCRIPTION
1
666 630
Blower
1
666 631
Venturi Tube
1
666 632
Windmill Type Anemometer
1
524 016
Profi-CASSY
1
734 48
WinFACT 6-COM3LAB / CASSY-Edition
1
568 342
Book: Flow-Through Measurement of Gases T 8.1.3.4
T 8.2.1.4 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY T 8.2.1.5 T 8.2.1.6
Brightness Control Speed Control
Small but super! Light controlled system and mini-machine system. The motorgenerator set consists of two coupled DC machines and an optical tacho-generator.
T 8.2.1.5 Training Objectives ➔ Brightness Control with PI controller ➔ Dynamic properties of fast closed loop control
T 8.2.1.6 Training Objectives ➔ Speed control of a motor-generator set with PID controller ➔ Voltage control with the motor-generator set
T 8.2.1.5 T 8.2.1.6 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY T 8.2.1.5 T 8.2.1.6
Brightness Control Speed Control
Basic Course: Technical Systems
Light-Velocity Brightness control is a practical example for the control of „fast“ systems. This finds application in large lighting systems in sports arenas, halls, etc. Speed control is another daily life application. In the experiment the controlled system (= motor) provides the non-electric controlled variable „speed“. The generator coupled to the motor acts as a sensor that converts the motor‘s rotary speed into an electrical voltage signal.
EQUIPMENT LIST T8.2.1.5
Brightness Control QUANTITY CAT. NO.
DESCRIPTION
1
578 51
Si Diode 1N 4007
1
734 02
Reference Variable Generator
1
734061
PID Controller
1
734 13
Power Amplifier
1
734 16
Manual/Automatic Switch
1
734 31
Light Control System
1
524 016
Profi-CASSY
1
734 48
WinFACT 6-COM3LAB / CASSY-Edition
1
568 222
Book: Fundamentals of Automatic Control Technology II, Vol. 2
EQUIPMENT LIST T8.2.1.6
Speed Control QUANTITY CAT. NO.
DESCRIPTION
3
505 23
Lamp 24 V / 5 W
1
734 02
Reference Variable Generator
1
734 061
PID Controller
1
734 11
Motor-Generator Set, 24V
1
734 13
Power Amplifier
2
734 19
Gain and Offset Adjust
1
734 39
Load Switch
1
524 016
Profi-CASSY
1
734 48
WinFACT 6-COM3LAB / CASSY-Edition
1
568 222
Book: Fundamentals of Automatic Control Technology II, Vol. 2
T 8.2.1.5 T 8.2.1.6 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.1.7
Listing Control
Listing controllers ensure a balanced course tracking for big transportation vessels.
Training Objectives ➔ Putting listing control into service ➔ Control parameter settings for stable stationary operation ➔ Creating oscillating instabilities
T 8.2.1.7 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.1.7
Listing Control
Basic Course: Technical Systems
Ship shape in bad shape The list (heeling over) of a container ship or ferry changes as it is loaded. Difficulties can also arise, for example, in keeping the pitch of railroad tracks aligned while moving railroad cars onto a ferry. The appropriate filling of ballast tanks can help to compensate for such undesirable ship list and pitchangles.
Profi-CASSY and its CASSYLab software combine to serve as a convenient controller. Controller parameters, as well as the controlled, manipulated and reference quantities are visible at a glance. EQUIPMENT LIST T8.2.1.7
Listing Control QUANTITY CAT. NO.
DESCRIPTION
1
734 02
Reference Variable Generator
1
734 061
PID Controller
1
734 300
Listing Controlled System
1
524 016
Profi-CASSY
1
734 48
WinFACT 6-COM3LAB / CASSY-Edition
1
510 48
Pair of Magnets
1
568 222
Book: Fundamentals of Automatic Control Technology II, Vol. 2
T 8.2.1.7 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.2
Fuzzy Control
Air conditioning system with fuzzy controller. The controlled system can be electrically heated with a halogen lamp and cooled by a fan.
Training Objectives ➔ Implementation of an electronic gas pedal (drive by wire) ➔ Control of an air conditioning system with fuzzy algorithm ➔ Speed control of vehicles with differing loads ➔ List control with fuzzy algorithm
T 8.2.2 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.2
Fuzzy Control
Basic Course
Of approximate values and membership functions Fuzzy describes an approach to the control of technical systems which avoids sophisticated mathematical modeling. The control strategy is defined in terms of conditional language. Fuzzy control is particularly well suited for systems with multiple controlled variables and is used frequently today in many common appliances, from washing machines to cameras.
Fuzzy techniques can even be found in automotive engineering. The „drive by wire“ technology transmits the driver‘s wish to change speed to a fuzzy controller. EQUIPMENT LIST T8.2.2
Fuzzy Control QUANTITY CAT. NO.
DESCRIPTION
2
734 02
Reference Variable Generator
1
734 061
PID Controller
1
734 10
Servo Set point Generator
1
734 11
Motor-Generator Set, 24V
1
734 12
Temperature Controlled System
2
734 13
Power Amplifier
1
734 14
DC-Servo
1
734 56
Tensile Test Bar
1
734 300
Listing Controlled System
1
524 016
Profi-CASSY
1
734 4722
WinFACT 6-Student License Type B
1
510 48
Pair of Magnets
1
568 222
Book: Fundamentals of Automatic Control Technology II, Vol. 2
T 8.2.2 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.3
Continuous Control
Experimental set-up of an electronic control loop.
Training Objectives ➔ Transient functions from P-controller and I-controlled systems ➔ Feedbacks in transfer elements ➔ Output quantities in an open loop control chain ➔ Simulation of a pneumatic pressure closed loop control ➔ Pneumatic pressure closed loop control ➔ Step-responses of PT1 and PT2 elements ➔ Characteristic of a temperature closed loop control ➔ Dead time element ➔ Transient function of various controls: PI-control, PIP-control with 1st order delay, PIDP-control with 1st order delay T 8.2.3 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.3
Continuous Control
Advanced Course
A cybernetic base model The set-up photo shows a typical course T 8.2.3 experiment configuration. The electronic control loop is made of discrete components. This type of structure is ideal for the simulation of technical control loops. The advantage to this approach is its simple mastery of electrical quantities in comparison to (somewhat more complex) physical process quantities.
EQUIPMENT LIST T8.2.3
Continuous Control QUANTITY CAT. NO.
DESCRIPTION
1
734 02
Reference Variable Generator
2
734 03
P Controller
1
734 04
Integral-Action Element
1
734 05
Derivative-Action Element
1
734 07
Summing Point, 2 Inputs
1
734 08
Summing Point, 5 Inputs
1
734 089
Dead Time Element
2
734 09
Simulated Controlled System
1
734 12
Temperature Controlled System
1
734 13
Power Amplifier
1
734 40
Test Function Generator
1
524 016
Profi-CASSY
1
734 48
WinFACT 6-COM3LAB / CASSY-Edition
1
568 232
Book: Fundamentals of Automatic Control Technology II, Vol. 1
Control loop odels: 1 controller 2 actuator 3 controlled system 4 sensor The upper block diagram shows a closed loop control in general form. The controlled variable X and the reference variable W are different physical quantities and must be transformed for compatibility to one another by way of sensor technology. The actuator provides the control loop with the necessary power. The lower block diagram illustrates a simplified closed loop control. The actuator is integrated into the controller or the controlled system. Here the controlled variable and the reference variable are of the same physical nature, this makes sensors unnecessary.
T 8.2.3 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.4
Discontinuous Control
The steam iron is a classic example of an application with a two-point controller.
Advanced Course Training Objectives ➔ Temperature control with a two point controller ➔ Discontinuous control with feedback
T 8.2.4 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.4
Discontinuous Control
Advanced Course
Discrete steps The temperature of a steam iron will rarely take on directly the desired reference value. In contrast to continuous control systems, the controlled system (heater) here can only be turned on or off. There are no intermediate values. There isn‘t even an active cooling mechanism available.
EQUIPMENT LIST T8.2.4
Discontinuous Control QUANTITY CAT. NO.
DESCRIPTION
1
734 01
Two Position Controller
1
734 02
Reference Variable Generator
1
734 08
Summing Point, 5 Inputs
1
734 09
Simulated Controlled System
1
734 095
Second Order Transfer Element
1
734 12
Temperature Controlled System
1
734 13
Power Amplifier
1
524 016
Profi-CASSY
1
734 48
WinFACT 6-COM3LAB / CASSY-Edition
1
568 232
Book: Fundamentals of Automatic Control Technology II, Vol. 1
1
568 222
Book: Fundamentals of Automatic Control Technology II, Vol. 2
T 8.2.4 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.5
Controlled System Classes
Experimental set-up for computer-aided recording of step responses.
Training Objectives ➔ Simulation of fill level control ➔ Investigation of reference behavior ➔ Investigation of oscillation behavior ➔ Control of a controlled system with start-up time and dead time by a PID-controller ➔ Discussion of disturbance transient function
T 8.2.5 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.5
Controlled System Classes
Advanced Course
Class reunions Controlled systems which are important from a technical point of view will be systematically classified here according to their recorded time behavior characteristics. Experiments with 10-turn PID-controllers achieve astonishing quantitative correlation between theory and measurements. For anyone who places value on theoretically quantifiable control techniques, this controller is a recommendable alternative to the standard design (734 061).
EQUIPMENT LIST T8.2.5
Controlled system Classes QUANTITY CAT. NO.
DESCRIPTION
1
734 02
Reference Variable Generator
1
734 03
P Controller
1
734 04
Integral-Action Element
1
734 063
PID Controller, 10 Turn
1
734 07
Summing Point, 2 Inputs
1
734 08
Summing Point, 5 Inputs
1
734 089
Dead Time Element
1
734 09
Simulated Controlled System
1
524 016
Profi-CASSY
1
734 48
WinFACT 6-COM3LAB / CASSY-Edition
1
568 232
Book: Fundamentals of Automatic Control Technology II, Vol. 1
T 8.2.5 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.6
Electronic Systems
Recording the locus diagram on a system with dead time.
Training Objectives ➔ Step response ➔ Frequency response ➔ Systematic of controlled systems ➔ Systematic of controllers ➔ Digital controllers ➔ Systematic and frequency behavior of closed loop controls
T 8.2.6 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.6
Electronic Systems
Advanced Course
Idea and reality Electrical control systems that replace their physical counterparts while maintaining the same system behavior are investigated here. pressure closed loop control temperature closed loop control
Control and evaluation with the PC.
EQUIPMENT LIST T8.2.6
Electronic Systems QUANTITY CAT. NO.
DESCRIPTION
2
734 03
P Controller
1
734 04
Integral-Action Element
1
734 41
Sample and Hold Element
1
734 061
PID Controller
2
734 07
Summing Point, 2 Inputs
1
734 08
Summing Point, 5 Inputs
1
734 089
Dead Time Element
2
734 09
Simulated Controlled System
1
734 095
Second Order Transfer Element
1
524 016
Profi-CASSY
1
734 48
WinFACT 6-COM3LAB / CASSY-Edition
1
568 222
Book: Fundamentals of Automatic Control Technology II, Vol. 2
In DDC (Direct Digital Control) mode, the Profi-CASSY acts as the interface between the control loop and the PC. Together with CASSY Lab or WinFACT software, the computer can take over various tasks: to provide a freely-configurable digital controller taking over of recording tasks as an XY/Yt recorder or step response plotter This also allows experiments to be performed in the time and frequency domain, e.g. the recording of step responses or the presentation of locus diagrams.
T 8.2.6 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.7
Stability & Optimization
Locus diagrams of an open loop control system for stability evaluation per Nyquist.
Training Objectives ➔ Simulation of electric motor speed control ➔ Stability testing a 3rd order control system ➔ Stability testing a simulated gas flow controller ➔ Controller settings for a controlled system with dead time ➔ Nyquist evaluation of a control system ➔ Nyquist evaluation of an oscillating closed loop control ➔ Experimental optimization by means of ISE criteria ➔ Optimizing according to Ziegler / Nichols ➔ Optimizing according to Chien / Hrones / Reswick ➔ Fundamental stability investigations ➔ Higher order systems ➔ Stability test on an open loop control ➔ Integral criteria for system optimization ➔ Controller optimization T 8.2.7 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY
T 8.2.7
Stability & Optimization
Advanced Course
On the swing Control loops are feedback coupled systems. As such, they tend to oscillate under certain conditions. This effect is generally undesirable and demands all of the engineer‘s talents to create a design that is adequate for its dynamic behavior yet does not lead to parasitic oscillations that could endanger the system or the process.
EQUIPMENT LIST T8.2.7
Stability & Optimization QUANTITY CAT. NO.
Some have their own intuitive notions about stability and process optimization. For the technician, this subject is a more somber matter but certainly no less interesting.
DESCRIPTION
1
734 04
Integral-Action Element
1
734 063
PID Controller, 10 Turn
1
734 08
Summing Point, 5 Inputs
1
734 089
Dead Time Element
2
734 09
Simulated Controlled System
1
734 095
Second Order Transfer Element
1
734 19
Gain and Offset Adjust
1
524 016
Profi-CASSY
1
734 48
WinFACT 6-COM3LAB / CASSY-Edition
1
727 71
Function Module
1
568 222
Book: Fundamentals of Automatic Control Technology II, Vol. 2
T 8.2.7 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY 70082 70083
COM3LAB Course Control Technology I COM3LAB Course Control Technology II
COM3LAB: master unit and course board are the only training materials required to conduct the computer-aided experiments.
Training Objectives 70082
Training Objectives 70083
➔ Everyday open and closed loop control
➔ Control system stability
➔ Analysis of controlled systems
➔ Controller design per Ziegler / Nichols
➔ Plants with/without compensation
➔ Systems with deadtime
➔ Higher order systems
➔ Reference variable limitations
➔ PID and PI control
➔ Cascade control
➔ Digital control
➔ Introduction to frequency response
➔ Performance criteria
➔ Frequency responses of individual basic elements
➔ PID controller settings ➔ Temperature control ➔ Rotary speed control ➔ Light Control ➔ Control with discontinuous controllers
➔ Frequency response of combined elements ➔ Controller design in the frequency domain ➔ Fuzzy control ➔ Adaptive Control
➔ Fault simulation
70082 70083 LEYBOLD DIDACTIC GMBH
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CONTROL TECHNOLOGY 70082 70083
COM3LAB Course Control Technology I COM3LAB Course Control Technology II
Multimedia
Measuring in the virtual laboratory COM3LAB frees you of the inconvenience associated with obsolete measuring instruments. PC and master unit are all that is required – and then the course‘s software unfolds on any pupil‘s desk into a richly equipped instrument laboratory with the following instruments: static characteristic plotter step response plotter (for analog control) DDC plotter (for sampling control) controller design computer for calculating optimal controller parameters from specified system parameters two multimeters function generator (synthesizer) oscilloscope frequency analyzer logic analyzer
EQUIPMENT LIST
COM3LAB Control Technology I/II QUANTITY CAT. NO.
DESCRIPTION
1
700 82
COM3LAB Course: Control Technology I
1
700 00
COM3LAB Master Unit
The control process is recorded on the DDC plotter versus the time axis. The reference variable is red, the manipulated variable is green and the controlled variable is blue. The example shows the rotary speed control of a fan motor as affected by a PID controller for various reference variables.
recommended: 1
700 83
COM3LAB Course: Control Technology II
The COM3LAB Control Technology II course is a supplementary course to 700 82. It uses the same experiment board and can be released by a dongle on course I.
70082 70083 LEYBOLD DIDACTIC GMBH
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LEYBOLD DIDACTIC
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