PERPUSTAKAAN UTHM
*30000001883571*
K O L E J U N I V E R S I T I T E K N O L O G I T U N H U S S E I N O N N
P E N G E S A H A N S T A T U S L A P O R A N P R O J E K S A R J A N A
R O B O T INTERFACING STUDIES FOR AUTOMATED
Saya M O H D YUSRI BIN M O H D YUSOP mengaku membenarkan laporan projek sarjana ini disimpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hakmilik Kolej Universiti Teknologi Tun Hussein Onn. 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi
pengajian tinggi. 4. **Si!a tandakan ( V )
MANUFACTURING SYSTEM DESIGN
SESI PENGAJIAN : 2006/2007
SULIT (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972)
T E R H A D (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
TIDAK T E R H A D
Disahkan oleh:
(TANDATANGAN PENULIS)
Alamat Tetap:
256.LOSONG HAJI A W A N G , 21000 K U A L A T E R E N G G A N U . T E R E N G G A N U .
PROF. MADYA DR. ZAINAL A L A M BIN HARON (Nama Penyelia)
Tarikh:
CATATAN: Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.
R O B O T I N T E R F A C I N G S T U D I E S F O R A U T O M A T E D M A N U F A C T U R I N G
S Y S T E M D E S I G N
M O H D Y U S R I BIN M O H D Y U S O P
A project report submitted in partial fulfillment of the requirements for
the award of the Degree of
M a s t e r of Elect r ica l Eng inee r ing
Faculty of Electrical and Electronics Engineering
Kolej Universiti Teknologi Tun Hussein Onn
7 NOVEMBER, 2006
ii
"I hereby declare that the work in this report in my own except for quotations and
summaries which have been duly acknowledged"
Student
Date
M O H D YUSRI BIN M O H D YUSOP
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Supervised by
Supervisor
ASSOC. PROF. DR. ZATNAL A L A M BIN H A R O N
Ill
D E D I C A T I O N
Dedicated to my parents, my beloved wife and children
for their support, love and understanding during
the completion of my Master study
iv
A C K N O W L E D G E M E N T
Bismillaahirrahmaanirahim.. .
Praise be all to Allah SWT, the Most Gracious, the Most Merciful. Shalawat and
salam be to Rasulullah Muhammad saw. By the grace of Allah SWT, this research is
finally completed to full fill the requirements for Degree of Master of Electrical
Engineering.
I would like to take this great opportunity to express my warmest gratitude to my
supervisor Associate Professor Dr. Zainal Alam bin Haron for his guidance, concern and
strong support at all the time especially during the difficulties that I faced throughout the
completion of this research. His enthusiasm has been a great source of inspiration to me
and it gives me a great sense of honour to be under their wings.
Great thanks to my friends who have assisted in making this thesis a wonderful
one and finally to those who have contributed to the success of this thesis, especially the
lecturer and technicians of Mechatronics laboratory. Without them this research would
not have been possible.
vi
A B S T R A K
Projek ini menerangkan pengajian tentang perhubungan robot dengan sistem
pembuatan automatik. Integrasi kepelbagaian komponen seperti robot, CIM dan PLC
dianalisakan bagi memberikan kefahaman tentang hubungan dan batasan berkaitan
dengan integrasi. Pengajian ini terbahagi kepada dua bahagian, iaitu hubungan di antara
robot dan PLC dan juga hubungan di antara keduanya dengan CIM. Y A M A H A
SCARA robot dan O M R O N PLC digunakan di dalam ujikaji untuk projek ini. Ujikaji
ini mengunakan sambungan 'point-to-point ' dan pergerakan robot dikawal oleh PLC.
Untuk integrasi pada sistem CIM memerlukan penyambungan talian dan juga perisian
SCADA.
C O N T E N T S
C H A P T E R I T E M
T I T L E
D E C L A R A T I O N
D E D I C A T I O N
A C K N O W L E D G M E N T
A B S T R A C T
A B S T R A K
C O N T E N T S
L I S T O F T A B L E
L I S T O F F I G U R E
L I S T O F A P P E N D I X
I I N T R O D U C T I O N
1.1 Introduction
1.2 The important of CLM/Robotics
1.3 Problems Identification in the Integration
1.4 Project Objectives
1.5 Scope of The Project
viii
I I A U T O M A T E D M A N U F A C T U R I N G S Y S T E M S
2.1 Introduction 6
2.2 Reasons for automated system 9
2.3 Interfacing 10
2.4 Standards 15
2.5 Safety 16
I I I L I T E R A T U R E R E V I E W
3.1 Introduction 17
3.2 Background 18
3.3 Y A M A H A Y K 350X SCARA Robot 20
3.4 Computer Integrated Machine (CIM) 26
3.4.1 Auto Storage and Retrieval System (ASRS) 28
3.4.2 Cartesian Robot 29
3.4.3 SCARA Robot 31
3.4.4 Pneumatic Pick and Place 33
3.4.5 Free Flow Conveyor 34
3.5 Programmable Logic Controllers (PLC) 35
3.6 An Integrated System 37
I V M E T H O D O L O G Y
4.1 Introduction 39
4.2 Familiarization with the robot, CIM and PLC operation 40
4.2.1 Y A M A H A Y K 350X SCARA Robot 40
4.2.2 CIM 50
4.2.3 O M R O N CQM1H-CPU21 PLC 58
ix
4.3 Identify and understand the I/O interface of the components 66
4.4 Programming 68
4.5 Integration 73
V R E S U L T AND A N A L Y S IS
5.1 Introduction 74
5.2 PLC controlling the robot 75
5.3 Robot interfacing to CIM system via PLC 80
VI C O N C L U S I O N A N D F U T U R E W O R K
6.1 Conclusion 83
6.2 Future work 84
R E F E R E N C E S
A P P E N D I X E S
86
88
X
L I S T O F T A B L E S
3.1 A description of I/O terminal 26
4.1 Error message table 46
4.2 A description of each I/O terminal 66
xi
L I S T O F F I G U R E S
N O O F F I G U R E T I T L E P A G E
2.1 Automation categories. 7
2.2 Production quantity versus product variety 8
2.3 The relative positions of the automation 9
2.4 Layout of star network. 12
2.5 Layout of Ethernet 13
2.6 Layout of Token Rings 14
2.7 Layout of Token Buses. 15
3.1 The Y A M A H A Y K 350X robot 20
3.2 The Y A M A H A RCX 40 robot controllers 22
3.3 System controlling for one robot 23
3.4 Computer connection to the controller 24
3.5 N P N specifications 25
3.6 PNP specifications 25
3.7 Overall CIM system 27
3.8 Overall layout for CIM system 27
3.9 ASRS Labelling Example 28
3.10 Auto Storage & Retrieval System (ASRS) 29
3.11 Cartesian robot 3 axes 30
3.12 Cartesian robot 31
3.13 SCARA robot 4 axes 32
Xll
3.14 SCARA robot 33
3.15 Pneumatic Pick and Place 34
3.16 Free Flow Conveyor 3 5
3.17 The O M R O N SYSMAC CQM1H-CPU21 PLC 36
4.1 Operation overview 40
4.2 Controller front panel 41
4.3 M P B programming unit 42
4.4 Robot controller connection 44
4.5 " M A N U A L " mode screen 45
4.6 M P B screen example 46
4.7 Sheet key layout 47
4.8 Basic operation mode 48
4.9 CIM controller setup 51
4.10 Block diagram for CIM line 52
4.11 Flowchart for free flow conveyor 53
4.12 Solenoid valve for all station 55
4.13 Motor control for all station 56
4.14 The connection between PLC and PC using RS 232C cable 59
4.15 The wiring configuration 59
4.16 C X - P R O G R A M M E R 60
4.17 C X - P R O G R A M M E R 61
4.18 C X - P R O G R A M M E R 61
4.19 C X - P R O G R A M M E R 62
4.20 C X - P R O G R A M M E R 63
4.21 C X - P R O G R A M M E R 64
4.22 C X - P R O G R A M M E R 64
4.23 Flowchart for Programmable Controller Design 65
4.24 The GRAFCET description 72
5.1 The GRAFCET for the robot operation 77
5.2 The wiring connection between the PLC and the robot controller 78
5.3 Robot controller connection (wiring) to the PLC 79
The existing controller setup
The purposed controller setup
xiv
L I S T O F A P P E N D I C E S
A P P E N D I X T I T L E P A G E
A Connector I/O Signals Table 88
B Connector Pin Numbers 89
C Lab Sheet: Using VIP software to program 90
the Y A M A H A Y K 350 X SCARA robot
D Y A M A H A Robot ' s program 98
E Ladder Diagram for Y A M A H A Robot 99
CHAPTER 1
INTRODUCTION
1.1 Introduction
In modern manufacturing operation, most of the production systems are using
automated system. Manufacturing system in the factory can be referred as equipment
arrangement and the workers who operate them. Manufacturing systems can be
individual work cells, consisting of a single production machine and worker assigned
to that machine or as groups of machines and workers, for example production line.
The future of the factory will be a fully automated factory that manufactures a wide
variety of products without human intervention. Although some "peopleless"
factories do exist and others will be built, the major advances being made today occur
in manufacturing operations where computers are being integrated into the process to
help workers create high-quality products. Computer-integrated manufacturing (CIM)
is an umbrella term for the total integration of product design and engineering,
process planning, and manufacturing by means of complex computer systems. Less
comprehensive computerized systems for production planning, inventory control or
scheduling are often considered as part of CIM. By using the powerful computer
system to integrate all phases of the manufacturing process, starting from the
customer order to final shipment, firms hope to increase productivity, improve
quality, meet customer needs, and offer more flexibility.
2
Computer Integrated Manufacturing (CIM) describes a new approach to
manufacturing, management and corporate operation. The Computer and Automation
System Association (CASA) of the Society of Manufacturing Engineers (SME)
defines CIM as, the integration of the total manufacturing enterprise through the use
of integrated systems and data communications coupled with new managerial
philosophies that improve organization and personnel efficiency. Although CIM
systems can include many advanced manufacturing technologies such as robotics,
computer numerical control (CNC), computer aided manufacturing (CAM) and just in
time production (JIT), it goes beyond these technologies. In addition to the above
definition, CIM might be viewed as an integration tool, which uses information and
automation hardware and software for production control and management. In this
context, CIM is considered as an integrative tool for an organization, which is able to
increase productivity, quality and competitive advantage. [1]
Many single purpose machines, often called hard automation, have some
features that make them look like robots. The International Standard Organization
(ISO) defines an industrial robot in standard ISO/TR/8373-2.3 as; a robot is an
automatically controlled, reprogrammable, multipurpose, manipulative machine with
several reprogrammable axes, which may be either fixed in place or mobile for use in
industrial automation applications. The key words are reprogrammable and
multipurpose, because most single purpose machines do not meet these two
requirements. Reprogrammable implies two elements:
1. The robot's motion is controlled by a written program.
2. The program can be modified to change significantly the motion of the
robot arm.
The purposed of this project is to apply the knowledge in robotics research to a
CIM environment and to integrate different subsystems into a concerted
manufacturing system with computer workstations. The robot-based CIM system, in
which hardware and software are integrated to perform manufacturing tasks, is
implemented and presented. A study of robot work cell and the integration of robots
into CIM systems will be the major focus in this project.
3
The existing stand-alone YAMAHA robot is being proposed for this project,
to be interfaced with the CIM system. This project will use OMRON CQM1H PLC
to control the YAMAHA YK 350X SCARA robotic arm and then interface with other
OMRON CQM1H PLC attached to CIM system, where the robotic arm will be
programmed and setup to perform some task.
1.2 The importance of CIM/Robotics
There is no doubt that many of the activities and functions currently being
performed by human will gradually taking over by the automation system. The
primary requirement for automating any function are the availability of a model of the
activity necessary for that function, the ability to quantify the model and a clear
understanding of the associated information and control requirements. There are
several reasons for some functions should be performed by CIM or robotics, which
are:
1. Design accuracy and tolerance requirement.
2. The nature of the activity being such that it cannot be performed by
human.
3. Speed and high production volume requirement.
4. Size, force, weight, and volume requirement.
5. Hazardous nature of the work.
6. Special requirement.
4
1.3 Problems Identification in the Integration
Computer-Integrated Manufacturing (CIM) was the best solution for
successful flexible automation of the world factories. CIM aims at the comprehensive
integration, by means of computers, of all stages of the manufacturing cycle. A
flexible manufacturing system (FMS) is only part of the CIM concept. Flexibility of
manufacturing system is the key issue in modern industry. As far as flexibility is
concerned, transport forms one of the most notorious bottlenecks in typical FMS. The
flexibility problem in transport function can be solving by the development of
industrial robots. Difficult interface problems, insurmountable so far, have prevented
the smooth introduction of robotics into CIM. The most problem lies in the interface
of the robot with the parts to be handled. The uncertainty in the robot environment
(inaccurately positioned parts) is another cause of problems, reducing the overall
system flexibility. External sensors, such as vision, force and tactile sensors are used
to resolve the problem, but still have a lot of space to be improved.
Beside mechanical interface problem, information interface are more even
important, and often the only alternative, for increasing the flexibility of CIM. To
execute a manufacturing task, the different components of an FMS must be able to
exchange information smoothly and swiftly. This requires interoperable data
interfaces and communication protocols. In the context, bandwidth and real-time
response issues must be addressed almost on an equal level with data exchange.
One of the key issues regarding CIM is equipment incompatibility and
difficulty of integration of protocols. Integrating different brand equipment controllers
with robots, conveyors and supervisory controllers is a time-consuming task with a lot
of pitfalls. Quite often, the large investment and time required for software, hardware,
communications, and integration cannot be financially justified easily. Another key
issue is data integrity. Machines react clumsily to bad data and the costs of data
upkeep as well as general information systems departmental costs are higher than in a
non-CIM facility. Another issue is the attempt to program extensive logic to produce
schedules and optimize part sequence. There is no substitute for the human mind in
5
reacting to a dynamic day-to-day manufacturing schedule and changing priorities. It
is an operational tool that, if implemented properly, will provide a new dimension to
competing: quickly introducing new customerized high quality products and
delivering them with unprecedented lead times, swift decisions, and manufacturing
products with high velocity.
1.4 Project Objectives
1. To integrate robotic work cell into CIM system.
1.5 Scope of the Project
There are three steps in running the projects, which are:
1. Understanding and familiarization of robotic work cell and how to
control the YAMAHA robot using OMRON PLC.
2. Understanding and familiarization of the CIM system and connection.
3. Analyze and identify the task (process) needed to be programmed and
integration requirement.
4. Control robot using the OMRON PLC and integrate to the CIM system
CHAPTER II
AUTOMATED MANUFACTURING SYSTEMS
2.1 Introduction
Some elements of the production system are likely to be automated, whereas
others will be operated manually. As per discussion here, automation can be defined
as a technology concerned with the application of mechanical, electronic and
computer-based systems to operate and control production. The automated element of
the production system can be separated into two categories: (1) automation of the
manufacturing systems in the factory and (2) computerization of the manufacturing
support system. The term computer-integrated manufacturing is used to indicate this
extensive use of computers in production system. The two categories of automation
are shown in Figure 2.1 below.
Automated manufacturing systems perform operations such as processing,
assembly, inspection or material handling. They are called cases automated because
they perform their operations with a reduced level of human participation compared
with the corresponding manual process. In some highly automated systems, there is
virtually no human participation.
7
Production system i
Manufacturing support system
Facilities: Factory Equipment
Potential computerization applications
Potential automation applications
\ CM
Figure 2 .1 : Automation categories
Automated manufacturing systems can be classified into three basic
types:
1. Fixed automation
It is a system in which the sequence of processing operation is fixed by
equipment configuration. Each of the operations in the sequence is usually
simple, involving perhaps a plain linear or rotational motion or an
uncomplicated combination of the two. It is the integration and
coordination of many such operations into one piece of equipment that
makes the system complex. Example of fixed automation includes
machining transfer lines and automated assembly machines.
2. Programmable automation
In the programmable automation, the production equipment is designed
with capability to change the sequence of operations to accommodate
different product configurations. The operation sequence is controlled by
a program, which is a set of instructions coded so that they can be read and
interpreted by the system. New programs can be prepared and entered into
the equipment to produce new products. Examples of programmable
8
automation include numerically controlled (NC) machine tools, industrial
robots and programmable logic controllers.
3. Flexible automation
It is an extension of programmable automation. A flexible automated
system is capable of producing a variety of parts with virtually no time lost
for changeovers from one part style to the next. Also no lost production
time while reprogramming the system and altering the physical setup.
Consequently, the system can produce various combinations and schedules
of parts (products) instead requiring that they be made in batches. What
makes it possible is that the differences between parts processed by the
system are not significant. Examples of flexible automation are the
flexible manufacturing systems for performing machining operations that
date back to the late 1960s.
The relative positions of the three types of automation for different production
volumes and product varieties are shown in Figure 2.2 and Figure 2.3. For low
production quantities and new product introductions, manual production is
competitive with programmable automation.
Product variety
Programmable automation
Manual production
Flexible automation
Fixed automation
100 10,000 1,000,000
Production quantity
Figure 2.2: Production quantity versus Product variety
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