PERPUSTAKAAN UTHM

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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