Hexagon Manufacturing Solutions Final Report
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Transcript of Hexagon Manufacturing Solutions Final Report
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FLEXIBLE
MANUFACTURING
SYSTEM PROJECT _____________________________________________________________________
AZHAR NIAZI
CAYURE CARNEIRO
DANIEL BREITKREUZ
JITHIN UTHUP
KARYTAS LEONEL
YOGIN DOSHI
April, 2015
Aaron Shatkosky
PROD1601
-
i
Typed by:
Cayure Carneiro
& Yogin Doshi
Date:
04/19/2015 Hexagon Manufacturing Solutions
Reviewed by:
Karytas Leonel
Date:
04/20/2015
FLEXIBLE
MANUFACTURING SYSTEM
PROJECT
Reviewed by:
Daniel Breitkreuz
Date:
04/20/2015
Reviewed by:
Jithin Uthup
Date:
04/20/2015
Approved by:
Azhar Niazi
Date:
04/20/2015
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ii
Table of Contents 1. Overview ............................................................................................................................... 1
2. Equipment .............................................................................................................................. 1
2.1 Process Cell Layout .......................................................................................................... 2
3. Description of Operation ......................................................................................................... 3
4. Product Specifications ............................................................................................................ 3
4.1 Finished Parts Drawings ................................................................................................... 5
5. Robot Documentation ............................................................................................................. 6
5.1 Methodology ..................................................................................................................... 6
5.2.1 Station # 1 Robot ....................................................................................................... 7
5.2.2 Station # 2 Robot ....................................................................................................... 8
5.2.3 Handshaking Process ...............................................................................................10
5.3 Cell layout ........................................................................................................................11
5.4 Point location table ..........................................................................................................12
5.6 Troubleshooting ...............................................................................................................13
6. PLC Documentation ..............................................................................................................14
6.1 Methodology ....................................................................................................................14
6.2 Flowchart .........................................................................................................................15
6.4 Troubleshooting ...............................................................................................................18
7. AS/RS Documentation ..........................................................................................................20
7.1 Methodology ....................................................................................................................20
7.2 AS/RS Program ...............................................................................................................21
8. CNC Documentation .............................................................................................................21
8.1 Troubleshooting ...............................................................................................................21
9. Grippers and Fixtures Design ................................................................................................22
9.1 Guidelines for Grippers and Fixture Design .....................................................................22
9.1 Gripper and Fixture Drawings ..........................................................................................23
10. Conclusion ..........................................................................................................................24
Appendix ...................................................................................................................................25
I/O TABLE .............................................................................................................................25
Tolerance Table ....................................................................................................................27
Attachments ..............................................................................................................................28
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iii
Figure 1 Flexible Manufacturing Cell layout ................................................................................ 2 Figure 2 Flat Stock ..................................................................................................................... 4 Figure 3 2 pcs. Of Round Stock ................................................................................................. 4 Figure 4 Flat Stock after Machining (Left Hand) ......................................................................... 5 Figure 5 Round Stock #1 after Machining..................................................................................5 Figure 6 Round Stock #2 after machining..5
Table 1: Point Location Table for both station ...........................................................................12
Table 2 Input Output Table........................................................................................................26
Table 3 LC10 Fit Table ..............................................................................................................27
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1. Overview
Flexible Manufacturing Cell consisting of Amatrol 863-AS/RS, Amatrol Programmable
Control System with Allen Bradly SLC 150 processor, Pegasus 5 axis articulated servo Robots,
Danford Mill and Lathe Machining Centers, and Amatrol Conveyor, is programmed to make family
of parts automatically in this project. Given the raw material the FMC is designed to receive the
materials from AS/RS and go through couple of machining processes to make family of parts. Cell
also collects the parts from the machining centers and store it back into the AS/RS. Team of 6
students made this entire project.
Grippers are designed for the robot arm in accordance to given material. Stationary fixtures
are also designed to hold the material before the particular machining process. Specific guidelines
are followed to make the Gripper and Fixture design versatile.
2. Equipment
Below is the list of equipment:
- Straight chain conveyor with pallet transfer and return, with 4 pallet unload stations
- Pallets with pallet fixtures
- CNC mill Centre
- CNC lathe Centre
- Two 5 axis articulated robots
- Amatrol 863 - AS/RS
- AB SLC 5/05 PLC Processor
- PLC with 7 slot chassis
- RFID readers
- Relevant hardware and software available in the lab
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2.1 Process Cell Layout
1
23
4
5
6
7
8
1 Operator2 Control Station3 ASRS4 Pallet Rack5 CNC Mill6 Mill Robot7 Lathe Robot8 CNC Lathe
Figure 1 Flexible Manufacturing Cell layout
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3. Description of Operation
Using PLC, the pallet will be called from AS/RS according to the users necessity. AS/RS put
the pallet on conveyor. The RFID readers on the conveyor recognizes the pallet and sends the
signal to PLC to stop the pallet on machining station. On machining station robot gets the signal
to unload the parts. When unloading is complete and robot is in a safe position, the pallet
continues to next station for further operation. Meanwhile, the robot sends signal to the vice/chuck
to get closed and then it moves to a safe position in order to start the machining cycle. A signal is
sent to CNC machine when the robot gets to safe position. Once machining cycle is complete,
robot receives a signal from CNC to unload the part. PLC gets a signal to call the pallet from
AS/RS. Another pallet comes and collects the finished parts. When two machines are in physical
proximity of each other, appropriate interrupts/interlocks are used to prevent accidental collision
or damage. The parts are loaded in the pallets on the AS/RS in a separate process outside of this
projects scope of work. Another process populate the data tables of the PLC that controls the
inventory and order information. This can be modified later and is outside of this projects scope
of work.
4. Product Specifications
This system processes the parts from a product family for a two part aluminum assembly.
Part one is a rectangular extruded flat stock with one large and one small, blind, spot faced hole
on its broad face. There is a left hand and right hand version of this part. Part two and three are
cylinders with the end turned down to press fit in the holes of part one. For tolerances see
Table 2 LC10 Fit.
The incoming material consists of:
Part 1: Aluminum Flat Bar x 2 x 3 LG c/w existing slot. The tolerance on the thickness
and width of the flat bar is per mill tolerances of Alum 6061-T6. The ends have already been
milled, so the length has a tolerance of +/- 0.010. See figure 2.
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Figure 3 2 pcs. Of Round Stock
Part 2: Aluminum Round Bar 1 x 2 LG. The tolerance on the diameter of the round bar is per
mill tolerances of Alum 6061-T6. The ends have already been faced to a length tolerance of +/-
0.010. See figure 1.
Figure 2 Flat Stock
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Figure 4 Flat Stock after Machining (Left Hand)
Figure 5 Round Stock #1 after Machining Figure 6 Round Stock #2 after machining
4.1 Finished Parts Drawings
Finished parts drawing are attached at the end of the report.
Drawings Include:
- Pin 1 (Sheet 1)
- Pin 2 (Sheet 2)
- Plate (Sheet 3)
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5. Robot Documentation
5.1 Methodology
For both station, random teach points are made in order to get the program tested and
avoid collision among machineries. The points used are listed point location table.
Once pallet reaches at the machining station PLC sends the signal to relevant robot to
unload the part from the conveyor. Being more specific, the robot unloads the raw stock from
pallet at the station and load it into the fixture. Then Robot sends the signal to CNC Machine to
open the door, once the door is opened CNC sends signal back to robot to put the part into the
vise/chuck. Robot then puts the part into the vise/chuck. CNC waits to get the signal for closing
the door and start the operation. Robot sends the signal back to CNC once it reaches to safe
position. Once the machining process is done Robot gets the signal to get the part from the CNC
machine. Meanwhile Robot and CNC sends the signal to AS/RS to call for empty pallet. Robot
then loads the finished part on empty pallet.
The entire process is programmed to machine one part family which includes: flat stock
and two round stock. Therefore, the robot loads and unloads the pallet, fixture and CNC with
pieces for just one assembly. However, we are totally able to do the same for unlimited parts as
long as we have enough spot on the fixtures and AS/RS. For example, we can use the command
Grwidth to measure the distance between the gripper fingers and set a conditions on that. If the
value obtained is zero then move to the second spot and so on until get some value. Once it is
done, continue for the next step, loading the fixture and then the CNC.
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5.2.1 Station # 1 Robot
Start
Wait for PLC
signal
Pick up parts on
conveyor
Signal the
Mill to open
the door
Load Mill
Is the part
ready?
A
Unload the CNC
Signal CNC
to close the
door
Leave the part on
fixture
Wait for machining A
Program End
YES
Signal PLC
to call the
pallet from
AS/RS
B
B
Wait for pallet
Is the pallet at the
station?
Load the
pallet at the
station
NO
Close Vice
Initialize
Robot
YES
NO
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5.2.2 Station # 2 Robot
Start
Wait for PLC
signal
Pick up part 1
on conveyor
Signal
the
Lathe to
open the
door
Load Lathe
w/ Part 2
Is the part
ready?
A
Unload the
Lathe
Signal
Lathe to
open the
door
Leave the
part on fixtureWait for
machining
A
NO
YES
Close
chuck
Initialize
Robot
Load Fixture
Pick up part 2
on conveyor
Close
the door
Pick up part 1
on fixture
Load Lathe
w/ Part 1
Wait for
machining
Close
chuck
Close
the door
B
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Program End
C
Wait for pallet
Is the pallet at the
station?
Load the pallet at the station
YES
NO
Signal PLC to
call the pallet
from ASRSC
Is the part ready?
B
Unload the Lathe
Signal Lathe
to open the
door
NO
YES
Load Conveyor
part 1
Load Conveyor
part 2
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5.2.3 Handshaking Process
Robot Has Come To Safe
Position
Once The Door Is Opened, CNC
Highs The Signal To Tell Robot To
Put The Part Into Vise/Chuck
Robot Sends Signal To CNC To
Open The Door
Wait For Robot To Come To Safe
Position
Robot And CNC Send Signal To
AS/RS And PLC To Call For Empty
Pallet
Robot Puts The Part Safely Into
Vise/Chuck and Come Back To
Safe Position
No Yes
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5.3 Cell layout
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5.4 Point location table
Point Location Table Robot #1 Point Location Table Robot #2
Point # Name Description Name Description
0 Robot Home Position Robot Home Position
1 Point_1 Ready Position Point_1 Ready Position
2 Point_2 Approach point for conveyor Point_2 Approach point from conveyor PIN 1
3 Point_3 Pick point for conveyor Point_3 Pick point from conveyor PIN 1
4 Point_4 Approach point for vise Point_4 Approach point from conveyor PIN 2
5 Point_5 Pick point for vice Point_5 Pick point from conveyor PIN 2
6 Point_6 Point clear of CNC Point_6 Approach point from fixture PIN 1
7 Point_7 Approach point for fixture Point_7 Pick point from fixture PIN1
8 Point_8 Pick point for fixture Point_8 Approach point from fixture PIN 2
9 - - Point_9 Pick point from fixture PIN2
10 - - Point_10 Approach point from the chuck
11 - - Point_10 Point clear from CNC Table 1: Point Location Table for both station
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5.6 Troubleshooting
As the robot is in constant communication with the CNC machines, it needs follow all
requirements. As we did not meet the client requirement to produce two different parts on the mil
(left hand and right hand), the robot program is written just for one operation. However, it can be
solved by adding points for the second spot on conveyor and fixture and set the communication
of the robot and PLC. It means that, the PLC sends a signal to robot inform that the second part
is ready to be processed. Waiti command keeps the robot for the PLC signal to start the second
part. It is necessary to add one more line on the robot program in order to notify that second part
is in process. We use the command Waiti 2, 1, which means that the robot proceeds for the
second operation just after this Input goes high. This signal comes from PLC when the operator
select the second CNC program. It works exactly the same for both station. Also, we had some
issues with the points on robot, especially at the second station. We were losing the points on
every new attempt. This is due the low repeatability of the robots and some crashes suffered by
it. The robot at the second station was notably twisted. The line highlighted below is to be added
on the program to separate the operations and make the system flexible.
Call Loadfixture_p1
Writeo 16, 0 //Open the door and chuck/vice for second operation
Waiti 15, 0 //Signal from CNC telling door and chuck opened
Waiti Input_2, on //SIGNAL FROM PLC TO START THE SECOND OPERATION
Call Loadcncp2
Writeo 16, 1 //SEND "PARTE READY" SIGNAL TO CNC CLOSE CHUCK/VICE
Waiti 15, 1 //WAIT FOR "CHUCK/VICE" SIGNAL FROM CNC
Release
Ddmove 2.20,7
Speed fast
Pmove Point_11 //Safe posit
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6. PLC Documentation
6.1 Methodology
Firstly RSLogix 500 English has to be configured using RSLinx Classic with
Programmable Logic Controller station. Once the system has been configured the program can
run on PLC, incorporating ASRS, Conveyor, Robot stations and Machining stations.
The first step in PLC program is to clear the ASCII buffer so any previous data in register
is removed. PLC send the signal to ASRS to put the pallet on the conveyor. Note that there is
different input (Toggle Switch) to call the specific pallet from the ASRS. Pallet is read on First
RFID and it sends the signal to station #1 stop pin to go high. After First pallet reaches to station
#1, Pallet positioner will be lifted and signal will be sent to robot #1 to get the part from the
conveyor. Once the part is taken and robot #1 reaches to safe position, it will send an output
signal to PLC to low the stop pin so the pallet can move further to Station #2. Pallet is now read
by second RFID and it sends the signal to station #2 stop pin to go high. After First pallet reaches
to station #2, pallet positioner is lifted and signal is sent to robot #2 to get the part from the
conveyor. Once both parts are taken and robot #2 reaches to safe position, it send an input signal
to PLC to low the stop pin so the pallet can move further to ASRS. Pallet reaches to end of the
conveyor and once it is read on last RFID, it sends a signal to ASRS to get the part from the
conveyor. PLC waits for the done signal from both machining and robot stations to put the empty
pallet on the conveyor. Empty pallet stops at station #1 and then station#2 to get the finished part.
For Input and Output addressed see the Table 1 Input Output Table. For handshaking between
robot and cnc see section 5.2.3. PLC program is attached at end of the report.
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6.2 Flowchart
Start PLC & Conveyor
Clear The ASCII Buffer
Wait For The First Pallet To
Pass First RFID
Read For Pallet At First
RFID
High First Station Stop Pin
Pallet Has Reached &
Stopped
Wait For Pallet One To
Reach At Station One
Get The Signal From Robot
To Pull Down The Stop Pin Back
Wait For The First Pallet To Pass Second RFID
Read For Pallet At
Second RFID
High Second Station Stop Pin
Wait For Pallet One To Reach At Station Two
Pallet Has Reached &
Stoped
Follow The Sub Process
One
Follow The Sub Process One
Pull Down The Stop Pin For
Pallet Station Two Back
Pallet One Will Go Back To
ASRS
A
Yes
No
Yes No
Yes
Yes
On The Toggle
Switch To Lift The Pallet Station
Positioner Up
Send The Signal
To ASRS To Put The Part On The
Conveyor
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Robot And CNC Will Give
The Signal To ASRS To
Get Empty Pallet On The Conveyor
Clear The ASCII Buffer
Wait For The Empty
Pallet To Pass First RFID
Read For Pallet At 1st RFID
High First Station Stop Pin
A
Follow The Sub
Process Two
Wait For The Empty Pallet
To Pass Second RFID
Read For Pallet At
2nd RFID
High Second Station Stop
Pin
Follow The Sub
Process Two
Signal ASRS To Get The
Pallet
End PLC Process
Yes
Wait For Both Machining
Process To Be Done
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Signal Robot To Pick The
Part
Sub Process One
Pull Down The Stop Pin
For Pallet Station Back
Wait For Robot To Put
The Part In Pallet
Pallet Has Reached
& Stopped
Finished Part Is In
The Pallet
Sub Process Two
Wait For Pallet One To
Reach At Station Second
Wait For Robot To Load The Part In CNC Machine
& Come Back To Safe Position
Robot Reached To
Safe Position
Continue To Next Step
Yes No Yes
No
Yes
Continue To Next Step
CNC Gets The
Input To Run
Specific
Program
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6.4 Troubleshooting
In order to make the cell flexible, the computer control system requires to distribute control
instruction to workstation. Which makes the Cell able to operate even if changes are made in part
design. That means if the PLC program has specific input to call to run specific CNC program
then it allows the cell to do production in non-batch mode. Also, if there is change in the design
of part, then new CNC program can easily be incorporated in the Manufacturing Cell by just adding
the program in CNC machining station by external source.
There are few Bit Options in PLC to send the signal to CNC to run the specific program. We
considered using MOV bit in program to send the signal to CNC to run particular program. So the
MOV bit output energizes when the specific input is given. MOV bit sends the source number to
register which is designated for particular machining center. For register and buffer see table 2
Input Output Table. Excel sheet has to be open in the machining center which has the information
for the register and the output. RSLinx configures the Rslogix with the process and processor
connects the Rslogix to machining center or material handling system via RSLinx. And thus
RSLinx also has to be open in the CNC machine. Once MOV bit output is energized in the PLC
program it sends the signal through RSLinx to run the program which has number written in the
Excel file. The program can be corrected by adding the rungs mentioned on next page.
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7. AS/RS Documentation
7.1 Methodology
Automatic Storage and Retrieval System is important integrated part of the Flexible
Manufacturing Cell. PLC calls AS/RS to put the pallet on conveyor. AS/RS receives the signal
from PLC and gets the pallet from AS/RS and put it on the conveyor. Note that there is a specific
input to call specific pallet from the AS/RS. After the machining cycle is done Robot and CNC
together send the signal to AS/RS and PLC to get the empty pallet. Once AS/RS receives the
signal it takes the empty pallet from AS/RS and put it into the conveyor. When Pallet reaches to
end of travel, it is read by RFID and PLC sends the signal to AS/RS to get the pallet from the
conveyor and load it into the relevant rack. To read the pallet number and make the AS/RS work
accordingly, program is made into the PLC.
The AS/RS program is provided along with the excel spread sheet to store the registers and
buffers. However we followed the procedure bellow to initialize the machine.
1) Turn the conveyor main power on
2) Turn the air supplier on
3) Turn the driver on
4) Turn the computer on
5) Open up the RSLinx to set the communication
6) Open the Excel spread sheet and update it
7) Open up the Mach 3
8) Press the main button on AS/RS
After all these steps, the program provided is load onto Mach3 and the cycle is started. Now,
the AS/RS is able to work and the PLC already gets the Input I: 2/6 (see Table 1 Input Output
Table). The excel spread sheet is populated automatically and there stores the value of the
N7:50 and N7:51 register, which means that the ASRS reads the value on there to get the pallet
informed.
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7.2 AS/RS Program
M106
M47
M30
8. CNC Documentation
For our CNC programs Mastercam was used to create our G-code. The CNC milling
operation consists of pocket operations. The milling program does the spot face and drilling
operation on one hole then the same on the next hole. A 3/8 cutter was used. Spindle speed is
2139. The plunge feed rate is 3.0 in/rev and the milling feed rate is 6.0 in/rev. Depth of cut was
0.1875
The CNC lathe operation consists of a facing, roughing, and finishing operation. A 55
degree cutter was used. Spindle speed was 2200. The roughing feed rate is 6.0 in/rev and
finishing feed rate was 3.0 in/rev. Depth of cut is 0.1.
CNC documentation is attached at the end of the project.
8.1 Troubleshooting
CNC mill speed has to be 2800 rpm. CNC lathe speed has to be 3000 rpm. Lathe feed rates
adjusted to 9.0 in/rev 6.0 in/rev. Program must have automatic tool change command, which
is M06 T05. CNC program for left hand and right part be separate so it can be run on signal it
machining center gets from the PLC.
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9. Grippers and Fixtures Design
9.1 Guidelines for Grippers and Fixture Design
The following guidelines have been taken into the consideration while constructing
grippers for use in two flexible manufacturing work cells. The purpose of the following design
description is to increase the output of the work cell by avoiding tool changes, grasp multiple part
orientations with a single gripper, and ensure a secure grasp of part and reduce material.
Ensure a Secure Grasp of Part
An increase in the speed of the robot is one of the desired effects. Any part has mass,
and attempting to accelerate this mass as it is moved from the parts feeder to the
assembly area requires force. This force comes through the grasp the gripper has on
the part. While it is best to design the gripper to fully encompass the part and not rely
on friction, this was not practical. In practice, for the best result was observed that it
would be better used for the plates a straight design in L shape, as to the cylinders
used a design in four opposing V grooves.
Avoid tool change and Grasp Multiple Part orientations with a Single Gripper
Avoid tool changes will decrease cycle time. One approach to avoiding tool changes
is to design each gripper to handle more than one part orientation. Both of the grippers
can handle the two orientations required in the work cells. The gripper is able to load
and unload the conveyor and the CNC.
Reduce material
In order to reduce the material the fixture was designed with simple slots for the Milling
parts and holes for the Lathe parts. A countersink was used to help with placing the
parts inside the fixtures.
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Mill fixture locating pin adjustment
The mill fixture had two locating holes to mount onto the stationary pallet. We had an
issue with one of the holes not aligning properly. We decided to create a slotted hole
on one of the holes to allow for clearance. We still retained the location we wanted
because of the other hole.
9.1 Gripper and Fixture Drawings
Finished Grippers and Fixtures design drawings are attached at the end of the report.
Drawings include:
- Gripper for Pins (Sheet 4)
- Gripper for Plate (Sheet 5)
- Fixture for Plate (Sheet 6)
- Fixture for Pins (Sheet 7)
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10. Conclusion
To be concluded the FMS project consists of simple few tasks. However, after trial and error we
find things that we need to change in order to make cell work in as desired.
PLC PLC part is most critical part of the whole project. It works as a liaison between
AS/RS, Material handling system, Robots, and CNC. Initially we find few errors in program and
we needed to consult other group for some help. Later we figured out couple of new bits
(commands) to make correct program. We also find some trouble in configuring our laptops with
PLC Processor which later with the help of lab coordinator sorted out.
CNC The G code for the CNC program is corrected couple of times to get the proper
alignment on the axis on the mill. Finding the correct sequence of codes to get the lathe to
handshake properly with the robot take us some time. The mill is easier process then the lathe.
Robotics The robot programming since the beginning is considered not to be the most
difficult part. However, proper CNCs program is needed for a series of handshaking. Also, the
points inside the CNC machine required a lot of patience and caution in order to avoid crashes.
For the lathe, we did not get repeatability to get the points already taught; therefore, we exchanged
the Lmove command inside the Lathe to Ddmove command. This way, we can sit the part in the
chuck without problems.
ASRS The ASRS is program is provided to us. Except safety procedure we did not have
to do much in AS/RS.
Fixture Design The fixture design was not successful at first. The first design was
scrapped due to its complexity and overuse of material. We went back to the drawing table and
made a leaner design. However, the new printed design needed some small changes as well.
The slots for the mill parts had to be made larger because the mill parts were fitting too tight.
Gripper Design We gave enough brainstorming to gripper design and we ended up going
with the leaner drawings.
Overall there were some hiccups in the process but that is the whole point of tackling the
task as a group. Through troubleshooting we were able to find our errors and connec
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Appendix
I/O TABLE
Input and Outputs
Pallet Station 1 - Stop Pin O:3/0
Pallet Station 1 - Restraint Pin O:3/1
Pallet Station 1 - Pallet Positioner O:3/2
Pallet Station 2 - Stop Pin O:3/3
Pallet Station 2 - Restraint Pin O:3/4
Pallet Station 2 - Pallet Positioner O:3/5
ASRS M26 (on), M27 (off) I:2/6
ASRS M28 O:4/7
Robot Station 2 Input_16 O:3/5
Robot Station 2 Output_15 I:1/4
Robot Station 1 Input_15 O:3/2
Robot Station 1 Output_15 I:1/1
Toggle 1 I:1/0
Toggle 2 I:1/1
Toggle 3 I:1/2
Toggle 4 I:1/3
Pallet Station 1 - Proximity I:1/0
Pallet Station 2 - Proximity I:1/3
Conveyor End of Travel (EoT) 1:2/5
Control Box Switch (Toggle) I:5/0
Control Box Switch (Toggle) I:5/1
Control Box Switch (Toggle) I:5/2
Control Box Switch (Toggle) I:5/3
Control Box Switch (Pushbutton) I:5/6
Control Box Switch (Pushbutton) I:5/7
Robot #1 (Mill) Output 1 I:5/12
Robot #1 (Mill) Output 2 I:5/13
Robot #2 (Lathe) Output 2 I:5/14
Robot #2 (Lathe) Output 1 I:5/15
Control box lamp ASRS and Get Pallet signal O:6/10
Control box lamp ASRS and Put Pallet signal O:6/11
Robot #1 (Mill) Input 1 O:6/12
Robot #2 (Lathe) Input 1 O:6/15
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Input and Outputs - Mill/Robot #1
Robot #1 to Mill Output_16 M66 (wait for high), M76 (wait for low)
Robot #1 from Mill Input_16 M62 (On), M64 (Off)
Mill to PLC I:1/15 M63(On) M65(Off)
Robot #1 to Vice Output 14 On = Closed, Off = Open
Input and Outputs - Lathe/Robot #2
Robot #2 to Lathe Output_16 M66 (wait for high), M76 (wait for low)
Robot #2 from Lathe Input_16 M62 (On), M64 (Off)
Lathe to PLC I:2/1 M63(On) M65(Off)
Lathe chuck M110 (Open), M111 (Closed)
Registers and Buffers
Mill Program Number N7:49
Lathe Program Number N7:48
ASRS Put Pallet Number N7:51
ASRS Get Pallet Number N7:50
RFID Buffer Clear Signal (to SLC 5/03) O:4/4 Table 2 Input Output Table
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Tolerance Table
Table 3 LC10 Fit Table
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Attachments
1. Robot program
2. PLC program
3. CNC program
4. Minutes meetings
5. Designs
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Hexagon Manufacturing Soultions
Flexible Manufacturing System
PROD 1601
Software: Pegasus II Control Software 1.1.3
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Programmer: Cayure Carneiro
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Hexagon Manufacturing Solutions
1
1. Robot programs
1.1 Station # 1 Robot
Global slow
Global fast
English
Pmove
Release
Grforce 0.5
Grwidth 3.5
Writeo 14, Off
Writeo 15, Off
Writeo 16, Off
Writeo 1,Off
Fast=200
Slow=40
Label Operation
Waiti Input_15, On
If Inp (Input_1) = On then Call Put parts
Writeo 1,0
Call Getparts
Writeo 15, On //RELEASING THE PALLET
Delay 2
Writeo 15, Off
Call Loadfixture
Writeo 14, Off //OPEN THE VICE
Delay 2 //TIME TO OPEN VISE
Writeo 16,1 //OPEN CNC DOOR
Waiti 16,1 //DOOR OPENED
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Hexagon Manufacturing Solutions
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Call Loadcnc
Writeo 14, On //CLOSE VISE
Writeo 16, 0 //TELLING CNC ROBOT READY, CNC START
Waiti 16, 0 //WAIT FOR "CNC DONE" SIGNAL FROM CNC
Writeo 14, 0 //OPEN VISE
Delay 2
Call Unloadcnc
Writeo 14,0 //OPEN VISE
Delay 2
Pmove Point_4
Speed Fast
Pmove Point_6
Writeo Output_1,On //Input I:5/12 on PLC Call Loadfixture
Call Loadfixture
Branch Operation
Sub Getparts
//TAKING PART FROM THE CONVEYOR
Pmove Point_1 //READY POSITION
Pmove Point_2 //APPROACH POINT FROM THE CONVEYOR
Speed slow
Lmove Point_3 //PICK POINT FROM THE CONVEYOR
Grasp
Lmove Point_2
Speed fast
Pmove Point_1
Return
Sub Loadfixture
Pmove Point_7 //APPROACH POINT FROM THE FIXTURE
Release
Pmove Point_6
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Hexagon Manufacturing Solutions
3
Return
Sub Loadcnc
Pmove Point_7 //APPROACH POINT FROM THE FIXTURE
Speed Slow
Lmove Point_8 //PICK POINT FROM THE FIXTURE
Grasp
Lmove Point_7
Speed Fast
Pmove Point_4 //MOVE TO APPROACH POINT FOR VISE
Speed Slow
Lmove Point_5 //MOVE TO PICK POINT FOR VISE
Release
Lmove Point_4
Speed Fast
Pmove Point_6 //MOVE TO TP CLEAR OF CNC
Return
Sub Unloadcnc
Pmove Point_4
Speed Slow
Lmove Point_5
Grasp
Return
Sub Putparts
Waiti Input_1, On //PALLET BACK TO GET THE PART READY
Pmove Point_2
Speed Slow
Lmove Point_3
Release
Lmove Point_3
Speed Fast
Pmove Point_1
Writeo Output_15, On //RELEASING THE PALLET
Delay 2
Writeo Output_15, Off
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Hexagon Manufacturing Solutions
4
Branch Operation
Return
1.2 Station # 2 Robot
Global slow
Global fast
English
Pmove
Release
Grforce 0.5
Grwidth 3.5
Writeo Output_14, Off
Writeo 15, Off
Writeo Output_16, Off
Fast=220
Slow=40
Label Operation
Waiti Input_16, ON //SIGNAL FROM CONVEYOR, LIFTER IS ON
If Inp (Input_1) = On then Call Puttingparts
Writeo Output_1,Off
Call Getparts
Writeo 15, On //RELEASING THE PALLET
Delay 2
Writeo 15, Off
Waiti 15,0 //OPENING CNC DOOR AND CHUCK
Call Loadcncp1
Writeo 16,1 //SEND "PARTE READY" SIGNAL TO CNC THEN CLOSE CHUCK
Waiti 15,1 //WAIT FOR "CHUCK" SIGNAL FROM CNC
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Hexagon Manufacturing Solutions
5
Release
Speed slow
Ddmove 2.25,7
Speed fast
Pmove Point_11 //SAFE POSITION
Writeo 16,0 //SIGNAL CNC TO CLOSE DOOR AND START OPERATION
Waiti 15,0 //WAIT FOR OPERATION DONE AND DOOR OPENED
Delay 2
Call Unloadcnc
Writeo 16,1 //SIGNAL TO OPEN THE CHUCK
Waiti 15,1 //SIGNAL FROM CNC TELLING THE CHUCK IS OPENED
Ddmove 2.25,7
Speed fast
Pmove Point_11 //SAFE POSITION
Call Loadfixture_p1
Writeo 16,0 //OPEN THE DOOR AND CHUCK FOR SECOND OPERATION
Waiti 15,0 //SIGNAL FROM CNC TELLING DOOR AND CHUCK OPENED
Call Loadcncp2
Writeo 16,1 //SEND "PARTE READY" SIGNAL TO CNC CLOSE CHUCK
Waiti 15,1 //WAIT FOR "CHUCK" SIGNAL FROM CNC
Release
Ddmove 2.25,7
Speed fast
Pmove Point_11 //SAFE POSITION
Writeo 16,0 //SIGNAL CNC TO CLOSE DOOR AND START OPERATION
Waiti 15,0 //WAIT FOR OPERATION DONE AND DOOR OPENED
Delay 2
Call Unloadcnc
Writeo 16,1 //OPEN THE CHUCK
Waiti 15,1
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Hexagon Manufacturing Solutions
6
Ddmove 2.25,7
Speed fast
Pmove Point_11 //SAFE POSITION
//INPUT I:5/15 ON PLC, MAKING THE INPUT_1 GOING HIGH TO CALL THE PALLET BACK
Writeo Output_1,On
Call Loadfixture_p2
Branch Operation
Sub Getparts
Pmove Point_1 //READY POSITION
Pmove Point_2 //APPROACH POINT FROM THE CONVEYOR
Speed slow
Lmove Point_3 //PICK POINT FROM THE CONVEYOR PIN 1
Grasp
Lmove Point_2
Speed fast
Pmove Point_19
Call Loadfixture_p1
Pmove Point_19
Pmove Point_4 //APPROACH POINT FROM THE CONVEYOR
Speed slow
Lmove Point_5 //PICK POINT FROM THE CONVEYOR PIN 2
Grasp
Lmove Point_4
Speed fast
Call Loadfixture_p2
Return
Sub Loadcncp1
Pmove Point_6 //APPRACH POINT FOR THE FIXTURE PIN 1
Pmove Point_14 //APPRACH POINT ON THE RIGHT ORIENTATION
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Hexagon Manufacturing Solutions
7
Speed slow
Lmove Point_13 //PICK POINT FOR THE FIXTURE PIN 1
Grasp
Lmove Point_14
Speed fast
Pmove Point_11 //AVOIDANCE POINT FROM CNC
//LOAD CNC MACHINE
Pmove Point_10 //APPROACH POINT FOR THE CHUCK
Ddmove -2.25,7
Return
Sub Loadcncp2
Pmove Point_8 //APPRACH POINT FOR THE FIXTURE PIN 2
Pmove Point_16 //APPRACH POINT ON THE RIGHT ORIENTATION
Speed slow
Lmove Point_15 //PICK POINT FOR THE FIXTURE PIN 2
Grasp
Lmove Point_16
Pmove Point_11
Speed fast
//LOAD CNC MACHINE
Pmove Point_10 //APPROACH POINT FOR THE CHUCK
Speed slow
Ddmove -2.25,7
Return
Sub Unloadcnc
//UNLOAD CNC MACHINE
Pmove Point_10 //APPROACH POINT FOR THE CHUCK
Speed slow
Ddmove -2.25,7
Grasp
//OPEN CHUCK
Return
Sub Loadfixture_p1
Pmove Point_6 //APPROACH POINT FOR THE FIXTURE PIN 1
Release
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Hexagon Manufacturing Solutions
8
Pmove Point_6
Pmove Point_12 //AVOIDANCE FOR PINS
Speed fast
Return
Sub Loadfixture_p2
Pmove Point_19
Pmove Point_8 //APPRACH POINT FOR THE FIXTURE PIN 2
Release
Speed Slow
Pmove Point_12
Speed fast
Return
Sub Puttingparts
Pmove Point_6 //APPRACH POINT FOR THE FIXTURE PIN 1
Speed slow
Lmove Point_7 //PICK POINT FOR THE FIXTURE PIN 1
Grasp
Lmove Point_6
Speed fast
Pmove Point_19
Pmove Point_2 //APPROACH POINT FROM THE CONVEYOR PIN 1
Speed slow
Release
Speed fast
Pmove Point_19
Pmove Point_8 //APPROACH POINT FOR THE FIXTURE PIN 2
Speed slow
Lmove Point_9 //PICK POINT FOR THE FIXTURE PIN 2
Grasp
Lmove Point_8
Pmove Point_19
Pmove Point_4 //APPROACH POINT FROM THE CONVEYOR PIN 2
Speed slow
Lmove Point_5 //PICK POINT FROM THE CONVEYOR PIN 2
Release
Lmove Point_4
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Hexagon Manufacturing Solutions
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Speed fast
Pmove Point_1
Writeo Output_15,On //RELEASING THE PALLET
Delay 2
Writeo Output_15,Off
Branch Operation
Return
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Hexagone Manufacturing SoultionsFlexible Manufacturing System
PROD 1601Programmer: Karytas Leonel & Yogin Doshi
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HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Processor Information
Page 1 Wednesday, April 22, 2015 - 21:41:38
Processor Type: 1747-L553C 5/05 CPU - 64K Mem. OS501 Series C FRN 10 and later
Processor Name: UNTITLED
Total Memory Used: *
Total Memory Left: *
Program Files: 5
Data Files: 10
Program ID: 0
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HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
I/O Configuration
Page 1 Wednesday, April 22, 2015 - 21:41:38
0 1747-L553C 5/05 CPU - 64K Mem. OS501 Series C F 1 1746-IB16 16-Input (SINK) 24 VDC 2 1746-IB8 8-Input (SINK) 24 VDC 3 1746-OB16 16-Output (TRANS-SRC) 10/50 VDC 4 1746-OB8 8-Output (TRANS-SRC) 10/50 VDC 5 1746-IB16 16-Input (SINK) 24 VDC 6 1746-OW16 16-Output (RLY) 240 VAC
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HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Channel Configuration
Page 1 Wednesday, April 22, 2015 - 21:41:38
GENERAL Channel 1 Write Protected: No Channel 1 Edit Resource/Owner Timeout(x1 sec): 60 Channel 1 Passthru Link ID(dec): 2 Channel 1 Diagnostic File: 0
Channel 0 Write Protected: No Channel 0 Edit Resource/Owner Timeout(x1 sec): 60 Channel 0 Passthru Link ID(dec): 1 Channel 0 Current Mode: User Channel 0 Mode Change Enabled: No Channel 0 Mode Change Attention Character: \1b Channel 0 Mode Change System Character: S Channel 0 Mode Change User Character: U Channel 0 Diagnostic File: 0
CHANNEL 1 (SYSTEM) - Driver: Ethernet Hardware Address: E4:90:69:A0:2D:AA IP Address: 192.168.2.100 Subnet Mask: 255.255.255.0 Gateway Address: 0.0.0.0 Default Domain Name: Primary Name Server: 0.0.0.0 Secondary Name Server 0.0.0.0 Msg Connection Timeout (x 1mS): 15000 Msg Reply Timeout (x mS): 3000 Inactivity Timeout (x Min): 30 Bootp Enable: No Dhcp Enable No SNMP Enable: Yes HTTP Enable: Yes Auto Negotiate Enable: No Port Speed Enable: 10 Mbps Half Duplex Forced Contact: Location:
CHANNEL 0 (SYSTEM) - Driver: DF1 Full Duplex Source ID: 0 (decimal) Baud: 19200 Parity: NONE Stop Bits: 1 Control Line : No Handshaking Error Detection: CRC Embedded Responses: Auto Detect Duplicate Packet Detect: Yes ACK Timeout(x20 ms): 50 NAK Retries: 3 ENQ Retries: 3
CHANNEL 0 (USER) - Driver: ASCII Baud: 9600 Parity: NONE Stop Bits: 2 Data Bits: 8 Control Line : No Handshaking Delete mode: Ignore Echo: No XON/XOFF: No Termination Character 1: \d Termination Character 2: \ff
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HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Channel Configuration
Page 2 Wednesday, April 22, 2015 - 21:41:38
Append Character 1: \d Append Character 2: \a
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HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Program File List
Page 1 Wednesday, April 22, 2015 - 21:41:38
Name Number Type Rungs Debug Bytes
[SYSTEM] 0 SYS 0 No 0 1 SYS 0 No 0MAIN PROG. 2 LADDER 21 No 694STATION 1 3 LADDER 7 No 200STATION 2 4 LADDER 7 No 187
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HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
Data File List
Page 1 Wednesday, April 22, 2015 - 21:41:38
Name Number Type Scope Debug Words Elements Last
OUTPUT 0 O Global No 9 3 O:2INPUT 1 I Global No 9 3 I:2STATUS 2 S Global No 0 83 S:82BINARY 3 B Global No 11 11 B3:10TIMER 4 T Global No 12 4 T4:3COUNTER 5 C Global No 6 2 C5:1CONTROL 6 R Global No 3 1 R6:0INTEGER 7 N Global No 52 52 N7:51FLOAT 8 F Global No 2 1 F8:0STRING 9 ST Global No 42 1 ST9:0
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HEXAGON MANUFACTURING SOLUTIONS (PRGRAMMED BY KARYTAS L. & YOGIN D.).RSS
LAD 2 - MAIN PROG. --- Total Rungs in File = 21
Page 1 Wednesday, April 22, 2015 - 21:41:38
S1/15 means that when the fist pass go high
0000S:1
15
First Pass
I:5
6 1746-IB16
CLEAR BUFFER OVERIDE(manually)
T4:3
DN
ACLAscii Clear BuffersChannel 0Receive Buffer YesTransmit Buffer Yes
ACL
O:4
4 1746-OB8
CLEAR BUFFER
RESC5:0
Reset the counterafter clear thebuffer
RESC5:1
SETTING DELAY ON COUNTER TO CLEAR THE BUFFER
0001C5:0
DN
Reset the counterafter clear thebuffer
T4:3
TT
EN
DN
TONTimer On DelayTimer T4:3Time Base 1.0Preset 2