Hexagon Manufacturing Solutions Final Report

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

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


7. AS/RS Documentation ..........................................................................................................20

7.1 Methodology ....................................................................................................................20

7.2 AS/RS Program ...............................................................................................................21

8. CNC Documentation .............................................................................................................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

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

Hexagon Manufacturing Solutions

Page 1 of 28

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


Page 2 of 28

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


Page 3 of 28

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.


Page 4 of 28

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


Page 5 of 28

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)


Page 6 of 28

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.


Page 7 of 28

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


Page 8 of 28

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


Page 9 of 28

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


Page 10 of 28

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


Page 11 of 28

5.3 Cell layout


Page 12 of 28

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


Page 13 of 28

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


Page 14 of 28

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.


Page 15 of 28

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


Page 16 of 28

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


Page 17 of 28

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


Page 18 of 28

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.


Page 19 of 28


Page 20 of 28

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.


Page 21 of 28

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.


Page 22 of 28

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.


Page 23 of 28

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)


Page 24 of 28

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


Page 25 of 28

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 (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


Page 26 of 28

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


Page 27 of 28

Tolerance Table

Table 3 LC10 Fit Table


Page 28 of 28

Attachments

1. Robot program

2. PLC program

3. CNC program

4. Minutes meetings

5. Designs

Hexagon Manufacturing Soultions

Flexible Manufacturing System

PROD 1601

Software: Pegasus II Control Software 1.1.3

\

Programmer: Cayure Carneiro


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


2

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


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


4

Branch Operation

Return

1.2 Station # 2 Robot

Global slow

Global fast

English

Pmove

Release

Grforce 0.5

Grwidth 3.5


Writeo 15, 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


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


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


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


6

Ddmove 2.25,7

Speed fast


//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


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


Speed slow


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


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_16 //APPRACH POINT ON THE RIGHT ORIENTATION

Speed slow


Grasp

Lmove Point_16

Pmove Point_11

Speed fast

//LOAD CNC MACHINE


Speed slow

Ddmove -2.25,7

Return

Sub Unloadcnc

//UNLOAD CNC MACHINE


Speed slow

Ddmove -2.25,7

Grasp

//OPEN CHUCK

Return

Sub Loadfixture_p1

Pmove Point_6 //APPROACH POINT FOR THE FIXTURE PIN 1

Release


8

Pmove Point_6

Pmove Point_12 //AVOIDANCE FOR PINS

Speed fast

Return

Sub Loadfixture_p2

Pmove Point_19


Release

Speed Slow

Pmove Point_12

Speed fast

Return

Sub Puttingparts


Speed slow


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


Grasp

Lmove Point_8

Pmove Point_19

Pmove Point_4 //APPROACH POINT FROM THE CONVEYOR PIN 2

Speed slow


Release

Lmove Point_4


9

Speed fast

Pmove Point_1

Writeo Output_15,On //RELEASING THE PALLET

Delay 2

Writeo Output_15,Off

Branch Operation

Return

Hexagone Manufacturing SoultionsFlexible Manufacturing System

PROD 1601Programmer: Karytas Leonel & Yogin Doshi

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


I/O Configuration


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


Channel Configuration


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


Channel Configuration


Append Character 1: \d Append Character 2: \a


Program File List


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


Data File List


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


LAD 2 - MAIN PROG. --- Total Rungs in File = 21


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

Documents

Hexagon Manufacturing Solutions Final Report