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MATERIALS HANDLING SYSTEMS
OPEN CIM LAB PRACTICE Report
Lecturer: Ass Pro. Nguyen Van Chung HCMC. December 2016
HCMC. December 2016
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TABLE OF CONTENTS I. II. III.
IV. V.
Introduction Objectives and outcomes Components of OpenCIM system 1. Conveyor 2. Automated Storage and Retrieval System(AS/RS) 3. Robot 4. BenchMill 6000 and BenchTurn 7000 Conclusion References
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I.
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Introduction
Open CIM system is a system of manufacturing that uses computers to integrate the processing of production, business and manufacturing so as to create more efficient production lines. CIM frameworks are modular and flexible solutions for instructing and preparing understudies in the standards and innovations of computer integrated manufacturing. CIM is the foundation to integration of modern information systems in the power industry. We believe that real-time integration of power system applications is not possible without a common data model that can be understood by everyone (human beings as well as computers). CIM has found a lot of applications in the power industry, such as operations and planning. Integration of systems and technologies – Supports numerous elements and manufacturing processes. – Material storage and feeding (ASRS, feeders, palletizing racks). – Material handling (robots, conveyors, slidebases, pneumatic transfer units, positioning tables,
vises, end effectors and tool changers). – Automated manufacturing and fabrication (assembly, glue dispensing, screwdriving, welding, grinding/deburring; hydraulic pressing). – CNC machining (turning, milling, engraving, routing, automatic tool changers). – Pneumatic and hydraulic systems (manipulators, feeders, presses) – Identification, detection and tracking (barcode scanning, pallet tracking, sensors, switches). – Quality control (machine vision, electronic calipers, coordinate measuring machine, laser scan meter, electronic height gauge). – Process control – Programmable logic controllers (PLC) Internet access – CIM Web viewer enables access to CIM manager via the Internet and allows users to monitor
CIM cell operations in real time from remote locations. – Using Internet browsers users can view realtime re ports generated by the CIM manager, remotely track live production cycles in the 3D graphic display, and view details of current CIM cell status. – Simultaneous Internet access by multiple users Modes of operation – Full simulation mode: software runs without any hardware or user intervention. Device
drivers notify the CIM manager when operations have been executed – Simulation with manual control: software runs without any hardware, but the user interactively emulates the hardware by using device driver control panels. – Mixed mode: some components actually operate, while others are simulated. The simulation is based on data that predicts and defines the duration of processes. Device drivers are used to 3
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simulate operation of inoperative or missing components. – Full online mode: Software runs the system according to user programming. Device drivers operate the workcell according to orders from the CIM manager. – Stand alone station operation: Individual stations and many components (e.g., robots, CNC machines, quality control devices) can be programmed, operated and controlled as stand-alone systems by means of their own software or the system’s device drivers. – User interface is identical in all modes of operation, which reduces the time and effort required for software familiarization
II.
Objectives and outcomes
Objectives
The objectives of Computer Integrated Manufacturing and Automation laboratory practice is: - To demonstrate the concepts discussed in Computer Integrated Manufacturing course. - To introduce CNC part programming for simulation of various machining operations. - To educate the students on Flexible Manufacturing System and Robot Programming. - To educate the students on the hydraulics, pneumatics and electro pneumatic systems. Outcome
The expected outcome of Computer Integrated Manufacturing and Automation lab is that the students will be able - To practically relate to concepts discussed in Computer Integrated Manufacturing course. - To write CNC part programs using CADEM simulation package for simulation of machining operations such as Turning, Drilling & Milling. - To understand & write programs for Flexible Manufacturing Systems & Robotics. - To understand the operating principles of hydraulics, pneumatics and electro pneumatic systems. - To apply these learnings to automate & improve efficiency of manufacturing process OpenCIM software provides a comprehensive solution for the study and practice of CIM methods and operations: – OpenCIM gives students experience and k nowledge in the concepts, uses and interconnections of the
various software modules that comprise a CIM system. – OpenCIM allows students to gain practical ex perience in translating theoretical manufacturing
methods and processes into actual CIM applications.
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– OpenCIM enables students to use and study components and subsystems individually as well as the entire integrated CIM system. – OpenCIM includes enhanced optimization functions and performance analysis to support studies in industrial management, operations research, management sciences and relate d fields.
III.
Components of Open CIM system
1. Conveyor
The conveyor frame is constructed of extruded, black anodized aluminum. A double flexiblechain moves in the inner and outer rails and moves the load (pallets) by friction. Due to the modular concept a large variety and sizes of conveyors can be created. The basic CIM cell described in this module includes two separate robotic stations, an ASRS and a machine. The conveyor is the mechanism responsible for transferring parts from one station to another. The conveyor has predefined stop locations, where the part is loaded on the conveyor and unloaded from it. Two rails of the conveyor move to bring each of the pallets go to staions * Pallet tracking system In each plallet, there are magnetic areas and each of them are different. There is an ID number on each pallet and the number is magnetically encoded in a bar on the pallet. In CIM operation, each pallet is stopped briefly when it arrives at a station to enable its magnetic code to be read. The magnetic code reading mechanism is that in the reading zone, when it detects any magnetic change, the valve will be turn on to hold the pallet. It then waits for the pallet to the right reading position and read the code, if the pallet is in the list then it will be allowed to pass. While a pallet is stopped, the conveyor continues to transport other pallets which are moving between stations. The pallet can be read correctly if and only if it is place in right direction, if not the reading mechanism won’t work. There is a monitor that show the status update of the pallet in each station.Via that, we can keep track all the information of the system. *Programmable Logic Controller (PLC) Station
The PLC (Programmable Logic Controller) can control and monitor the flow of pallets on the conveyor with the help of sensors and actuators that are build into the stop stations. Various PLC types (Siemens, Omron, Allen-Bradley) and field bus systems (digital I/O, PROFIBUS, ASI bus) are supported.
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2. Automated Storage and Retrieval System(AS/RS )
A storage station is used to store raw materials prior to production, as well as finished products following the production process. Such stations are fully automatic and controlled by robotic arms. The ASRS is a robotic storage device used to store and retrieve parts in a CIM cell. The ASRS is used as the main source of raw material for the cell, and can also serve as a warehouse for parts in various stages of production. Storage cells in the ASRS contain templates, either empty or containing parts. A CIM cell may contain any number of ASRS stations. Template will be taken out from the warehouse then loaded into the conveyor to drive it to 2 station which are: Drilling and Turing The ASRS station also include movement sensors to determine when the activity is interrupted by collisions and impacts or reaching to mechanism limit. The ASRS storage station is a floor-mounted or a table top automated storage and retrieval (ASRS) system designed for educational use. The system’s dedicated Cartesian robot transfers parts between storage cells and conveyor pallets stopped at the ASRS station. The robot is controlled by Controller-USB and by a dedicated ASRS software module in the OpenCIM software. An optional hand-held teach pendant can also be used for direct control of the ASRS. ASRS Components • Templates: Templates are plastic trays which can hold various types of parts. They allow
parts to be transported on the conveyor. A template contains a matrix of holes in which pins are placed to fit the dimensions of a part. Each part may only be held by its assigned template. • ASRS Robotic Arm: The ASRS robotic arm performs these tasks using a forklift gripper which
is connected to the robotic arm. The robotic arm moves the gripper within the ASRS robots work envelope. • Controller-USB: Controls the ASRS robot using the SCORBASE application that supports the
SCORBASE language (an advanced robotic programming language). The SCORBASE program accesses the Controller-USB through the PC USB interface. 3. Robot
In order to run this robot arm, there are 3 mains basic code parts, as well as the ASRS consists of three parts which is “Go to position”, position, “Speed”, speed(%). The first part, in general, tells the robot of where to go next, the specific position. These positions are recorded into the system’s
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internal memory. For the arm, the position is made of six coordinate values, each of which represents an axis or degree of freedom. 1. The first part, which is mainly focus on the movement of the robot, it means that it guide the robot the direction, where to go or stop with the accuracy positions. These positions has been programmed in the system’s internal memory. (speed %) 2. The second part controlls the magnitude of the speed the arm must operate. The value of this part code is determined by what kind of action or movement the arm is perfoming. The purpose of this is minimize the damage for the raw material when putting into Milling machine or CNC machine. 3. The last one guides the robot to the closet buffer, picks up part to prepare for the milling machine. Robot 1 works between warehouse and convey : First, take 1 template in warehose and put it
on the conveyor. Then take that template and bring it back to the warehouse with different position. We handle with the problem by divide it to small simple action. From home position, bring robot to the opposite site with the needed templte Bring the arm of robot forward Lift up the template Take robot’s arm back, rotate 90 degree
Move straight forward to conveyor Bring robot’s arm forward
Put it down Turn back to safety point *We do vice versa to take template from the conveyor to warehouse ***Robot works base on 4 free level, the monitor control will show 3 axis X,Y,Z for each level
Level 1: move to conveyor, X increases
Level 2: move down, Z decreases
Level 3: bring robot’s arm forward then Y increase, and Y de crease for vice versa
Level 4: rotate with clockwise then angle increases, and vice versa
Production Operations (code)
At the beginning, the initial point of arm stay far from the left of milling machine, then the position of the robot will be 505 which is in front of the buffer. The arm will be at an angle of 90 degrees with the buffer When reaching the buffer, the arm continues turning toward the conveyor and 7
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lowers itself. The grip is not yet directly on top of the template at the buffer. The grip is opened to start the pick-up sequence. Go to position 505 Speed 50(%) Go to position 100 Speed 50(%) Open Gripper At the position 100, the robot will be controlled to move downward and toward the conveyor that is about the template in order to continue to take the raw material at the template. Go to position 11 Speed 50(%) Go Linear to position 1 Speed 30(%) After that, the grip is closed and the arm starts its ascending to position 11 and then 100. Close Gripper Go Linear to position 11 Speed 30(%) Go to position 100 Speed 50(%)
Take template from warehouse Position 800: to position of template needed Position 801: bring robot’s arm forward Position 802: lift template up Position 803: take robot’s arm back Position 804: rotate robot’s arm 90 degrees based on parameters showed on the
monitor Robot put template to conveyor
Go to position 498 Fast Go to position 11 Speed 50(%) Go to position 1 Speed 20(%) Go to position 21 Speed 50(%) Wait 10 (10Ths of seconds) Go to position 499 Speed 50(%)
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Robot gets template from conveyor
Go to position 21 Fast Go to position 1 Speed 40(%) Go to position 11 Speed 20(%) Wait 10 (10Ths of seconds) Go to position 498 Speed 50(%) Manual adjustment This one is done manually, now we make it automatically. Revise the code, the origin position is 800 with the speed of 30%, move to 801, then 802, then 803, then move to forward to 499. The movement is combined from 4 axis ( 800,801,802 is moving on separate axis ). If only I could control under a very good condition as called “ well established “, then the combined action would be more faster, reduce lead time and the robot works more smoothly. However, it could be dangerous since it may have impact. Everything else wil continue work easily, it may be a difficult problem since you have to create a robot that works fast, smoothly and safely. We transform the complicated action into simple action, by doing this, we make a trade off between time and impacting – risk.
Robot 2: Take the raw material into the Milling machine The robot 2 works with 6 free levels. When the robot works, the more small of the free level the more easy for us to control it. It is controled by compressed air. When touching something, it cannot stop immediately. To take the template from conveyor to milling: Step 1: robot load it in Step 2: robot slide to the opposite position with milling Step 3: bring template to milling Step 4: adjust the clamp fix to the template Step 5: lower template Step 6: robot release template Step 7: clamp tightly template with its exact size
The purpose of this code is let the platform out and send it outward closer to the arm: Call Subroutine PLACE VICE IN LOADING POSITION 9
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The door will be opened to load the part: Call Subroutine OPEN DOORM Call Subroutine OPEN VISE The robot is sent to position 201 with the speed 50(%) ( outside of the machine) Go to position 201 Speed 50(%) Then the robot moves inward to the loading position which is below the platform, ready to lower the part: Go to position 261 Speed 50(%) Go Linear to position 251 Speed 10(%) After reaching the position, the arm opens the grip, releasing the part for processing: Open Gripper Then air is pumped into the piston, take the part in place, then the door is closed and begin the process in milling machine Call Subroutine CLOSE VISE Call Subroutine OPEN DOORM Get the finished part from the milling machine
The code for taking the part from the milling machine is just the reverse order of putting raw material into the milling machine Go to position 200 Speed 50(%) Go to position 710 Speed 50(%) Call Subroutine PLACE VICE IN LOADING POSITION Call Subroutine OPEN DOORM Wait 20 (10Ths of seconds) In addition to the similar codes, there are extra ones such as “Wait 20(10ths of seconds)”. The first delay is because of the milling door’s movement. Go to position 201 Speed 50(%) Open Gripper This is a new position comparing to the loading part of the code. This position is inside of the milling machine and on top of the platform. In this position, the arm is ready to move vertically (“Go Linear to”):
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Go to position 221 Speed 10(%) Go linear to position 211 Speed 10(%) Call Subroutine OPEN VISE Close Gripper Wait 20 (10Ths of seconds) If the arm proceeded its next command, which is moving the arm into the machine to retrieve the part, it would collide and damage the door.The second pause has to be added to the code because, when the piston receives an order to release the processed part. Go to position 221 Speed 30(%) Call Subroutine CLOSE VISE Go to position 201 Speed 50(%) Go to position 200 Speed 50(%) Call Subroutine CLOSE DOORM Go to position 509 Speed 50(%) Return the part to its template
Go to position 100 Speed 50(%) Go to position 505 speed 50(%) Go to position 11 Speed 50(%) Go Linear to position 1 Speed 30(%) Open Gripper Go to position 11 Speed 50(%) Go to position 100 Speed 50(%)
4. BenchMill 6000 and BenchTurn 7000 BenchMill 6000
The BenchMill 6000 is a versatile PC-based benchtop CNC machining center that enables you to deliver robust instruction in computer numerical control and advanc ed manufacturing for your students. 11
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The BenchMill 6000 comes equipped with Ethernet-based motion control, 3-axis stepper motors, ball screws, a variable speed brushless spindle motor, and ISO20 taper tooling. This CNC system requires no assembly, arriving at your facility ready to ru n on an Ethernet port on a standard PC, and fits comfortably into any classroom, without sacrificing features. Like larger industrial machines, the BenchMill 6000 uses EIA, ISO, and Fanuc-compatible G&M code programs to cut parts in a variety of materials.
BenchTurn 7000
The BenchTurn 7000 is a versatile PC-based benchtop CNC turning center that delivers strong instruction in computer numerical control and advanced manufacturing. The BenchTurn 7000 is equipped with 2-axis stepper motors, ball screws, a variable speed brushless spindle motor, limit/home switches, and an MT3 taper spindle with MT2 taper tailstock. This benchtop CNC system requires no assembly and is ready to run on an Ethernet port on a standard PC, and fits comfortably without sacrificing features. The BenchTurn 7000 uses EIA, ISO, and Fanuc-compatible G&M code programs to cut parts in a variety of materials.
IV.
Conclusion
General understanding of Open CIM system
A CIM cell is an automated assembly line that uses a network of computers to control robots, production machines, and quality control devices. In this case, OpenCIM is a system which teaches students the principles of automated production using robotics, computers, and CNC machines. It also allows advanced users to search for optimal production techniques by experimenting with different production techniques.
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Advantages and disadvantages of Open CIM system:
Advantages - Accuracy due to complex construction and precise calculation. - Noise reduction: the system can clear out errors between input and output signals, hence remains unaffected to external noises. - Rapid access - Computer-aided scheduling - Optimization: Real-time production data can improve quality by using techniques such as statistical process control to optimize the production processes. - Less lead time - Greater consistency - Monitoring of system at all time. Disadvantages - High initial investment, also due to complex construction and seting-up process. - Not suited for non-complex products. - Complex maintainance. - Highly skilled labour required.
Overall, the CIM system has many advantages and less disadvantages. If manufacturer use it, it will bring on a lots of profit anf benefit in production. However, in the system we think that the warehouse to stored materials and finished goods should be separated in order to prevent the mistake of taking the wrong materials. When putting materials and finished goods separated we can categorize it easier and pick up faster. By that way, we can save time and money. We should not store materials and finished goods in the same place. Moreover, we think that the area near the CNC Milt and the robot arm should be placed in glass box to ensure safety. Application
There are multiple areas of usage of CIM system: In Industrial and Production engineering In mechanical engineering In electronic design automation (printed circuit board (PCB) and integrated circuit design data for manufacturing)
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