Open-Cim Lab Report Course Material Handling System.pdf

VIETNAM NATIONAL UNIVERSITY - HO CHI MINH CITYINTERNATIONAL UNIVERSITY

SCHOOL OF INDUSTRIAL ENGINEERING & MANAGEMENT

-OPEN-CIM LAB REPORT

Course: Material Handling SystemLecturer: Dr Nguyen Van Chung

Contribution table (Group 11)

Ho Chi Minh City, VietnamSemester I - 2022

Table of Contents

I INTRODUCTION 3

1 Definition of OpenCIM system 3

2 Advantages of OpenCIM 3

3 Components of OpenCIM system 3

II OPERATIONS OF THE SYSTEM 4

1 Overall production operations 4

1 General understanding of OpenCIM 20

2 Advantages and Disadvantages 20

I INTRODUCTION

1 Definition of OpenCIM system

Computer-integrated manufacturing (CIM) is an automated production that uses robots,computers and CNC machines in their operation Additionally, OpenCIM is a system thatstimulates the basic operation of CIM Therefore, students can gain not only basic principles ofautomated productions but also practical experience by operating CIM system via its stimulationmode.

OpenCIM provides different production techniques to find optimal production strategiesby trial and errors without using the CIM equipment OpenCIM supports students applyhypotheses regarding optimal computer-integrated production techniques such as:

 The effect of different machines which can perform the same process Modifying a process by changing a machine’s control program Alternate part definitions

With an aim to find the optimal production strategies, OpenCIM can stimulate thefollowings:

 The causes of production bottlenecks

 The effects of alternative production schedules What-if analyses

3 Components of OpenCIM system

Basic elements of OpenCIM systems include:

 Conveyor: A device that transports and delivers parts (raw materials or finished goods)

between different stations.

 CIM Manager: The PC that contains the CIM Manager software which controls and

manages the functioning of all devices in the cells using a LAN.

 Station Manager: A PC that controls the different devices at a station and has a

communication link with the CIM Manager Device control is performed by OpenCIM

device drivers that run on this PC A device driver controls the operation of a device atthe station in response to commands from the CIM Manager and other CIM elements. Assembly Station: A station where parts are put together with the help of machine by

linking a computer and controlling via coding.

 ASRS Station: Automated Storage and Retrieval System- an automatic warehouse which

supplies raw materials to the OpenCIM cell, stores parts in intermediate stages ofproduction, and holds finished products.

 Machine Station: Station where materials are shaped, formed, or otherwise processed In

our lab, we have a milling machine and turning machine.

 QC Station: Quality Control Inspection of parts using machine vision, laser scan meter,

height gauge, continuity tester, CMM, caliper or other QC machines.

 Robot: A device which moves parts around the station and (or) performs assembly

 Robot controller: For example, an ACL controller which controls the robot and certain

optional peripheral devices (e.g X-Y table, barcode scanner).

OpenCIM system in Lab

(Note: 1: Robot controller; 2: Robot; 3: Conveyor; 4: ASRS; 5: Turning Machine; 6: MillingMachine)

II OPERATIONS OF THE SYSTEM1.Overall production operations

 Supplied parts (raw materials) are loaded into storage locations (the AutomatedStorage and Retrieval System (AS/RS) station) This station is responsible for storingraw materials, parts in intermediate stages of production, and also finished goods.

 When there is a manufacturing order generated by CIM Manager, parts are unloadedfrom the AS/RS and transported on the conveyor to production stations in the form ofpallets The ID number is installed on every pallet and checked at the stop station todetermine whether it should stop at that station or not.

 Typical production tasks include:

 Machine Station: materials are shaped, formed, or otherwise processed using aCNC machine or laser engraver.

 Assembly Station: parts are put together and the resulting new part is called anassembly.

 QC Station where parts are inspected, before ending the process.

 Between stations, robots return processed parts to the conveyor for delivery to thenext station.

 The finished goods are unloaded from the machine on the conveyor, and the AS/RSrobot loads them into AS/RS system for storage.

2 Conveyor

a Overall

The conveyor, a component of the OpenCIM cell, is a device that transports parts fromstation to station A robot places the template carrying a part on a pallet on the conveyor, then theOpenCIM conveyor carries pallets in a continuous circuit from station to station.

b Pallet

A pallet is a tray which travels on the CIM conveyor and carries a template An IDnumber is magnetically encoded in a bar on each pallet When arriving at a station, each pallet isstopped briefly so that its magnetic code can be read Meanwhile, the conveyor continues totransport other pallets which are moving between stations.

c Template

A template is a plastic tray which can hold various types of parts and allow parts to betransported on the conveyor It contains the following elements:

 A set of holes in which pins are placed to fit the dimensions of a part

 A handle, on top of or in front of the template, allowing a robot’s gripper to grasp thetemplate

 A barcode sticker, on the side of the template, showing the template’s ID code

d Conveyor light

A conveyor light, placed at each workstation, performs the signaling function.

Conveyor light

 Green lights indicate the station is waiting for the pallet to arrive Red lights indicate a pallet is stopped for use at the station

 Flashing red lights indicate an error has been reported at the station by an OpenCIMdevice driver

 Flashing red lights at all stations indicate all stations have stopped because theEmergency Stop Button has been pressed

e PLC (programmable logic controller)

The operation of the conveyor is directed by a PLC which keeps track of pallets.Magnetic code readers at each station enable the PLC to identify the pallet ID numbers If thepart on the pallet does not require processing at the station, the pallet is allowed to continue onthe conveyor If the PLC determines that the pallet is needed at the station, it informs the CIMManager, and the pallet remains at this station until the CIM Manager sends a release command.

The PLC is normally connected to one of the Station Manager PCs

3 Robots

Parts in station are moved by CIM robots Robots differ in terms of driving mechanism,working envelope (horizontally or vertically articulated), range of motion (degrees of freedom),speed, payload, and accuracy.

In this particular lab, there are two robots used which are SCORBOT – ER 4u andSCORBOT-ER 9Pro.

3.1 SCORBOT-ER 4u

The SCORBOT-ER 4u is designed and developed to emulate an industrial robot It is aflexible solution for industrial robotics teaching and training Tabletop, pedestal, or linear slidebase mounting options are available for the SCORBOT-ER 4u robot arm The SCORBOT-ER 4uis used to handle the materials.

The robot is held up by ScorBase robotics programming and control software.

Students can design, build, and control simulated industrial workcells using the optional

RoboCell 3D graphic software, which also provides dynamic simulation of the robot and

workcell devices during position teaching and program execution.

a Components:

The SCORBOT-ER 4u is a vertical articulated robot, with five revolute joints The robothas five degrees of freedom when the gripper is mounted With this design, a sizable workspacemay accommodate the end effector in any position or orientation The robot’s components:

 Base: The robot's base is often anchored to a stationary work surface However, it may

be connected to a slide base, giving it a wider working range.

 Shoulder: is positioned above the base, moves vertically and in a circular motion, but its

range of motion is limited because a small block is present behind it for process safety.It has an axis range of -158 to +158

 Elbow: Although it is limited to working with the same mobility as the shoulder with a

broader range that can reach up to 360 degrees, it is just as useful as that of a person.The speed is approximately 26.3°/sec, with a range of -260° to 260°.

 Wrist pitch: The gripper can be moved vertically between -260° and 260° from its

position between two metallic

 Wrist roll: is connected right next to the Wrist Pitch, is responsible for rotating the

gripper horizontally up to 570 degrees (electrically) and indefinitely.

 Gripper (keeper): has a rubber-pad-equipped servo jaw gripper These pads can be

taken off to provide room for other end effectors, like suction pads, to be attached Thissection simulates the opening and closing motions of human fingers.

 End effectors: include a DC servo gripper with an optical encoder and parallel finger

motion Software and the Gripper sensor are used to measure the object's size.

The artificial arm has five joints (5 rotational axes), each of which is represented by adifferent angle value in joint coordinates With varying processing ranges that are constrained, itis denoted by Base, Shoulder, Elbow, Pitch, and Roll

1 Base Rotates the body 3100 200/ sec2 Shoulder Raises and lowers the upper arm 1580 26.30/ sec3 Elbow Raises and lowers the forearm 2600 26.30/ sec4 Wrist Pitch Raises and lowers the end effector

(gripper) 2600 830/ sec5 Wrist Roll Rotates the end effector (gripper) 5700 1060/ sec6 Gripper Opens and closes

Additional Specifications

Maximum Operating Radius 610 mm [24”]

Maximum Gripper Opening 75 mm [3”] without rubber pads65 mm [2.6”] with rubber pads

Position Repeatability ±0.18 mm [0.007”] at TCP

Maximum Path Velocity 700 mm/ sec (27.6”/sec)

Ambient Operating Temperature20 -400C (360 -1040F)

The following is the figure depicting the components of SCORBOT-ER 4u:

SCORBOT-ER 4u

b Procedures:

This robot will be used with the intention of making it function like a human arm.However, the robotic arm needs to take numerous small, easy steps to do an activity like ahuman.

 To start, raw parts are transported to the robot station on a tablet The conveyor will alertthe robotic arm to take the materials with the gripper when the tablet comes to a halt Inthis stage, the arm is lowered horizontally with the shoulder rotating vertically totransport the materials to the assembly region.

 The robot arm will then move to another location to bring the necessary components andthen return to the assembly area after placing the materials in the assembly area.

 Finally, the robot will pick up the finished goods and turn them slowly into the conveyorsystem The procedure will then start a fresh cycle with all the aforementioned phases.

c Operating with software:

The practice we conduct is to control the SCORBOT-ER 4u to take the raw part from itsoriginal position on the conveyor then put it on a template and finally put it back on the conveyor.

The position 1,2,3,4,5,6 with particular coordinate is tested and saved To be specific: Position 1: the original position of robot in ASRS - safety point

 Position 2: where the robot arm is perpendicular to the position of the raw componentaccording to the Y-coordinate.

 Position 3: where the raw part is placed on the ray, opposite the robot arm.

 Position 4: to place the raw part to the template, the robot arm rotates 90 degrees tothe left (Z-coordinate).

 Position 5: where the robot arm is perpendicular to the position of the templateaccording to the Y-coordinate.

 Position 6: new position to put the raw part on.

After that, the robot arm functions following the programmed procedures with the savedpositions The speed ranges from 0% to 100% with 0% meaning no motion and 100% meaningvery fast motion.

Step 1: Robot gets the raw part from the conveyor:

1 Open Gripper.

2 Go to Position 1 with Speed 50%: the original position of robot in ASRS - safety point3 Go to Position 2 with Speed 50%: where the robot arm is perpendicular to the position of

the raw component according to the Y-coordinate.

4 Go to Position 3 with Speed 30%: where the raw part is placed on the ray, opposite therobot arm.

5 Close Gripper: take the raw part.

Step 2: Take the raw part to the template:

6 Go to Position 2 with Speed 20%7 Go to Position 1 with Speed 20%

8 Go to Position 4 with Speed 20%: to place the raw part to the template, the robot armrotates 90 degrees to the left (Z-coordinate).

9 Go to Position 5 with Speed 20%: where the robot arm is perpendicular to the position ofthe template according to the Y-coordinate.

10 Go to Position 6 with Speed 20%: new position to put the raw part on.11 Open Gripper: release the raw part.

Step 3: Leave the raw part move back to safety point:

12 Go to Position 5 with Speed 50%.13 Go to Position 1 with Speed 50%.

Step 4: Take the raw part back to its original position:

14 Go to Position 4 with Speed 50%.15 Go to Position 5 with Speed 50%.16 Go to Position 6 with Speed 30%.17 Close Gripper: take the raw part.18 Go to Position 5 with Speed 20%.19 Go to Position 4 with Speed 20%.20 Go to Position 1 with Speed 20%.21 Go to Position 2 with Speed 20%.

22 Go to Position 3 with Speed 20% to put the raw part back23 Open Gripper: release the raw part.

Step 5: Robot arm goes back safety point

24 Go to Position 2 with Speed 50%.

a Structure of the robot

The SCORBOT-ER 9Pro is a vertical articulated robot, with five revolute joints (5rotational axes) corresponding to five degrees of freedom It is indicated by Base, Shoulder,Elbow, Pitch, and Roll with different restricted axis ranges.

1 Base Rotates the body 270�

2 Shoulder Raises and lowers the upper arm 145�

3 Elbow Raises and lowers the forearm 210°4 Pitch Raises and lowers the gripper 196°

5 Roll Rotates the gripper 737°

The gripper is attached and has simulated motions the same as human fingers which areopening and closing This design permits the gripper to be positioned and oriented arbitrarilywithin a large workspace.

SCORBOT-ER 9Pro joints and links

b Procedure of the robot

The SCORBOT-ER 9Pro is controlled by the Scorbase robotics control and simulationsoftware installed on Lab PC The general procedure of the robot is described below.

 When the tablet carrying raw materials arrives at the station where the robot stands, therobotic arm picks up the materials.

 After the material is kept by the gripper, the base of the robot horizontally turns to theCNC machine.

 The shoulder lowers the upper arm close to the CNC machine. The gripper puts the material accurately where it is programmed. After accomplishing the first-half job, it is back to the initial form.

 When the material is transformed into finished products, the robot’s procedure at thefirst-half job is implemented in vice versa with slower speed.

On our lab day, the system had some errors, and we could not observe the operation ofthe SCORBOT-ER 9 Pro Therefore, we cannot provide a detailed description of the operationbut a general one.

Since on our lab day, the AS/RS system malfunctioned, we could not observe operationsof the AS/RS in detail The following is just the general information of this system.

a Definition