i Independence – Freedom– Happiness Ho Chi Minh City, December 30, 2023 GRADUATION PROJECT ASSIGNMENT 1st student's name: NGUYEN THANH DAT Student ID: 19145129 2nd student's name: NGUY
INTRODUCTION
Problem statement
Figure1- 1 Global pharmaceutical manufacturing market
This project uses glass bottles with rubber caps, common in the pharmaceutical industry for medicine storage Figure 1-1 shows the pharmaceutical manufacturing market’s significant growth, expected to triple by 2030
Figure 1-2 shows per capita medicine consumption in Vietnam The Vietnamese market is attractive and poised for growth Despite current limitations in medicine manufacturing, progress is inevitable The need for filling and capping systems will significantly increase in the coming years
This involves the use of glass bottles with rubber caps, specifically designed for veterinary medicine These bottles are essential in the veterinary medicine market, which was valued at $22,973 million in 2019 and is projected to reach $29,698 million by 2027, growing at an annual rate of 4.6% To enhance the efficiency of handling these bottles, a robotic arm is being utilized The robotic arm, with its precision and speed, ensures safe and effective handling of the bottles, thereby streamlining the operations in this rapidly growing market This integration of advanced technology not only improves productivity but also provides a competitive edge in the veterinary medicine sector
Figure1- 2 Consumption of medicine per capita in Vietnam
Figure 1-3 depicts a production line for veterinary medicine with rubber caps
Modern robotic arms are transforming industries due to their superior capabilities and benefits These advancements have led to a surge in demand, making robotic arms a sought-after investment for businesses Incorporating robotic arms into production lines significantly increases productivity and efficiency, automating complex tasks with incredible speed and precision Moreover, their compact design optimizes space utilization, while pre-programming simplifies operation and reduces labor costs by eliminating the need for constant human intervention.
Figure 1-5 shows the growth of Vietnam’s robotics market [2] Major players like
Figure1- 3 Veterinary medicine production line
ABB Ltd., Robot 3T Group, Sony Corporation, Midea Group Co Ltd., Honda Motor
Co Ltd, Siemens AG, DENSO Corporation, Rockwell Automation Inc., KION Group AG, and Seiko Epson Corporation are driving this growth Given the country’s economic and technological progress, a local player may emerge soon
Figure1- 4 Global robotic arm market
Figure1- 5 Growth of the Vietnam robotics market
East Asian servos, namely from Japan and Korea, have gained significant popularity in Vietnam Mitsubishi servos are widely used, as evidenced in Figure 1-6, due to their availability and prominence However, German servos remain less prevalent Siemens holds a commanding global market share of 44.5% in the PLC sector, as illustrated in Figure 1-7.
Furthermore, Siemens PLCs are preferred due to their superior durability compared to other brands This project aims to bridge the gap between Siemens PLC and Mitsubishi servos to better suit the Vietnamese market In this project, a Siemens PLC is used to control Mitsubishi Servos
Figure1- 6 AC servo market in Vietnam
Research objectives
There are several particular objectives for this project:
- Filling Accuracy: Aim for less than 5% error in filling bottles
- Capping Success Rate: Strive for 95% success in capping bottles
- Bottle Placement: Achieve 100% success in orderly placement of bottles in a box
- Continuous Bottle Feeding: Enable continuous feeding of bottles, unlike other systems
- Performance: Improve system to handle 3 bottles per minute
- Power Recovery: Ensure system resumes from where it stopped after a power shutdown
- Manual Panel: The system includes a panel to control robot position and other actuators.
Report layout
the robot gets the first bottle
- Web Server: Enables control and monitoring via PLC hosted address on devices like laptops, PCs, and smartphones
The robot's movement is based on dynamics, focusing on motion rather than forces Instead of employing individual joint controllers or calculating kinetics, the robot operates with default controller settings, eliminating the need for complex calculations and ensuring efficient motion.
- Drive Mechanism: The robot uses belts for movement, not complex designs like helical, bevel, or worm gears This means it’s less protected from dust and might not last as long Also, the joints can’t move as fast as they could with servo motors
- Image Processing: The project doesn’t include image processing
The reason why this project is conducted is represented The scope, constraint, and research method are also written.
LITERATURE REVIEW
Industrial Manufacturing Line
A Manufacturing Line, also known as an Assembly Line, is a series of steps in a factory where raw materials are transformed into a final product or where parts are put together to make a finished product It’s a well-structured and efficient process where the product moves from one point to another, with each point carrying out a specific task This process is depicted in Figure 2-1
The manufacturing line is structured to enhance efficiency, reduce the duration of production, and maintain uniform quality It promotes the effective use of resources such as workforce, equipment, and materials The line generally follows a set order of operations, with each station focusing on a particular task
Many industries use assembly lines to make various products like cars, electronics, appliances, food, drinks, and medicines The making process may involve people, machines, robots, or a mix, depending on the product’s complexity and production needs
2.1.2 History of the Manufacturing Line
The assembly line has developed from earlier production and organization ideas, especially in the meat-processing sector It started in the late 1700s and early 1800s when the first factories in England and the US began splitting tasks and building products on a line
The advent of mechanization and the use of machines indeed revolutionized the manufacturing process The assembly line concept, where products move through a sequence of workstations, each performing a specific task, emerged as a significant development in the early 20th century
Figure2- 1 An electronics Assembly Line
Figure2- 2 The first Assembly Line
However, the assembly line system developed and peaked during the Industrial Revolution in the late 19 th and early 20 th centuries, when Henry Ford applied this to automobile manufacturing technology (Figure 2-2) Ford pioneered the first assembly line system in his car production process, increasing productivity, reducing costs, and decreasing production time
Since then, the assembly line system has expanded and become crucial to the manufacturing industry The related technologies and processes have also been developed and improved over time, including automation, robotics, and the application of information technology
The assembly line system continues to evolve and is applied in various industries, from automotive, electronics, and machinery to appliances, food, and pharmaceutical industries Its effectiveness in increasing productivity, reducing costs, and ensuring product quality has been proven
Figure2- 3 Modern Assembly Line with Robots
Figure2- 5 Fanuc robots in the industry
1 Machinery and equipment: This refers to the tools and devices used in production, like tools for machining, packaging, welding, cutting, quality checking, and automatic control machines
2 Conveyor systems: These are used to move items between different stages of production Conveyors can be made from rubber, plastic, or metal and can be controlled either electronically or mechanically
3 Robots and automation: Industrial robots do automated tasks on the production line, like assembly, welding, and handling products Automation also includes automatic control systems and sensors for managing production
4 Control systems: These are used to monitor and control operations on the production line They may include computers, control software, sensors, and measuring devices for accurate and efficient production
5 Transportation and storage systems: These include transportation systems like forklifts, cranes, pallet systems, and storage solutions for moving and storing items during production
6 Energy systems: These ensure the supply of energy to the equipment and machinery on the production line This system includes electricity, compressed air, cooling systems, and other energy sources
7 Tools and instruments: These include tools and devices like clamps, drills, cutting tools, screws, bolts, and others used in the production process
Each production stage in a manufacturing line consists of specific stages and activities to transform raw materials or components into the final product
1 Processing:This stage changes and treats raw materials or parts to make sub- assemblies Methods can include cutting, grinding, turning, milling, welding, pressing, and CNC machining
2 Assembly: This stage involves putting together parts to make the final product It can involve machines, tools, and manual labor
3 Quality Inspection: This stage makes sure the product meets quality standards and technical requirements Methods can include checking dimensions, testing strength and function, and assessing defect rates
4 Packaging: After the product is finished, it’s packaged to protect it and prepare it for transport Packaging can involve putting the product in boxes, bags, bubble wraps, or pallets
5 Transportation and Storage: This stage involves moving the product from the production line to storage or to the customer It can involve using vehicles like forklifts, lifting equipment, and storage systems like pallets or warehouses
6 Maintenance and Repair: This stage focuses on keeping the machinery and equipment in the production line working well It involves inspecting, maintaining, and repairing parts to ensure continuous operation and high performance
Figure2- 6 CNC machine of the Wood industry
It’s hard to find a manufacturing business without a production line Production lines are in almost every industry, helping to simplify and automate tasks with machines, and even completely replacing human labor in many stages of production
Table 2-1 illustrates the primary industries that benefit from modern manufacturing lines
Table 2-1 Applications of the Manufacturing Line
This involves assembling vehicles, welding and attaching parts, quality testing, and finishing products
This includes fabricating electronic circuits, placing components, soldering and assembling, and quality testing and contro
This involves packaging and bottling, sorting and packaging agricultural products, and processing and packaging food
This includes packaging and bottling, quality testing, and secure packaging processes.
This involves mass production and assembly of household products and appliances
This includes weaving and garment production, fabric cutting and processing, assembly and finishing of garments, quality testing, and packaging
This involves processing plastic and rubber, molding and casting plastic parts, and assembly and quality testing of plastic and rubber products
This includes producing construction materials like cement, bricks, wood, and steel, assembling and testing building components, and constructing and finishing building projects
This involves processing metal, welding and attaching components, fabricating and assembling mechanical products, and testing and quality finishing.
General Magician Robotic Arm
Industrial robots, including those designed for bottle processing and handling, have greatly transformed the manufacturing and automation industry They’ve enhanced efficiency, accuracy, and productivity across numerous sectors These advanced machines are engineered to perform repetitive tasks with high precision and reliability, making them indispensable in today’s industrial settings
Industrial robots have revolutionized manufacturing, offering improved productivity, precision, and safety They are particularly effective in tasks such as bottle processing and handling, where precision and consistency are paramount As technology advances, robots will play an increasingly significant role in refining production processes and shaping the future of industrial automation
Table 2-2 provides an overview of the formation and development of industrial robots from the 1950s to the present
Table 2-2 History of Industrial Robots
1954 George Devol invented the first industrial robot
Unimate was the first industrial robot sold commercially
SCARA (Selective Compliance Assembly Robot Arm) robots were developed
(cobots) that can work with humans appeared
Multi-purpose robots that are used in many industries became widespread
Robots that can move and navigate on their own in industrial environments were developed
Collaborative robots that use artificial intelligence and machine learning are becoming more popular
2.2.2 General of the 3-DOF Dobot Magician
Robot Magician robot arm is a sophisticated robotic manipulator suitable for various applications in education, research, and industrial automation, including bottle handling tasks Its versatility and precision make it ideal for a wide range of tasks, from delicate operations to handling everyday objects like bottles
As shown in Figure 2-7, the Robot Magician features a compact and sleek design, allowing easy integration into different workspaces It has multiple articulated joints that mimic human arm movements, enabling it to perform complex actions with precision and accuracy This includes the precise movement required for bottle handling, making it a valuable tool in environments such as laboratories, factories, or even bars and restaurants
The Dobot Magician excels in programmability, offering control through multiple programming languages This ease of customization empowers users to tailor the robot's functionality to their unique requirements, fostering accessibility across diverse knowledge levels Through intuitive software platforms, users can automate tasks, enabling efficient and customized operation.
The Dobot Magician comes with a variety of end effectors and accessories, such as grippers, suction cups, and laser engravers, which further expand its capabilities This adaptability enables the robot arm to perform diverse tasks, including 3D printing, pick-and-place operations, writing, drawing, and light assembly tasks, as shown in Figure 2-8
With its user-friendly interface and comprehensive documentation, the Dobot Magician is ideal for educational purposes It allows students and researchers to explore the principles of robotics and automation It also serves as a practical tool for industrial applications, enhancing productivity and efficiency in various manufacturing processes, as shown in Figure 2-8
Figure2- 8 Structure of the Dobot Magician
Figure2- 9 Dobot Magician’s application in sorting products
In summary, the Dobot Magician robot arm, with its versatility, precision, and programmability, is a valuable tool for robotics enthusiasts, educators, and professionals in the automation field It’s simple, yet powerful
2.2.2.1 Factory’s parameters of the Dobot Magician
Based on the user manual and technical specifications of the Dobot Magician, Table 2-3 shows its key parameters
Table 2-3 Parameters of the Dobot Magician
Rotation Range of Joint 1 (Base) 360° (Infinite)
Rotation Range of Joint 2 (Rear Arm) 0° to 180°
Rotation Range of Joint 3 (Forearm) 0° to 180°
Interface USB, Bluetooth, WiFi (optional)
Supported Software DobotStudio, Blockly, Python, C++,
2.2.2.2 Applications and developments of the Dobot Magician
- Education: The Dobot Magician is a robot that’s used in schools to help students learn about robots and how to write programs for them It’s a fun and hands-on way to learn about robotics
- Research and Development: Scientists and researchers use the Dobot Magician when they’re working on new ideas for robots It’s very flexible and can be programmed to do many different things, which makes it a great tool for trying out new concepts
- Manufacturing and Assembly: The Dobot Magician can do the same task over and over again without getting tired This makes it really useful in factories, where it can do jobs like picking up items or 3D printing It helps make the work faster and more accurate
- Automation and IoT Integration: It can be part of larger systems due to its programmable interface and compatibility
- Personal Projects and Hobbyists: eople use it for small projects and DIY tasks because it’s versatile and easy to use
- Dobot Magician is always improving Updates to its software and hardware make it more precise and give it more functions It’s a flexible robot platform used in many fields
PLC Siemens SIMATIC S7-1200
Siemens SIMATIC S7-series is a line of Programmable Logic Controllers (PLC) developed by Siemens It is a widely used family of PLC in the Industrial Automation and Process Control industry SIMATIC S7-series consists of various models shown in Table 2-4, each designed and developed to meet the diverse application needs of the industry
Table 2-4 History of the SIMATIC S7-series establishment
Compact size, integrated analog inputs/outputs
High-speed processing, modular design
Increased performance, large memory capacity
Integrated Ethernet, expanded communication options
Advanced motion control, enhanced security features
Figure2- 10 CPU S7-1200 with the extended modules
The Siemens SIMATIC S7-1200 is a family of PLCs designed for small to medium-sized automation projects, offering a compact and modular design Its range of models with varying specifications and capabilities allows for customization to meet specific application requirements The S7-1200 is widely utilized in industrial automation and control systems, particularly in space-constrained installations.
The S7-1200 PLCs are equipped with powerful CPUs with fast processing speeds, enabling efficient execution of control tasks and real-time data processing It supports various communication interfaces, including Ethernet, PROFINET, and serial communication protocols This PLC allows seamless integration with other devices and systems, enabling data exchange and remote monitoring
They are known for their reliability, flexibility, and ease of use SIMATIC S7-1200 is commonly used in various industries such as manufacturing, process control, building automation, and more Its compact size, powerful performance, and extensive communication capabilities make it an ideal choice for small to medium- sized automation projects
2.3.3 TIA Portal - Supportive software for Siemens SIMATIC S7-1200
To program the SIMATIC S7-1200 CPUs, relevant knowledge and skills are required In addition to understanding the hardware, programmers need powerful tools to support programming and simulate real-world applications on the PLC The primary tool, which plays a significant role, is TIA Portal with the interface in Figure 2-
TIA Portal (Totally Integrated Automation Portal) and SIMATIC STEP 7 are essential software tools for programming and configuring SIMATIC S7-1200 CPUs TIA Portal serves as a comprehensive engineering framework, providing a unified platform for various automation tasks, as shown in Figure 2-12 It enables seamless project management and efficient workflows by integrating all the necessary tools and software components into a single environment
Figure2- 11 TIA Portal software interface
Figure2- 12 Insides a program of TIA Portal
SIMATIC STEP 7, part of the TIA Portal, is the programming software designed explicitly for the SIMATIC S7-1200 CPUs It offers a powerful and intuitive programming interface, supporting multiple programming languages such as ladder diagram (LAD), function block diagram (FBD), and structured text (ST) With SIMATIC STEP 7, programmers can develop control logic and configure the PLCs according to their application requirements
TIA Portal and SIMATIC STEP 7 provide essential features and tools to support the programming and simulation of applications for SIMATIC S7-1200 CPUs They enable engineers to efficiently program, test, and commission automation projects These software tools offer advanced functionalities such as system diagnostics, project documentation, and seamless integration with other automation components
A strong understanding of the hardware and proficiency in using TIA Portal and SIMATIC STEP 7 empowers programmers to unleash the full potential of SIMATIC S7-1200 CPUs With these tools, they can design and implement real-world automation applications, ensuring the reliable operation of industrial processes.
AC Servo Motor Mitsubishi MR-J3
2.4.1 Structure of an AC Servo Motor
An AC servo motor, or alternating current servo motor, is a type of electric motor specifically designed to control position, speed, and acceleration precisely It is commonly used in applications that require high-precision motion control, such as robotics, industrial automation, CNC machines, and other motion control systems
Based on Figure 2-13, the AC Servo Motor has the following main components:
1 Rotor: The rotor is the rotating part of the motor, connected to the shaft It experiences the force from the magnetic field and generates rotational motion
2 Stator: The stator is the stationary part of the motor, containing the winding coils arranged in a spiral pattern around the rotor When alternating current is controlled through the coils, it creates a magnetic field around the rotor
Figure2- 13 Structure of the AC Servo motor
4 Encoders: The AC Servo Motor typically includes feedback encoders Encoders measure and provide information about the position and speed of the rotor to the controller This information adjusts the current flowing into the motor and ensures accuracy and responsiveness
5 Driver: The controller is the central control unit of the AC Servo Motor It receives control signals from the system and adjusts the current into the motor to meet the position, speed, and force requirements
6 Control System: The AC Servo Motor is typically controlled by control systems such as a PLC or specialized controllers The control system sends signals to the motor's controller to regulate its operation
2.4.2 Benefits of using AC Servo Motor
AC servo motors offer several advantages, including high dynamic performance, fast acceleration and deceleration, precise positioning, and smooth operation They can deliver high torque at low speeds, making them suitable for applications requiring power and precision AC servo motors are commonly paired with servo drives or motion controllers to achieve precise motion control in various industrial and automation applications
If we compare AC versus DC Servo motors, it can be claimed that the AC ones are better in variant parameters, as shown in Table 2-5
Table 2-5 Comparison between AC and DC Servo motor
Features AC Servo Motor DC Servo Motor
Operating Principle Use AC power Use DC power
Flexibility Suitable for a wide range of diverse applications
Suitable for applications requiring high speed
Precision Capable of precise control
Capable of achieving high precision
Responsiveness Faster response time Slower response time
Reliability High reliability High reliability
Structure and Size Complex structure and larger size
Simple structure and smaller size
Cost Often more expensive Often less expensive
Applications Widely used in industrial automation, robotics, CNC machines
Suitable for industrial automation, small to medium-sized machinery
2.4.3 General AC Servo Motor Mitsubishi MR-J3
The Mitsubishi MR-J3 AC Servo Motor is a high-quality motor made by Mitsubishi Electric It’s great for many industrial uses because of its advanced features
The motor uses a special driver, called the MR-J3 amplifier, to control it This driver gives the motor the power and control signals it needs for accurate movement and positioning It changes command signals into the right voltage and current signals, which makes the motor move at the needed speed and force
The driver has features that help the motor work better It usually has built-in feedback systems, like encoders, that give accurate position feedback to the control system This lets the motor’s position, speed, and force be controlled precisely
Figure2- 14 AC Servo motors Mitsubishi MR-J3 and driver
Table 2-6 Basic parameters of the driver of MR-J3
Input Power Voltage AC 200-240V (single-phase or three-phase)
Output Power Voltage AC 200-240V (three-phase)
Feedback Mechanism Encoder (Absolute Encoder)
Communication Interfaces Ethernet, RS-485, Analog I/O
Protection Functions Overload, Overvoltage, Overcurrent,
Control Modes Position Control, Speed Control, Torque
Mounting Options Position Control, Speed Control, ToDIN rail or panel mount
2.4.4 Absolute Encoder of the Servo Motor
An Absolute Encoder is a position sensor used in various systems and applications to provide accurate and absolute position information Unlike incremental encoders that track relative changes in position, Absolute Encoders offer a unique digital code for each position within a full revolution
Based on Figure 2-15, it consists of a disc or a strip with multiple tracks and a read
An absolute encoder head's structure comprises tracks adorned with slots or optical marks aligned with precise positions These tracks are read by sensors or detectors located in the read head, converting the detected patterns into electrical signals.
The Absolute Encoder's output is a binary code or a digital value that represents the absolute position of the encoder This value remains constant even if the power is turned off It is then restored, ensuring that the exact position is always known
Absolute encoders are commonly used in applications where precise positioning and accurate feedback are critical, such as robotics, CNC machines, servo systems, and industrial automation They offer high resolution, excellent repeatability, and immunity to power interruptions, making them suitable for demanding and high- precision applications.
Design and simulation software
SolidWorks (with logo as Figure 2-16 shows) is a leading 3D design software in the industrial and engineering sectors It provides a powerful, flexible graphic design environment for accurate and detailed 3D models
With SolidWorks, users can create technical drawings like Figure 2-17, 3D models, and complex assemblies The software offers powerful tools for design activities, including 3D modeling, motion simulation, mechanical analysis, and detailed technical drawing creation
Figure2- 16 The brand logo of SolidWorks
SolidWorks is a multifaceted software that caters to a multitude of engineering disciplines, including mechanical design, manufacturing, automotive, aerospace, and electronics It empowers users to craft intricate 3D models, manipulate components and assemblies, and conduct comprehensive analyses and simulations This robust toolset ensures the viability and performance of products, allowing engineers to optimize designs and minimize potential risks.
SolidWorks is a comprehensive tool for 3D design, modeling, simulation, and documentation, empowering engineers and designers to bring their ideas to life and streamline product development
MATLAB (MATrix LABoratory) is a popular computational and programming environment widely used in science, engineering, and mathematics Developed by MathWorks, MATLAB (logo in Figure 2-18) provides a powerful programming language and comprehensive tools for numerical computation, data analysis, and application development
With MATLAB, the way of researching and development becomes more accessible by the simple interface, such as in Figure 2-19, due to its support in:
Simscape is a multidomain physical modeling and simulation tool within MATLAB/Simulink It is used for modeling and simulating physical systems spanning various engineering domains such as mechanical, electrical, thermal, and hydraulic systems (example in Figure 2-20) Simscape allows engineers and scientists to describe the behavior of physical components and systems using fundamental
Figure2- 18 The brand logo of MATLAB physical principles
Simscape provides a block diagram environment in Simulink where users can assemble their models using prebuilt components and elements representing physical components like resistors, capacitors, springs, valves, motors, etc In this project, we use the Simscape tool for re-verifying the Kinematics of the Magician Robotic Arm
2.5.3 TIA Portal and SCADA Interface
Siemens' Totally Integrated Automation Portal (TIA Portal) is an integrated engineering software platform for programming and configuring automation systems It streamlines the design, configuration, programming, and diagnostics processes, facilitating efficient automation system development.
With TIA Portal, users can streamline their engineering workflows by accessing all the necessary tools and functions within a single software package The platform supports various Siemens automation devices, including PLCs, HMIs, drives, etc This integration allows for seamless communication and coordination between different components of an automation system
In TIA Portal, SCADA (Supervisory Control and Data Acquisition) functionality is provided through the WinCC (Windows Control Center) system WinCC is a powerful visualization and process control software that allows users to monitor, control, and optimize their industrial processes in real-time Figure 2-22 shows a project: monitoring a mixing system by SCADA interface
Figure2- 21 The brand logo of Siemens TIA Portal
With SCADA, users can create dynamic and interactive graphical interfaces, known as HMI (Human-Machine Interface), to visualize and interact with their automation systems The WinCC system offers various tools and features for designing, configuring, and deploying HMI applications.
Former Filling and Capping system projects
2.6.1.1 "THIẾT KẾ MÔ HÌNH GIÁM SÁT VÀ ĐIỀU KHIỂN HỆ THỐNG CHIẾT
RÓT VÀ ĐÓNG NẮP SỬ DỤNG PLC S7-1200" of NGÔ NHỰT HÀO
The K15 student’s is about an automatic bottle filling and capping system using a Programmable Logic Controller (PLC) The system can fill different size bottles with fluid and identify empty bottles during the process The PLC is the major element of the whole process, providing smooth operation, low cost, and high filling speed However, it’s unclear if the system can handle bottles continuously at the input or operate one bottle simultaneously
Figure2- 23 Hao and Hiep project's model
Figure2- 24 Conclusion of Hao, Hiep's project
2.6.1.2 "MÔ HÌNH CHIẾT RÓT ĐÓNG NẮP CHAI TỰ ĐỘNG PHỤC VỤ CHO
DẠY HỌC" of VÕ THANH PHÚC 11911018 AND NGUYÊN ĐÌNH NHÃ TRIẾT 11911025 [4]
The K11 student’s also involves a similar system However, the performance is not calculated and there’s a comment that “Bottles are executed separately, the speed and accuracy are low.” They used a PLC S7-200 in their project
Figure2- 25 Phuc and Triet's project model
2.6.2 Real industrial Filling and Capping system
A standard industrial manufacturing line has a washing station and can handle many
Figure2- 26 Conclusion of Phuc and Triet bottles at the entrance The performance ranges from 1000 to 36000 bottles per hour, depending on the size of bottles and types of liquid The whole process must be clean, especially for holding medicine or beverages
Figure2- 27 Tofflon 120VPM of Manufacturing Line
Figure2- 29 Washing station of Tofflon
2.6.2.2 Marya Filling and Capping system
The Marya manufacturing line's high-performance is ensured by its metal casing and the continuous movement of bottles With a production capacity ranging from 1000 to 36000 bottles per minute, it guarantees filling accuracy of under 1% and a capping qualification rate exceeding 99.9% Moreover, the line maintains a consistent temperature, contributing to its exceptional performance.
MATHEMATICAL MODEL & HARDWARE STRUCTURE
Design in SolidWorks
the robot gets the first bottle
- Web Server: Enables control and monitoring via PLC hosted address on devices like laptops, PCs, and smartphones
- Robot Control: The robot moves based on dynamics, which is about motion, not forces It doesn’t use individual joint controllers or calculate kinetics All controllers are at their default settings
- Drive Mechanism: The robot uses belts for movement, not complex designs like helical, bevel, or worm gears This means it’s less protected from dust and might not last as long Also, the joints can’t move as fast as they could with servo motors
- Image Processing: The project doesn’t include image processing
The reason why this project is conducted is represented The scope, constraint, and research method are also written
Basic knowledge about PLC, AC Servo, Filling and Capping system, and
Magician Robotic Arm are shown
The structure of hardware includes SolidWorks design, MATLAB simulation, wiring diagram, and configuration of devices are described in detail
An explanation of each program is shown through flowcharts Parameters for each driver are also written
Performance and success rates are examined
Some brief conclusions and development directions are written
A Manufacturing Line, also known as an Assembly Line, is a series of steps in a factory where raw materials are transformed into a final product or where parts are put together to make a finished product It’s a well-structured and efficient process where the product moves from one point to another, with each point carrying out a specific task This process is depicted in Figure 2-1
The manufacturing line is structured to enhance efficiency, reduce the duration of production, and maintain uniform quality It promotes the effective use of resources such as workforce, equipment, and materials The line generally follows a set order of operations, with each station focusing on a particular task
Assembly lines are widely employed in diverse industries for efficient product manufacturing, including automobiles, electronics, appliances, food and beverages, and pharmaceuticals The manufacturing process can entail a combination of human labor, machinery, and robotics, varying based on the product's complexity and production requirements.
2.1.2 History of the Manufacturing Line
The assembly line has developed from earlier production and organization ideas, especially in the meat-processing sector It started in the late 1700s and early 1800s when the first factories in England and the US began splitting tasks and building products on a line
The advent of mechanization and the use of machines indeed revolutionized the manufacturing process The assembly line concept, where products move through a sequence of workstations, each performing a specific task, emerged as a significant development in the early 20th century
Figure2- 1 An electronics Assembly Line
Figure2- 2 The first Assembly Line
However, the assembly line system developed and peaked during the Industrial Revolution in the late 19 th and early 20 th centuries, when Henry Ford applied this to automobile manufacturing technology (Figure 2-2) Ford pioneered the first assembly line system in his car production process, increasing productivity, reducing costs, and decreasing production time
The assembly line system has profoundly impacted the manufacturing industry, evolving and becoming its cornerstone This system has fostered the development and refinement of related technologies and processes, encompassing automation, robotics, and the integration of information technology These advancements have played a pivotal role in enhancing efficiency, productivity, and quality within the manufacturing sector.
The assembly line system continues to evolve and is applied in various industries, from automotive, electronics, and machinery to appliances, food, and pharmaceutical industries Its effectiveness in increasing productivity, reducing costs, and ensuring product quality has been proven
Figure2- 3 Modern Assembly Line with Robots
Figure2- 5 Fanuc robots in the industry
1 Machinery and equipment: This refers to the tools and devices used in production, like tools for machining, packaging, welding, cutting, quality checking, and automatic control machines
2 Conveyor systems: These are used to move items between different stages of production Conveyors can be made from rubber, plastic, or metal and can be controlled either electronically or mechanically
3 Robots and automation: Industrial robots do automated tasks on the production line, like assembly, welding, and handling products Automation also includes automatic control systems and sensors for managing production
4 Control systems: These are used to monitor and control operations on the production line They may include computers, control software, sensors, and measuring devices for accurate and efficient production
5 Transportation and storage systems: These include transportation systems like forklifts, cranes, pallet systems, and storage solutions for moving and storing items during production
6 Energy systems: These ensure the supply of energy to the equipment and machinery on the production line This system includes electricity, compressed air, cooling systems, and other energy sources
7 Tools and instruments: These include tools and devices like clamps, drills, cutting tools, screws, bolts, and others used in the production process
Each production stage in a manufacturing line consists of specific stages and activities to transform raw materials or components into the final product
1 Processing:This stage changes and treats raw materials or parts to make sub- assemblies Methods can include cutting, grinding, turning, milling, welding, pressing, and CNC machining
2 Assembly: This stage involves putting together parts to make the final product It can involve machines, tools, and manual labor
3 Quality Inspection: This stage makes sure the product meets quality standards and technical requirements Methods can include checking dimensions, testing strength and function, and assessing defect rates
4 Packaging: After the product is finished, it’s packaged to protect it and prepare it for transport Packaging can involve putting the product in boxes, bags, bubble wraps, or pallets
5 Transportation and Storage: This stage involves moving the product from the production line to storage or to the customer It can involve using vehicles like forklifts, lifting equipment, and storage systems like pallets or warehouses
6 Maintenance and Repair: This stage focuses on keeping the machinery and equipment in the production line working well It involves inspecting, maintaining, and repairing parts to ensure continuous operation and high performance
Figure2- 6 CNC machine of the Wood industry
Production lines are ubiquitous in manufacturing industries, serving to streamline operations and enhance productivity By leveraging machines for task automation, production lines have significantly reduced reliance on human labor in various production stages This automation offers numerous advantages, including increased efficiency, consistency, and cost-effectiveness.
Table 2-1 illustrates the primary industries that benefit from modern manufacturing lines
Table 2-1 Applications of the Manufacturing Line
This involves assembling vehicles, welding and attaching parts, quality testing, and finishing products
This includes fabricating electronic circuits, placing components, soldering and assembling, and quality testing and contro
This involves packaging and bottling, sorting and packaging agricultural products, and processing and packaging food
This includes packaging and bottling, quality testing, and secure packaging processes.
This involves mass production and assembly of household products and appliances
This includes weaving and garment production, fabric cutting and processing, assembly and finishing of garments, quality testing, and packaging
This involves processing plastic and rubber, molding and casting plastic parts, and assembly and quality testing of plastic and rubber products
This includes producing construction materials like cement, bricks, wood, and steel, assembling and testing building components, and constructing and finishing building projects
This involves processing metal, welding and attaching components, fabricating and assembling mechanical products, and testing and quality finishing
Industrial robots, including those designed for bottle processing and handling, have greatly transformed the manufacturing and automation industry They’ve enhanced efficiency, accuracy, and productivity across numerous sectors These advanced machines are engineered to perform repetitive tasks with high precision and reliability, making them indispensable in today’s industrial settings
General structure of the Magician Robot Arm
3.3.1 Notations about the design of the Magician Robot Arm
The Magician is special because it’s a 3-DOF robotic arm, but its end always stays horizontal There’s a diagram that shows this According to the Inverse Kinematics calculations, the red line DB is a3, and the green line EBC is a4 These two lines, DB and EBC, form one solid piece
From Figure 3-22, we can observe two parallelograms: GABH and BFCI The properties of these parallelograms are as follows:
Figure3- 22 Geometric model of Magician Robot Arm
From Figure 3-22, we can observe two parallelograms: GABH and BFCI The properties of these parallelograms are as follows:
• In parallelogram GABH, GA is equal to BH (GA = BH)
• In parallelogram BFCI, BF is equal to CI (BF = CI)
GA is fixed, so the direction of HB is also fixed HBF is a triangle and is fixed This means the directions of BF and CI are fixed too CIK is a fixed triangle, so the direction of CK compared to the ground is fixed For CK to be horizontal, the sum of the angles AAG, HBF, and ICK must be 180 degrees That is,
Figure3- 23 Magician Robot Arm model by SolidWorks
The movement of the robotic arm is driven by the rotation of the motor-controlled part AD While the optimal angle for ECB is 180 degrees, it is reduced to 150 degrees to avoid interference with the pulley's belt This adjustment results in a potential issue when the end part approaches point A, causing the shape ADEB to disappear and aligning AD with EB This alignment could lead to the detachment of part EBC.
In Inverse Kinematics, the angle of motor 2 or actuator 2 is θ2 But θ3 is not the angle of ac3 The value of θ3 is affected by both ac2 and ac3
From the figure, we have -θ3 = bBC = EBC - EBb = 150° - EBb
This means -θ3 = 150° - DAB = 150° - (ac3 - θ2) = 150° - ac3 + θ2 So, ac3 = θ2 + θ3 + 150°
MATLAB Simulation
The "DH angles to angles of actuators" block facilitates the conversion of kinematics angles to actuator angles, while the "angles of actuators to angles of Simulink" block performs the reverse conversion to obtain actual angles within the Simulink environment This conversion is crucial as the Simscape-multibody file generation process produces angles that diverge from the established conventions in terms of both position and direction.
Code for the Inverse Kinematics:
Code for the Forward Kinematics: function y = fcn(px,py,pz) a2B; d1.1; a31; a41; a50.44; a6; theta1=atan2(py,px)+asin(a6/sqrt(px^2+py^2));
K1=px*cos(theta1)+py*sin(theta1)-a2-a5;
K2=pz-d1; theta3=-acos((K1^2+K2^2-a4^2-a3^2)/(2*a3*a4)); theta2_y=(K2*(a4*cos(theta3)+a3)-a4*sin(theta3)*K1)/((a4*sin(theta3))^2+
(a4*cos(theta3)+a3)^2); theta2_x=(K1+function [px,py,pz] = fcn(theta1, theta2, theta3) a2B; d1.1; a31; a41; a50.44; a6; px=cos(theta1)*(a2+a4*cos(theta2+theta3)+a3*cos(theta2)+a5)+a6*sin(theta1); py=sin(theta1)*(a2+a4*cos(theta2+theta3)+a3*cos(theta2)+a5)-a6*cos(theta1); pza4*sin(theta2+theta3)+a3*sin(theta2);
Figure3- 24 Model of the rotary disk
The function `fcn` takes three input angles (`theta1`, `theta2`, and `theta3`) and calculates the corresponding Cartesian coordinates (`px`, `py`, and `pz`) using the provided constant coefficients The calculation involves trigonometric functions and the `atan2` function to determine the `theta2` angle The coefficients `a2`, `a3`, `a4`, `a5`, `a6`, `d1.1`, and `B` are assumed to have predefined values.
Figure3- 25 Inverse Kinematics block diagram
Figure3- 26 Moving the end manipulator along the z-axis in position control mode
Figure3- 27 The result from the Simscape-multibody link
Figure 3-26 shows the result after moving the end manipulator along the z-axis Besides, Figure 3-27 is the robotic arm in Simscape multibody link after converting from Solidwork Unnecessary bodies are eliminated to reduce the burden of processing information
Cost of the project
the robot gets the first bottle
- Web Server: Enables control and monitoring via PLC hosted address on devices like laptops, PCs, and smartphones
Robot control in this system relies on dynamics, focusing on motion rather than forces Individual joint controllers or kinetic calculations are not employed Notably, all controllers maintain their default settings, resulting in a streamlined and efficient control mechanism.
- Drive Mechanism: The robot uses belts for movement, not complex designs like helical, bevel, or worm gears This means it’s less protected from dust and might not last as long Also, the joints can’t move as fast as they could with servo motors
- Image Processing: The project doesn’t include image processing
The reason why this project is conducted is represented The scope, constraint, and research method are also written
Basic knowledge about PLC, AC Servo, Filling and Capping system, and
Magician Robotic Arm are shown
The structure of hardware includes SolidWorks design, MATLAB simulation, wiring diagram, and configuration of devices are described in detail.
SOFTWARE STRUCTURE
Mitsubishi AC Servo MR-J3 parameters setting [6]
In this project, the parameters listed below are different from default values Other parameters which are not listed remain at default values
This parameter is used to choose the control mode for the drive If the absolute encoder is read through DI or communication, the value of this parameter must be zero
- 1: Position control mode and speed control mode
- 3: Speed control mode and torque control mode
- 5: Torque control mode and position control mode
• PA02 - Regenerative option (Default value: 000h)
The regenerative resistor is an external device that dissipates excess energy when the motor is overloaded or braking In this project, the load is not too high Therefore, internal regenerative resistors are used However, if the power of the motor is higher, the instruction below must be followed:
- A regenerative resistor is not used for a servo amplifier of 100W
- A built-in regenerative resistor is used for a servo amplifier of 200 to 7kW
- Supplied regenerative resistors or regenerative option is used with the servo amplifier of 11k to 22kW
- For a drive unit of 30kW or more, select a regenerative option by the converter unit
• PA03 - Absolute position detection system
- 1: Used in the absolute position detection system ABS transfer by DI0
- 2: Used in the absolute position detection system ABS transfer by communication
This parameter is used to read data from Absolute Encoder and Counter If PA03 is set at 1 or 2, an external battery must be installed behind the driver In this project, the value of PA03 is set at 1 instead of 2 because a Siemens PLC is used to control a Mitsubishi AC Servo The communication protocol between the two devices is not compatible An external communication device will be unnecessary if the reading is conducted through inputs and outputs Hence, the cost is must lower However, if a Mitsubishi PLC is used, I recommend transferring signals through communication because there are fewer wires in the system
• PA05 - Number of command input pulses
Figure4- 1 The process of executing command pulse train
This parameter specifies the number of input pulses per revolution (Figure 4-1) When "0" (initial value) is set in parameter No.PA05, the electronic gear (parameter No.PA06, PA07) is valid When the setting is other than "0," the electronic gear is disabled Figure 4-1 describes how the command pulse train is processed
• PA06 - Electronic gear numerator (CMX)
• PA07 - Electronic gear denominator (CDV)
When the number of pulses per revolution exceeds 50000 or fractional, these parameters are preferred over PA05 In general, the load movement of one pulse follows the equation:
• PA08 - Auto tuning mode (Default value: 0001h)
In this project's scope, we only control the robot through kinematics without designing a controller Therefore, every parameter related to control is set at fully auto-tuning mode 0001h
• PA13 - Selection of command pulse input form
This type of drive can receive three forms of pulse-train and both kinds of logic: negative and positive The description of each form is listed in Table 4-1 The signed pulse train is the most popular form because only one output is required to operate at high frequency
Table 4-1 Command pulse input form
Setting Pulse train form Description
Forward rotation pulse train Reverse rotation pulse train (Negative logic)
A-phase pulse train B-phase pulse train
Forward rotation pulse train Reverse rotation pulse train (Positive logic)
A-phase pulse train B-phase pulse train
The value of the parameters of each drive is set as Table 4-2 Parameters that are not listed remain default
Table 4-2 Setting parameters for each drive
Joint 1 Joint 2 Joint 3 Rotary disk
Motion control by Siemens Simatic S7-1200 V6.0 [7]
Motion control is an advanced technique of S7-1200 PLC Siemens A high seed pulse output cards are used to generate a pulse train for the servo or stepper drive The drive receives pulses from PLC as the input signal These signals are subsequently used to control the motor
4.2.1 Signal types of the Pulse Train Output
In order to ensure bidirectional rotation of motors, it is necessary to provide two outputs for each motor This requirement arises from the need to control the motors in both directions In the case of an S7- PLC, this can be achieved by assigning two outputs to each motor, enabling it to rotate in both the clockwise and counterclockwise directions.
1200 PLC in general, five types of output signals of the PTO (pulse train output) are listed in Table 4-3
Table 4-3 Signal types and number of outputs required
Signal type Number of pulse generator outputs
Pulse A and direction B (direction output disabled) 1
Clock up A and clock down B 2
This PTO is the most common configuration; one output generates pulses to control distance The other output is used to control the direction There is a bit of delay after changing the direction to ensure the drive receives the command correctly (Figure 4-2)
In this configuration, one output generates the signal for position direction The other is used to generate the signal for the negative direction
Figure4- 2 PTO – pulse (A) and direction (B)
• PTO clock up A and clock down B
Figure4- 3 PTO clock up A and clock down B
In this configuration, one output generates the signal for position direction The other is used to generate the signal for the negative direction (Figure 4-3)
• PTO – A/B phase-shifted (as of V4)
The positive edge of one output in each case is evaluated for this type of signal
If signal A leads signal B 90 , the motor will rotate positively If signal B leads signal A 90 , the motor will rotate in the negative direction
This form is an advanced configuration of A/B phase-shifted Both the positive edges and negative edged of both outputs are considered There are four edges in each period Therefore, the pulse frequency at output is reduced to a quarter (Figure 4-4)
Figure4- 4 PTO – A/B phase-shifted and (A/B phase-shifted - quadruple)
4.2.2 Assigning the outputs of PLC to PTO
Table 4-4 Maximum frequency of outputs
214C CPU DC/DC/DC From Q0.0 to Q0.3 100 kHz
6ES7 222-1BD30-0XB0 From 4.0 to Q4.3 200 kHz
PLC S7-1200 offers two output types: Transistor and Relay Notably, Relay outputs lack pulse generation capabilities For PTO outputs, only the main CPU or signal board can provide them Table 4-4 details the equipment's maximum frequency parameters.
Outputs of the SM board cannot be used for PTO even if they are transistor outputs
In this project, the configuration PTO – pulse (A) and direction (B) is assigned to all four motors The main advantage of this configuration is that only one output needs to generate pulses at high frequencies The pin that controls direction doesn't need to operate at high frequency
Figure4- 5 Create motion control block
Figure4- 6 Setting configuration for motion control
Utilizing all four motion control blocks of the PLC, this project's program conforms to the guidelines outlined in Table 4-5 The evaluation of load movement for this table is detailed in Chapter 3 Moreover, Figures 4-5 and 4-6 visually depict the process of configuring the motion control blocks' parameters.
Table 4-5 Configuration of motion control blocks
4.2.3 Motion control instructions (From motion control manual)
Information in this section is taken from the motion control V6.0 manual However, the tables below have been changed to keep the necessary information
The Motion Control instruction "MC_Power" from Table 4-6 turns an axis on or off
Axis INPUT TO_Axis Axis technology object
All current jobs are interrupted by the "StopMode" configured The axis is stopped and disabled
Enable positioning axis position- controlled
If a request to disable the axis is pending, the axis brakes at the configured emergency deceleration
The axis is disabled after reaching a standstill
Motion Control instruction "MC_Home" from Table 4-7 matches the axis coordinates to the real, physical drive position Homing is required for the absolute positioning of the axis The following types of homing can be executed
Parameter Declarati on Datatype Description Axis INPUT TO_Axis Axis technology object
Execute INPUT BOOL Start the command with a positive edge
The absolute position of the axis after completion of the homing operation
Direct homing (absolute) The new axis position is the position value of parameter
Done OUTPUT BOOL TRUE Command completed
The "MC_MoveAbsolute" Motion Control instruction starts an axis positioning motion to move it to an absolute position shown in Table 4-8
Axis INPUT TO_Axis Axis technology object
Execute INPUT BOOL Start the command with a positive edge
Absolute target position Limit values:
The velocity of the axis: This velocity is not always reached because of the configured acceleration and deceleration and the target position to be approached
The absolute target position reached
Busy OUTPUT BOOL TRUE The command is being executed
The "MC_MoveRelative" Motion Control instruction starts a positioning motion relative to the start position shown in Table 4-9
Axis INPUT TO_Axis Axis technology object
Execute INPUT BOOL Start the command with a positive edge
Absolute target position Limit values:
The velocity of the axis: This velocity is not always reached because of the configured acceleration and deceleration and the target position to be approached
The absolute target position reached
Busy OUTPUT BOOL TRUE The command is being executed
Motion control instruction "MC_MoveVelocity" moves the axis constantly at the specified velocity shown in Table 4-10
Axis INPUT TO_Axis Axis technology object
Execute INPUT BOOL Start the command with a positive edge
Velocity specification for axis motion Limit values:
≤ maximum velocity (Velocity = 0.0 is permitted)
Absolute Encoder
4.3.1 Absolute position detection system of Mitsubishi AC Servo Motor MR-J3
To prevent the absolute position-erase error (AL25) caused by encoder cable issues or battery depletion, set PA01 to 0000h and PA03 to 0001h before installing the battery AL25 typically occurs during initial battery installation or PA03 setting to 0001h For first-time installations, resolve the error by cycling the power Regularly replace the battery every two years to maintain optimal performance and prevent AL25 errors.
4.3.1.2 I/O interfaces for reading the absolute position
In this project, absolute encoder data is read directly through the inputs and outputs of drive and PLC without any standard communication protocol The name and number of each pin for this reading are listed in Table 4-11 The function of these pins will be changed if the drive is not in reading absolute position mode
Signal name Code CN1 Pin
While ABSM is on, the servo amplifier is in the ABS transfer mode and cannot be moved
Turn on ABSR to request the ABS data in the ABS transfer mode
Indicates the lower bit of the ABS data (2 bits) which is sent from the servo to the programmable controller in the ABS transfer mode
Indicates the upper bit of the ABS data (2 bits), which is sent from the servo to the programmable controller in the ABS transfer mode
Indicates that the data to be sent is being prepared in the ABS transfer mode
A diagram from the MR-J3 manual for communication protocol through the I/O
97 interface is described in Figure 4-7 There are 32 bits for data and 6 bits for checksum Remember that data from ABS does not represent distance directly from slots of the absolute encoder or ABS counter Each bit from ABS data represents a distance equal to one command pulse Therefore, this data relates directly to PA05, PA06, and PA07 values The description of this procedure is described below:
1 At power on, the PLC turns on ABSM and SON simultaneously (ABSM can be turned on before SON a little bit)
2 When ABSM is on, the drive is in ABS transfer mode The servo detects and calculates the absolute position When this process is done, ABST (transmission data ready) is turned on to notify the PLC that the servo is ready
3 After acknowledging that ABST has been turned on, the PLC turns ABSR (ABS request) ON
4 In response to ABSR, the drive transmits 2 bits from ABS data, and the ABST is turned OFF
5 After acknowledging that the ABST has been turned OFF, the PLC reads 2 bits of ABS data and then turns ABSR off
6 The drive turns ABST on again to respond to the subsequent request Steps 3 and
6 are repeated until 32-bit data and the 6-bit checksum have been transmitted
7 After receiving the 19th ABS transfer turn, ABSM must be turned off If this procedure is processed incorrectly, alarms related to each particular mistake will occur The ABS data can only be read once when the power is ON The absolute encoder cannot be reread if the base circuit is ON
Figure4- 7 Communication protocol through I/O interface
4.3.2 Program for reading Absolute Encoder
Table 4-12 describes the meaning of variables in the flow chart The main ideas for reading absolute encoder and homing are illustrated in Figure 4-9 and Figure 4-10
Name Describe i encoder This variable indicates the order of the first 32 bits of ABS data j checksum This variable indicates the order of the last 6 bits of ABS data
This variable stores the sum of the first 32 bits of the ABS data The process of calculating the sum from the first 32 bits is illustrated in Figure 4-8
Checksum B This variable stores the sum of the last 6 bits from ABS data to compare with the first 32 bits
Figure4- 9 Flow chart of the homing process
Figure4- 10 Flow chart of reading absolute encoder process
Structure of software
Figure4- 11 Flow chart of the main program
The system's program comprises three distinct sections The Homing subprogram (detailed in Section 4.3) pertains to the MR-J3 hardware, while unrelated operations are segregated into a subprogram labeled "the rest of the system."
4.4.1 Flow chart of Magician Robotic Arm
Robotic arms' movement is separated into position control and velocity control
The end manipulator's trajectory is outlined in Table 4-13, with coordinates subject to change based on device positioning The system incorporates an SMC pneumatic gripper, which activates to close when a signal is present and opens when the signal is absent Figure 4-12 provides a comprehensive overview of the robotic arm's software.
Table 4-13 The trajectory of the end manipulator
Example of position or velocity along the z-axis
This state is a safe position to start
Here, collision is avoided while the robotic arm starts working
Move to the (x;y) position of the bottle on the conveyor Z is set at 130, which is high to avoid bottle collision
The end manipulator is lower, nearly touching the cap of the bottle
The end manipulator is moved gradually from the top to the bottle's neck
5 Position (61;317;93.5) ON Position of the neck of the bottle
The bottle is moved straightly from the conveyor
Position of the bottle when being removed from the conveyor
Move the bottle to a safe position on the box The bottle is not moved directly in the box to avoid collisions X,y position can be changed according to the order of the bottle in the box
The bottle is lowered above the box
The bottle is moved straightly to the box The trajectory must be straight vertically to avoid collision with other bottles
The bottle is put in the right position in the box
12 Velocity 20 OFF Gripper is higher from the box
Gripper is moved higher completely The robotic arm returns to state 1
Figure4- 12 Flow chart of the robotic arm
4.4.2 Flow chart of the rest of the system
Aside from the robotic arm, this system is separated into three stations: filling water, capping lids by a pneumatic cylinder, and output which removes the bottle from the rotary disc The main idea is that the rotary disk will rotate when all three stations complete their work 90 The flow chart is represented in Figure 4-13
Figure4- 13 Flowchart of the rest of the system
4.4.3 Flow chart of the rest of the system
In addition to the robotic arm, this automated system consists of three separate stations: water filling, lid capping via a pneumatic cylinder, and output handling to remove bottles from the rotary disk The system operates on a synchronized cycle; when each station completes its task, the rotary disk rotates 90 degrees A detailed flowchart of the process is provided in Figure 4-13 for visual reference.
RESULT
Overview
- Overview of the panel system (Figure 5-1)
- Overview of the panel system with the view buttons (Figure 5-2)
- The wiring system of the panel (Figure 5-3)
- Overview of the whole project hardware (Figure 5-4)
Figure5- 1 The actual wiring system of the panel
Figure5- 2 Overview of the actual electrical cabinet
Figure5- 4 Overview of the project
Images of the working process
Initially, empty bottles are placed on the input conveyor and pushed towards the end of the conveyor to fill water into the bottles, as shown in Figure 5-5
Figure5- 5 Bottles in the input conveyor
Figure5- 6 Filling water into a bottle
The bottles are then transported to the capping process, where a restraining bar is designed by the sliding edge mechanism to hold the cap in place for easy sealing, as Figure 5-7 shows
The capped bottles have a shape as shown in Figure 5-8
Figure5- 8 Cap before it is capped
Figure5- 9 Pneumatic cylinder is capping the bottle
In the next step, they are moved to the capping station and tightly sealed by a pneumatic mechanism, as shown in Figure 5-9
The culmination of the assembly line involves propelling the bottles onto the output conveyor (Figure 5-10) At this critical juncture, it is imperative that the bottles are filled with the appropriate quantity of water and securely capped This final step ensures that the bottles are ready for distribution or further processing in a satisfactory condition.
However, in reality, after multiple runs of the entire system, there is still a possibility of errors occurring, such as the cap not being applied correctly onto the bottle mouth As a result, the pneumatic system may fail to seal the bottle tightly
Upon completion of the output conveyor process, bottles are positioned within a designated waiting area and secured by 3D-printed barriers (Figure 5-11) Within this holding zone, filled and capped bottles undergo a progressive retrieval process by the Magician Robotics Arm, meticulously placing them into storage.
Figure5- 10 Bottles are delivered to the output conveyor
Figure5- 11 3D printing barrier to stop the bottle
The robot begins to grip the bottles, as shown in Figure 5-12
Figure5- 12 A pneumatic cylinder grips bottle
Figure5- 13 Robotics Arm puts the bottles into the storage
Figure5- 14 Movement after each gripping
The completed bottles then be put into storage, as shown in the black circle in
In the final step, the Magician Robotics Arm is moved to the safe position and repeats the gripping process as performed in Figure5-14.
CONCLUSION AND DEVELOPMENT
Conclusion
- Mechanical design is effective Overall, the entire process operates correctly In particular, lids are successfully placed on bottles
- The robotic arm operates correctly without any errors over a long period
- The PLC successfully reads the absolute encoders of AC servos
- A creative wiring diagram has successfully bridged the differences between the two brands, Siemens and Mitsubis
- Noise has been eliminated by the earthing system
- We can check and adjust our system using a web server
- The system ensures resumption from where it stopped after a power shutdown
- When a box of 9 bottles is empty, the system starts over and the robot gets the first bottle
- The filling accuracy is low The error is extremely high the first time filling occurs when there isn’t any water in the pipe
- The durability is low Joints in the pneumatic cylinder and conveyors must be repaired after 1 hour of operation
- The earthing system is not entirely effective Electrocution remains a problem
- The web server can only be used and checked locally, not from far away
- The robotic arm still makes mistakes when using the position control method.
Development
There are several ways of development for this project:
- An image processing system can be implemented to eliminate defective products
- Advanced mechanical devices, such as helical gears, bevel gears, and worm gears, should be installed to enhance robot performance
- By connecting an IoT kit to the PLC, we can check and adjust the system from anywhere
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HỆ THỐNG CHIẾT RÓT VÀ ĐÓNG NẮP SỬ DỤNG PLC S7-1200," HCMC University of Technology and Education, Ho Chi Minh, 2019
[4] P T Võ and T Đ N Nguyễn, "MÔ HÌNH CHIẾT RÓT ĐÓNG NẮP CHAI TỰ ĐỘNG," HCMC University of Technology and Education, Ho Chi Minh, 2016
[5] "Vial Liquid Filling Sealing Production Line," Marya, [Online] Available: https://www.techsciresearch.com/report/vietnam-robotics-market/8078.html
[6] Mitsubishi Electric, "MELSERVO-J3 Series SERVO AMPLIFIER INSTRUCTION MANUAL," Tokyo, 2014
[7] Siemens, "STEP 7 S7-1200 Motion Control V6.0 to V7.0 in TIA Portal V16,"