Design Of Automatic Loading And Unloading Of Workpiece System For HAAS CNC Milling Machine

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

DESIGN OF AUTOMATIC LOADING AND UNLOADING OF

WORKPIECE SYSTEM FOR HAAS CNC MILLING MACHINE

This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Robotics and Automation) with Honours

by

THILIBAN SIVAPRAGASAM B051210258

910923-07-5987

DECLARATION

I hereby, declared this report entitled “Design of Automatic Loading and Unloading of Work pieces System for HAAS CNC Milling Machine” is the result of my own project

except as cited in references.

Signature :

Author’s Name : Thiliban A/L Sivapragasam

APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Robotics & Automation) (Hons.). The member of the supervisory committee is a follow:

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ABSTRACT

ii

ABSTRAK

iii

DEDICATION

iv

ACKNOWLEDGEMENT

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TABLE OF CONTENTS

Abstrak i

Abstract ii

Dedication iii

Acknowledgement iv

Table of content v - ix

List of Tables x

List of Figures xi - xiii

CHAPTER 1: INTRODUCTION 1

1.1 Background of the Project 1

1.2 Problem Statement 3

1.3 Objectives 3

1.4 Scopes 4

CHAPTER 2: LITERATURE REVIEW 5

2.1 Introduction about HAAS VF-1 CNC Milling Machine 5 2.2 Types of system used for loading and unloading process 6 2.2.1 Man power in loading and unloading process 6 2.2.2 Hydraulic jack system in loading and unloading process 8 2.2.3 Robot operation system in loading and unloading process 9

2.3 Type of loading and unloading robot system 10

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2.3.2 Wheeled robots 11

2.3.3 Legged robots 12

2.3.4 Flying robots 12

2.3.5 Mobile spherical robots 13

2.4 Types of robots geometry 14

2.4.1 Cartesian Geometry 15

2.4.2 Cylindrical Geometry 16

2.4.3 Spherical Geometry 17

2.4.4 Articulate Geometry 18

2.5 Types an end effector 20

2.5.1 Vacuum Grippers 20

2.5.2 Magnetic Grippers 21

2.5.3 Standard Grippers 22

2.6 Type of power source 23

2.6.1 Pneumatic Power Source 24

2.6.2 Hydraulic Power Source 25

2.6.3 Electric Power Source 26

2.7 Type of software 27

2.7.1 Types of Robotic Software 27

2.7.2 Types of CAD Software 28

2.7.2.1 CATIA 28

2.7.2.2SolidWorks 29

2.7.2.3 UGSNX 30

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CHAPTER 3: METHODOLOGY 31

3.1 Flow Chart of the Project 31

3.2 Gantt Chart of the Project 32

3.3 Selection of type system for loading and unloading process 32 3.4 Selection of type of loading and unloading robot system 36

3.5 Selection of Types of Geometry of the Robot 37

3.6 Selection of the Gripper 40

3.7 Selection of Power Source 41

3.8 Selection of the Robot Soft Prototype 42

3.9 Selection of CAD Soft Prototype 43

3.10 Design Ideas 44

3.10.1 Design 1 46

3.10.2 Design 2 47

3.10.3 Design 3 48

3.11 Selection of Gripper Design 49

3.12 Conclusion 50

CHAPTER 4: DESIGN AND ANALYSIS OF GRIPPER AND ROBOT

WORKSPACE 51

4.1 Process Simulation 51

4.1.1 Creating Mechanism 52

4.1.1.1 Gripper Mechanism 52

4.1.1.2 CNC Machine Mechanism 56

4.1.2 Creating Simulation Path 59

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4.1.2.2 Target 61

4.1.2.3 Path 61

4.1.2.3 Smart Component 63

4.1.2.4 SC_Gripper 63

4.1.2.5 SC_CNC Machine 65

4.1.2.6 Station Logic 67

4.1.2.7 RAPID Coding 68

4.1.2.8 System Layout 71

4.2 Finite Element Analysis (FEA) 72

4.3 Analysis of Maximum Work Load 72

4.4 Gripping Force 73

4.5 Applied 143N Force 76

4.6 Factor of Safety 76

4.7 Modified Parallel Gripper 79

4.8 List of Standard Part 82

4.9 List of Fabricate Part 83

4.10 Sustainability 83

CHAPTER 5 : CONCLUSION AND RECOMMENDATION FOR FUTURE

WORK 84

5.1 Conclusion 84

5.2 Recommendation for Future Work 85

ix APPENDICES

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LIST OF TABLES

Table 2.1 Robot Brand and their language 27

Table 3.1 Comparison between hydraulic jack system and robot operating

system 34

Table 3.2 Comparison between robot’s geometry 37

Table 3.3 Rating system for robot geometry 39

Table 3.4 Rating system for gripper selection 40

Table 3.5 Rating system of Power Source 42

Table 3.6 Rating system between gripper designs 49

Table 4.1 List of Smart Components in Gripper 63

Table 4.2 List of Smart Components in SC_CNC Machine 65

Table 4.3 List of Standard Parts 82

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LIST OF FIGURES

Figure 1.1 HAAS VF-1 Milling Machine at FKP Lab 2

Figure 1.2 Manual loading of work piece into CNC Machine 3 Figure 2.1 Process of Loading inside HAAS VF-1 CNC Milling Machine 7

Figure 2.2 Cartesian Geometry 15

Figure 2.3 Cylindrical Geometry 17

Figure 2.4 Spherical Geometry 18

Figure 2.5 Articulate Geometry 19

Figure 2.6 Vacuum Grippers 21

Figure 2.7 Magnetic Grippers 22

Figure 2.8 Standard Grippers 23

Figure 3.1 Flow chart of the project methodology 32

Figure 3.2 Working space of CNC Machine 35

Figure 3.3(a) Front Viewof Design 1 46

Figure 3.3(b) Side Viewof Design 1 46

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Figure 3.3(d) Isometric Viewof Design 1 46

Figure 3.4(a) Front Viewof Design 2 47

Figure 3.4(b) Side Viewof Design 2 47

Figure 3.4(c) Top Viewof Design 2 47

Figure 3.4(d) Isometric Viewof Design 2 47

Figure 3.5(a) Front Viewof Design 3 48

Figure 3.5(b) Side Viewof Design 3 48

Figure 3.5(c) Top Viewof Design 3 48

Figure 3.5(d) Isometric Viewof Design 3 48

Figure 4.1 Importing gripper parts to RobotStudio 52

Figure 4.2 Assembly of gripper 53

Figure 4.3 Type of Mechanism 54

Figure 4.4 Type of Joint 55

Figure 4.5 Tool Data of Gripper 56

Figure 4.6 (a) Assembly of HAAS CNC Machine 57

Figure 4.6 (b) CNC Machine Mechanism Type. 57

Figure 4.6 (c) Link Setting for CNC Machine 58

Figure 4.6 (d) Joint Setting for CNC Machine 59

Figure 4.7 WorkObject 60

Figure 4.8 Creating Target 61

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Figure 4.10 SC_Gripper Connection 64

Figure 4.11 Line Sensor 64

Figure 4.12 SC_CNC Machine 66

Figure 4.13 Station Logic 67

Figure 4.14 Zone Data 70

Figure 4.15 (a) Isometric Viewof System Layout 71

Figure 4.15 (b) Top Viewof System Layout 71

Figure 4.15 (c)Front Viewof System Layout 71

Figure 4.15 (d) Side Viewof System Layout 71

Figure 4.16 Gripping Force of a Parallel Gripper 74

Figure 4.17 Coefficient of friction 75

Figure 4.18 Modal of the Gripper 77

Figure 4.19 Characteristics of the Plain Carbon Steel 77 Figure 4.20 Result for von Mises Stress fot 143N force applied. 78 Figure 4.21 Result for Factor of Safety when 143N force applied 79

Figure 4.22(a) Initial Dimension of Gripper 80

Figure 4.22(b) Modified Dimension of Gripper 80

Figure 4.23 Shows the result for von Mises Stress for 143N force applied for

Modified Parallel Gripper 81

Figure 4.24 Result for Factor of Safety when 143N force applied for the

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CHAPTER 1

INTRODUCTION

1.1 Background of the Project

Automation has become an important aspect in manufacturing industry. At early stage, human was responsible for executing all the process from forging, grinding, until welding. Even though automation have been replaced the human labor, yet manufacturing still relies on the manual labor due to the complexity of the process requires the human dexterity. (Charalambons, Fletcher, and Webb. 2008)

Nowadays automation also involved together with Computer Numerical Control Machine (CNC). CNC machine is a type of operating machine, whereby a computer monitors the machine tools. CNC is actually a further innovation from NC Machine. Almost every manufacturing industry uses CNC machine in their process. CNC machine can execute same operation repeatedly for a long period of time as long the work piece is being feed into in.

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more effective and efficient compare to human labor because human could not execute any task for a long period of time as fatigue will takes toll on them. HAAS VF – 1 CNC Milling Machine are designed to perform machining process only. Hence it need the work piece to be feed into it in order for it to operates

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1.2 Problem Statement

The problem arises when the HAAS CNC Milling Machine in CNC Lab at Block B of Faculty of Manufacturing Engineering, UTeM uses human operator to load and unload the raw work piece or semi finish work piece into the machine. This action seems to be less productive and also might cause injuries if the operator that is loading the work piece accidentally drops it. To solve this problem, a suitable automatic system will be selected and designed to load and unload the work piece.

Figure 1.2: Manual loading of work piece into CNC Machine

1.3 Objective

i. To select a suitable automatic system for loading and unloading work pieces for HAAS CNC Milling Machine.

ii. To design a suitable gripper or tool for handling the work pieces for loading and unloading the CNC Milling Machine

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1.4 Scopes

i. Study and select a suitable automatic system such as robot or other equipment for loading and unloading work pieces for HAAS CNC Machine.

ii. To design a suitable tool or gripper for handling the work piece based on the following dimension:

Length = 150mm (max) Width = 150mm (max) Height = 80mm (max) Work piece material = Steel Density of steel = 8050 kg/m³

Maximum weight of the work piece : = Volume x Density

= Width x Height x Density

= 0.15m x 0.15m x 0.15m x 0.08m x 8050kg/m³ = 14.49kg

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CHAPTER 2

LITERATURE REVIEW

This chapter discusses the entire element that needed to automate the loading and unloading of the work piece into HAAS VF – 1 CNC Milling Machine. This chapter uses various resources from books, journals, and also internet to review the elements in the automated process

2.1 Introduction about HAAS VF – 1 CNC Milling Machine

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Besides that, high performance of vector drive spindles, high – torque brushless servos, and rigid cast – iron construction are among of few features possess by the CNC Milling Machine. Configurations range from 40 – 50 taper gear – driven models for high – torque, heavy – duty cutting, to Super Speed models with the inline direct – drive spindles to handle the most demanding high – speed machining operations. (Haas Automation, 2013).

2.2 Types of system used for loading and unloading process

The process of loading and unloading the work piece falls on the Flexible Manufacturing System (FMS). Simultaneously process medium – sized volumes of a variety of part types is called FMS whereby it is an integrated, computer controlled complex of automated material handling devices and numerically controlled (NC) machine tools. In FMS, there are several methods used to execute loading and unloading task, namely hydraulic jack system, and robot operation system. These systems will be compared and analyzed with the current method of loading and unloading the work piece.

2.2.1 Man power in loading and unloading process

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work piece. This kind of ineffective requires a human labor besides the machine all the time just to load the work piece and unload the finished product.

Figure 2.1: Process of Loading a work pieces for the HAAS VF-1 CNC Milling Machine