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TABLE OF CONTENTS
CHAPTER TITLE PAGE
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENTS iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENTS vii
LIST OF TABLES xi
LIST OF FIGURES xii
LIST OF ABBREVIATIONS xv 1 INTRODUCTION 1.1 Project Introduction 1 1.2 Project Objective 4 1.3 Scope Of Project 4 1.4 Organization Of Thesis 5 2 LITERATURE REVIEW 2.1 Gantry Robot 6 2.2 Programmable Logic Controller 8 2.2.1 PLC Introduction 8
2.2.2 PLC Features 8
2.2.3 System Scales 9 2.2.4 User Interface 9
2.2.5 Communication 10 2.2.6 PLC Compared With Other Control Systems 10 2.2.7 Digital and Analogue Signal 12
2.2.8 Programming Language 13 2.2.9 Siemens PLC 14 2.3 Profibus Communication Protocol 16 2.3.1 Profibus Introduction 16 2.3.2 Profibus Origin 18 2.3.3 Advantages Profibus Compare Other Fieldbuses 18 2.4 Servo Drive 19
2.4.1 Introduction To Digital Servo Drive 19 2.4.2 Lenze 9300 Positioning Servo Drive 20
3 PROJECT BACKGROUND
3.1 Previous Control System for ABB Robot 22 3.2 Problem with Previous ABB Gantry System 27 3.2.1 Obsolete Parts 27
3.2.2 No Local Support Available For Robot 27 3.2.3 Complicated Control System 28 3.2.4 Homing In Every Movement 29 3.2.5 Unnecessary Tray Scanning Process 29
3.2.6 No Permission Required To Enter Cage 29 3.2.7 Cannot Run In Manual Loading & Unloading 30 3.2.8 Robot Don’t Have Safety Parking Position 30 3.2.9 No Proper Indication Of Alarm Or Fault Signal 30
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4 METHODOLOGY
4.1 Introduction 31 4.2 Siemens Programmable Logic Controller 32
4.2.1 Siemens PLC Hardware Configuration 32 4.2.2 Siemens Network Configuration 34 4.2.3 Siemens PLC Program Editor 35 4.2.3.1 Siemens S7-Graph Editor 36
4.2.3.2 Siemens Ladder Diagram (LAD) Editor 39 4.2.3.3 Siemens Statement List (STL) Editor 41 4.3 Siemens Human Machine Interface (HMI) 43 4.4 Global Drive Control 45
5 PLC PROGRAM IMPLIMENTATION
5.1 Introduction 46 5.2 Robot Auto Cycle 48 5.3 Machine Ready, Safety and Error Handling Program 54 5.4 Decision Making Program 58 5.5 Drive Control Program 61 5.6 Execution Of FB3 Programs 63
6 HMI IMPLIMENTATION
6.1 Introduction 67 6.2 Main Screen 68 6.3 Auto Cycle Screen 69 6.4 Semi Auto Cycle Screen 74 6.5 Manual Cycle Screen 76 6.6 System Diagnostic Screen 77 6.7 Teaching Mode Screen 78
7 DRIVE IMPLIMENTATION
7.1 Introduction 79 7.2 Drive Parameter Configurations 79 7.3 Position Configuration 81 7.4 Drive Program Editor 82
8 RESULTS AND DISCUSSION
8.1 Introduction 84 8.2 Development Stages 85 8.3 Error Recording Program (FC250) 87 8.4 Features Of New Robot Gantry System 88 8.4.1 Simple And Reliable Control System 88 8.4.2 Easy Maintenance & Troubleshooting Process 91 8.4.3 One Touch Button Control Concept 92 8.4.4 Optimize Movement Concept 92 8.4.5 Improved Safety 93
8.4.6 Improved Tray Scanning Process 94 8.4.7 Variable Speed Control To Improve Process Time 95 8.4.8 Touch Screen For The Robot 95
9 CONCLUSION AND RECOMMENDATION
9.1 Conclusion 97 9.2 Recommendation 98
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LIST OF TABLES
TABLE NO. TITLE PAGE
3.1 Loading Control System Unit 23 3.2 Unloading Control System Unit 24 3.3 ABB Gantry Robot Control System Unit 25 4.1 List Of Hardware Used For Gantry Robot 33 5.1 Function List For The Robot Auto Cycle Sequence 60
LIST OF FIGURES
FIGURE NO. TITLE PAGE
1.1 Gantry Robot Structure 3 1.2 Loading Station 3 1.3 Unloading Station 4 2.1 Digital Servo Drive 20 3.1 S5 100u CPU 23 3.2 Sanyo Denki Stepper Motor Drive 24 3.3 S5 115u CPU With Input Output Card 25 3.4 Telemeqanique NUM 17.20 CPU 26 3.5 ABB NUM NC Controller Card 26 3.6 BOSH-REXROTH Indramat Servo Drive Axis Module 27 4.1 Hardware Configuration 34 4.2 HMI and PLC Communication Interface 35 4.3 Graph-7 Programs 37 4.4 Robot Programs Written In S7-Graph Language 38 4.5 Ladder Diagram Editor Siemens PLC 40 4.6 Ladder Diagram Editor Siemens PLC 41 4.7 STL Editor Siemens PLC 42 4.8 WinCC Flexible 2008 HMI Screen Editor Software 44 4.9 Global Drive Control Software 46 5.1 Flow Chart For Robot Auto Cycle Control 48 5.2 FC20 Monitoring X & Y Reach Position Function 49 5.3 Tray Status For The Robot 50 5.4 Tray Location For The Robot 51 5.5 Programs Code For Updating Tray Value At Location 10 52 5.6 Sequence Queue List 53
xiii
5.7 Current Running FB Highlighted At Screen 53 5.8 Step Number 10 At FB3 55 5.9 Safety And Error Programs Control’s Flow Chart 56 5.10 Error Message For Emergency Button And Safety Door 56 5.11 Ladder Diagram Check Machine Emergency 57 5.12 Ladder Diagram Check Main Air Pressure 58 5.13 Machine Ready Condition Displayed At Screen 59 5.14 Flow Chart Of Decision Making Program 60 5.15 Profibus Control Program For X-Axis 61 5.16 Flow Chart For Drive Control Programs 62 5.17 Error Message Related Drives At Touch Screen 63 5.18 Ladder Diagram Check Priority For FB3 64 5.19 Flow Chart FB3 Functions 66 6.1 Main Screen 68 6.2 Auto Cycle Screen 69 6.3 Actual Position And Speed Value 70 6.4 Tray Status 70 6.5 Start Button Hidden 71 6.6 Start Button Displayed 71 6.7 Machine Ready Status 71 6,8 Sequence Status 72 6.9 Set Axis Speed Parameter 73 6.10 Set Maximum Tray Value 73 6.11 Semi Auto Cycle Screen 74 6.12 Semi Auto Mode Go To Location 75 6.13 Semi Auto Part Program 75 6.14 Manual Cycle Screen 76 6.15 System Diagnostic Screen 77 6.16 Teaching Mode Screen 78 7.1 Motor Data Parameter 80 7.2 Position Configuration 81 7.3 FB Editor Software 83 7.4 Program Process List For Drive 83 8.1 Gantry Robot In Operation 85
8.2 Screen Used For Control Robot Movement 86 8.3 Screen Used To Test Auto Cycle Movement 86 8.4 Error Recording Program 87 8.5 Siemens 10” Touch Screen For Gantry Robot 90 8.6 Siemens S7-317-2DP CPU 90 8.7 Lenze 9300 Positioning Servo Drives 91 8.8 Safety Relay Used For The Project 94 9.1 Keyence Imaging Device 98
xv
LIST OF ABBREVIATIONS
PLC - Programmable Logic Controller NC - Numeric Controller
PWM - Pulse Width Modulation CPU - Central Processing Unit IO - Input Output
MS-DOS - Microsoft Disk Operating System MTC - Machine Tool Control
DP - Distributed Peripheral USB - Universal Serial Bus PROFIBUS - Process Field Bus System HMI - Human Machine Interface PA - Process Automation
