2.1 Gantry Robot Programmable Logic Controller PLC Introduction 8

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1 vii TABLE OF CONTENTS CHAPTER TITLE PAGE DECLARATION DEDICATION ACKNOWLEDGEMENTS ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES LIST OF ABBREVIATIONS ii iii iv v vi vii xi xii xv 1 INTRODUCTION 1.1 Project Introduction Project Objective Scope Of Project Organization Of Thesis 5 2 LITERATURE REVIEW 2.1 Gantry Robot Programmable Logic Controller PLC Introduction 8

2 viii PLC Features System Scales User Interface Communication PLC Compared With Other Control Systems Digital and Analogue Signal Programming Language Siemens PLC Profibus Communication Protocol Profibus Introduction Profibus Origin Advantages Profibus Compare Other Fieldbuses Servo Drive Introduction To Digital Servo Drive Lenze 9300 Positioning Servo Drive 20 3 PROJECT BACKGROUND 3.1 Previous Control System for ABB Robot Problem with Previous ABB Gantry System Obsolete Parts No Local Support Available For Robot Complicated Control System Homing In Every Movement Unnecessary Tray Scanning Process No Permission Required To Enter Cage Cannot Run In Manual Loading & Unloading Robot Don t Have Safety Parking Position No Proper Indication Of Alarm Or Fault Signal 30

3 ix 4 METHODOLOGY 4.1 Introduction Siemens Programmable Logic Controller Siemens PLC Hardware Configuration Siemens Network Configuration Siemens PLC Program Editor Siemens S7-Graph Editor Siemens Ladder Diagram (LAD) Editor Siemens Statement List (STL) Editor Siemens Human Machine Interface (HMI) Global Drive Control 45 5 PLC PROGRAM IMPLIMENTATION 5.1 Introduction Robot Auto Cycle Machine Ready, Safety and Error Handling Program Decision Making Program Drive Control Program Execution Of FB3 Programs 63 6 HMI IMPLIMENTATION 6.1 Introduction Main Screen Auto Cycle Screen Semi Auto Cycle Screen Manual Cycle Screen System Diagnostic Screen Teaching Mode Screen 78

4 x 7 DRIVE IMPLIMENTATION 7.1 Introduction Drive Parameter Configurations Position Configuration Drive Program Editor 82 8 RESULTS AND DISCUSSION 8.1 Introduction Development Stages Error Recording Program (FC250) Features Of New Robot Gantry System Simple And Reliable Control System Easy Maintenance & Troubleshooting Process One Touch Button Control Concept Optimize Movement Concept Improved Safety Improved Tray Scanning Process Variable Speed Control To Improve Process Time Touch Screen For The Robot 95 9 CONCLUSION AND RECOMMENDATION 9.1 Conclusion Recommendation 98 REFERENCES 99

5 xi LIST OF TABLES TABLE NO. TITLE PAGE 3.1 Loading Control System Unit Unloading Control System Unit ABB Gantry Robot Control System Unit List Of Hardware Used For Gantry Robot Function List For The Robot Auto Cycle Sequence 60

6 xii LIST OF FIGURES FIGURE NO. TITLE PAGE 1.1 Gantry Robot Structure Loading Station Unloading Station Digital Servo Drive S5 100u CPU Sanyo Denki Stepper Motor Drive S5 115u CPU With Input Output Card Telemeqanique NUM CPU ABB NUM NC Controller Card BOSH-REXROTH Indramat Servo Drive Axis Module Hardware Configuration HMI and PLC Communication Interface Graph-7 Programs Robot Programs Written In S7-Graph Language Ladder Diagram Editor Siemens PLC Ladder Diagram Editor Siemens PLC STL Editor Siemens PLC WinCC Flexible 2008 HMI Screen Editor Software Global Drive Control Software Flow Chart For Robot Auto Cycle Control FC20 Monitoring X & Y Reach Position Function Tray Status For The Robot Tray Location For The Robot Programs Code For Updating Tray Value At Location Sequence Queue List 53

7 xiii 5.7 Current Running FB Highlighted At Screen Step Number 10 At FB Safety And Error Programs Control s Flow Chart Error Message For Emergency Button And Safety Door Ladder Diagram Check Machine Emergency Ladder Diagram Check Main Air Pressure Machine Ready Condition Displayed At Screen Flow Chart Of Decision Making Program Profibus Control Program For X-Axis Flow Chart For Drive Control Programs Error Message Related Drives At Touch Screen Ladder Diagram Check Priority For FB Flow Chart FB3 Functions Main Screen Auto Cycle Screen Actual Position And Speed Value Tray Status Start Button Hidden Start Button Displayed Machine Ready Status 71 6,8 Sequence Status Set Axis Speed Parameter Set Maximum Tray Value Semi Auto Cycle Screen Semi Auto Mode Go To Location Semi Auto Part Program Manual Cycle Screen System Diagnostic Screen Teaching Mode Screen Motor Data Parameter Position Configuration FB Editor Software Program Process List For Drive Gantry Robot In Operation 85

8 xiv 8.2 Screen Used For Control Robot Movement Screen Used To Test Auto Cycle Movement Error Recording Program Siemens 10 Touch Screen For Gantry Robot Siemens S DP CPU Lenze 9300 Positioning Servo Drives Safety Relay Used For The Project Keyence Imaging Device 98

9 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

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