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Programming a Six-Axis Motoman HP3C Robot for Industrial Sorting Application

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2015 ASEE Annual Conference & Exposition


Seattle, Washington

Publication Date

June 14, 2015

Start Date

June 14, 2015

End Date

June 17, 2015





Conference Session

Instrumentation Division Technical Session 1

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Page Numbers

26.1261.1 - 26.1261.19



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Paper Authors


Hamza Kadir Purdue University Calumet (College of Technology) Alumni

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Hamza Kadir, M.Sc., currently works as a Controls Engineer in the Packaging Machinery OEM industry. He completed his Masters from Purdue University Calumet, majoring in Mechatronics Engineering Technology. He conducted his M.Sc. Directed Project at the Nick and Nancy Wilson Mechatronics Engineering Technology Laboratory. This project involves integration of modern automation tools for an intelligent part sorting system. He has previously worked with use of High Speed Vision System for troubleshooting at higher machine rates. His earlier works include application of a new SS7-Sigtran protocol interchanger for communication for RTU in SCADA systems; evolution of mobile backhaul to 3G and smart grid solutions. He has received his B.Sc. in Electrical and Electronic Engineering from Islamic University of Technology, Bangladesh. Email: LinkedIn:

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Md Jubair Hossain Purdue University Calumet (College of Technology)

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Md Jubair Hossain, M.Sc. He completed his Masters from Purdue University Calumet, majoring in Mechatronics Engineering Technology. From 2013 he started working for college of technology as a student worker. He was awarded Claude S. Breeden Scholarship in 2013 for excellence and creativity in approaching solution to problems in the packaging industry from Packaging Machinery Manufacturers Institute (PMMI). He had previously worked with SCARA robot that involved enhanced algorithm to maximize throughput for assemble and produce medical devices. He has received his B.Sc. in Electrical and Electronic Engineering from Chittagong University of Engineering and Technology, Bangladesh. His interests are in the area of Robot programming, Cad modeling, industrial process control, modeling and simulation of Mechatronics devices and systems, programmable logic controllers related projects.

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Nirjhar Das Sharma Purdue University Calumet

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My name is Nirjhar Das Sharma. I was born on November 20, 1990 in Chittagong, Bangladesh. I pursued my passion for engineering from my early childhood while I was going through High school education. I completed a four year B.Sc. course in Electrical and Electronic Engineering (2008-2013) from Chittagong University of Engineering & Technology, Bangladesh. The last two years of the Bachelor study introduced me to some real-life learning along with a lot of important experiences. I personally believe that the Industrial training at TICI (Training Institute for Chemical Industries), Narshingdi was the most valuable tour where I experienced about the Industrial Production Technology, sensing and control systems, manufacturing, packaging and Programmable logic controllers(PLC). This training made my decision easier to become a Graduate student of Mechatronics Engineering Technology at Purdue University Calumet, USA (from August, 2013 till present). Now I am learning Electrical controls, PLC (allen bradley), HMI programming and Robot (Motoman) programming as the integral part of my research. Besides, I have been working as an Instructor for an undergraduate level course 'Electricity and Electronics fundamentals' from January, 2014 at Purdue University Calumet. Throughout the journey that I made so far as a Graduate student, I have also experienced to work as a Teaching Assistant, designing PLC trainers and working with several mechatronics projects. At present, I am also working as an Engineering Intern at A Packaging System, La porte, IN (from May, 2014) experiencing different technologies like liquid filling machine, Bottle capping machine in a primary packaging environment. I strongly believe that my experience and education would create excellent opportunities for me and would flourish my knowledge in the future.

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Suraiya Jannat Khan Purdue University Calumet

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Suraiya Jannat Khan is a graduate student in the Department of Engineering Technology at Purdue University Calumet. Her focus is on Mechatronics Engineering Technology. At present she is also a student worker for the Department of Engineering Technology. She is currently working with MOTOMAN HP3C robot at the Nick and Nancy Wilson Mechatronics Engineering Technology Laboratory. Her previous works include designing a low noise amplifier, designing voltage surge protector and voltage instability protector and designing a temperature and humidity meter with microprocessor 8086. She has received the Bachelor of Science in Electrical and Electronic Engineering from Ahsanullah University of Science and Technology, Bangladesh. Email:

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Akram Hossain Purdue University Calumet (College of Technology)

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Akram Hossain, Purdue University Calumet
Akram Hossain is a professor in the department of Engineering Technology and Director of the Center for Packaging Machinery Industry at Purdue University Calumet, Hammond, IN. He worked eight years in industry at various capacities. He is working with Purdue University Calumet for the past 27 years. He consults for industry on process control, packaging machinery system design, control and related disciplines. He is a senior member of IEEE and he served in IEEE/Industry Application Society for 15 years at various capacities. He served as chair of Manufacturing Systems Development Applications Department (MSDAD) of IEEE/IAS. Currently, he is serving a two-year term as the chair of the Instrumentation of ASEE (American Society of Engineering Education). He authored over 29 refereed journal and conference publications. In 2009 he as PI received NSF-CCLI grant entitled A Mechatronics Curriculum and Packaging Automation Laboratory Facility. In 2010 he as Co-PI received NSF-ATE grant entitled Meeting Workforce Needs for Mechatronics Technicians. From 2003 through 2006, he was involved with Argonne National Laboratory, Argonne, IL in developing direct computer control for hydrogen powered automotives. He is also involved in several direct computer control and wireless process control related research projects. His current interests are in the area of packaging machinery system design & control, industrial transducers, industrial process control systems, modeling and simulation of Mechatronics devices and systems in virtual environment, programmable logic controllers, programmable logic devices, renewable energy related projects, wireless controls, statistical process control, computer aided design and fabrication of printed circuit board.

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PROGRAMMING A SIX AXIS MOTOMAN HP3C ROBOT FOR INDUSTRIAL SORTING APPLICATIONAbstract:Efficiency in Industrial sector can be achieved by interchanging human workforce with robotictechnology. With the virtue of automation this picture is gradually being visible. Inspection hasbecome a very crucial part of the packaging industry. Having a near to 100% accurate inspectionand detection of the parts with a robotic arm coupled with high speed camera vision system canbe very much applicable for a manufacturing environment. However the investment-to-yieldratio must make sense. A lean approach to come up with an approved design of a modularinspection and sorting setup can be used repeatedly wherever such an inspection will be required.The impetus of this research originated from a common problem encountered in themanufacturing industries. Generally, an inspecting conveyor system requires a human operator tovisually inspect the part or in case of an automatic detection, the process is limited in itsinspecting ability. In case of human operator inspecting process, the operator requires to betrained in the particular inspection criteria as well as the use of precision hand-tools to determinethe defect. This is training cost, overhead expenditure (higher pay-scale due to experience), andother labor fees for a monotonous, repetitive and no-brainer job. In case of an automaticdetection system the detection method is limited and not adoptable to various types of parts andits defects. Again, quality control is one of the most important steps of manufacturing process.The objective of this research project is to build an automated setup consisting of an industrialrobot, servomotor controlled conveyor system, and a pneumatic gripper, where they will inspectand sort parts based on its acceptability using a high speed pattern recognition system. A 6 -axisarticulated arm industrial robot known as Motoman (produced by Yaskawa), coupled with aCognex high speed pattern recognition system can replace the currently error-prone inspectionstage with high degree of accuracy. After the detection the failed part is diverted to the reject-lane for further consideration by the inspection system. The unacceptable parts from the systemcan be further processed to be recycled if it is worthwhile to do so or could be modified to beconsidered as good parts.DescriptionWhen it comes to improved level of accuracy and increased rate of production then machinevision system comes to focus. This robot has been interfaced with an allen Bradley micrologixPLC, a high definition cognex camera and a pneumatic gripper. Each steps of the programmingfor the robot is performed by constructing the user frames. Figure 1 represent a MOTOMANHP3C robot mounted with Cognex camera and pneumatic gripper. Figure 1: MOTOMAN HP3C robot mounted with Cognex camera and pneumatic gripperEach of these user frames should assign the position variables which means the X,Y,Z co-ordination of a fixed location of the system. A high definition cognex camera has been used torecognize the probable defects of the parts and send the right digital pulse to the robot forseparating the defective parts. Here programmable logic controllers are important if the wholeprocess run with the PLC programming to send and receive proper signal and communicate withMotoman. This research will encompass study involving sizing of the components required forthe retrofit of the Main Conveyor setup. Both electrical and mechanical aspects will be covered,with emphasis on the electrical portion. Sizing components and overall system setup will bedictated by a proper understanding of the process and its requirements. The electrical scope ofthe project will cover programming knowledge of the industrial robot, PLC programming, basicsof pattern recognition, and electrical circuitry. This research will emphasize on ease ofadoptability and automated calibration as the parts vary. The mechanical scope of the project willcover End of the arm design, Robot cell design, robot base design and modification of thesecondary conveyor stands. This arrangement will build a setup which is representative of aninspecting and intelligent sorting setup used in the industrial application. This inspection can bebased on any unique characteristics that can be derived from the product at hand. Thesecharacteristics are related to the quality of the manufactured products. The products which do notmeet the required quality will be diverted to a rejected lane of the system. The programmingstructure and architecture must be modular, providing a scope for future extensions andimprovements.

Kadir, H., & Hossain, M. J., & Das Sharma, N., & Khan, S. J., & Hossain, A. (2015, June), Programming a Six-Axis Motoman HP3C Robot for Industrial Sorting Application Paper presented at 2015 ASEE Annual Conference & Exposition, Seattle, Washington. 10.18260/p.24598

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