June 14, 2015
June 14, 2015
June 17, 2015
26.1261.1 - 26.1261.19
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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