YASIR AMZAD ALI BIN MOHD YASEEN

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1 DEVELOPING PLC BASED GANTRY ROBOT USING POSITIONING SERVO DRIVE WITH PROFIBUS DP COMMUNICATION PROTOCOL YASIR AMZAD ALI BIN MOHD YASEEN A project report submitted in partial fulfillment of the requirement for the award of the degree of Master of Engineering (Electrical Mechatronics & Automatic Control) Faculty of Electrical Engineering Universiti Teknologi Malaysia NOVEMBER, 2009

2 iii Dedicated to my beloved wife Dr Rokiah Binti Khalid Son, Yasir Adham Ali Parents, Janathul Nisa & Mohd Yaseen

3 iv ACKNOWLEDGEMENT In preparing this thesis, I was in contact with many people, researchers, academicians, and engineers. They have contributed towards my understanding and thoughts. In particular, I would like to acknowledge and express my sincere appreciation to my main thesis supervisor, Dr Hazlina Selamat, for encouragement, guidance, critics and friendship. His readiness to help and valuable suggestions were highly appreciated towards to meeting the project objective. My fellow postgraduate students should also be recognized for their support. My sincere appreciation also extends to all my colleagues and others who have provided assistance at various occasions. I am grateful to all my family members.

4 v ABSTRACT PLC (Programmable Logic Controller) is one of the most important device in industrial automation nowadays. PLC is the device which control the machine so that the machine can run fully automatically. PLC is rarely use to control movement of the axis. Usually axis movement will be controlled by CNC (Computer Numeric Controller) machines. But in this Project, PLC is used to control gantry robot with three axis using positioning servo drive and its communicate via PROFIBUS (Process Fieldbus). The reason that PLC used to control the robot is because, PLC based machine is relatively much cheaper compare to machine that use CNC.

5 vi ABSTRAK PLC merupakan salah satu alat yang terpenting dalam bidang automasi industri pada masa kini.plc merupakan alat yang mengawal mesin untuk berfusngi secara automatik sepenuhnya.plc jarang digunakan untuk mengawal pergerakan paksi sesuatu mesin.kebiasanya tugas mengawal paksi ini dilakukan oleh CNC.Tetapi dalam Projek ini, PLC digunakan untuk mengawal pergerakan robot gantri tiga paksi yang digerakkan oleh motor servo dan berkomunkasi mengunakan PROFIBUS. Tujuan mengunakan PLC sebagai alat mengawal ialah kerana mesin yang berlandaskan PLC secara relatifnya adalah lebih murah berbanding dengan mesin yang mengunakan CNC.

6 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

7 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

8 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

9 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

10 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

11 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

12 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

13 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

14 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

15 CHAPTER 1 INTRODUCTION 1.1 Project Introduction SKF Bearing Industries Sdn Bhd is world-class manufacturer of bearings employing the most modern technology in the industry. Plant is located in Nilai and supplies the world with quality bearings. In order to manufacture Cylindrical Roller Bearing (SRB), heat treatment process for the roller is one of the crucial and importance process. Every minute thousands of rollers need to supply to the furnace to undergo heat treatment process. To supply the roller for the furnace, SKF Nilai is using fully automated gantry robot loading system. There is three major component of the gantry system. First system is loading station. In loading station the roller is sorted at the tray and then it will be transported to the furnace by robot. Robot will arrange the tray at pallet in several layers before deliver the pallet into furnace.

16 2 Second system is unloading system. After the roller finished heat treatment process, robot will unload the pallet from furnace and deliver the tray to unloading station. Unloading station will distribute the roller for grinding process. Previous gantry robot system is using ABB automation control design. This robot s design is outdated & not efficient in this new era. The ABB robot is using CNC controller and using three separate PLCs to control loading and unloading station. The idea is to replace old fashion of automation control to new, fast, reliable, user friendly, easy to troubleshoot & easy to maintain gantry robot automation system. This project is to upgrade the old gantry robot system to cheap & reliable robot control system using PLC control system. After I had done some research and studies, I had found out the simplest & much reliable robot design using PLC & positioning servo drive. Another aspect which was given high priority before design the system is availability of spare part in our store & local support of the device that we use. Almost 70% of the items include (PLC CPU, Input Output Card, Communication Card, Touch Screen) is available in our spare part store. This will drastically reduce downtime for robot due to availability of spare parts.

17 3 Figure 1.1 : Gantry Robot Structure Figure 1.2 : Loading Station

18 4 Figure 1.3 : Unloading Station 1.2 Project Objective Project objective is to develop complete control system for 3 axis gantry robot using Siemens s7 PLC, Lenze positioning servo drive, Siemens touch screen and these devises is communicate via Profibus - DP protocol. 1.3 Scope Of Project In order to achieve the objective of the project, there are several scope had been outlined. The scope of this project includes writing PLC software using Siemens Step 7 software, writing and designing HMI program Siemens WinCC

19 5 Flexible 2008 and configuring and writing Lenze drive program Global Positioning Drive software. 1.4 Organization of Thesis This thesis consists of eight chapters. Chapter 1 provides preliminaries studies on the current scenarios of this project. In Chapter 2, literatures on devices and technology that used in this project will be discussed briefly. Chapter 3 describes and briefs the theoretical background of the project. In this chapter, will discussed comparison between previous robot system and future robot system will be discussed. Chapter 4 will discuss methodology that used in order to complete these projects. In this chapter, software and hardware that used for the projects will be discussed briefly. Meanwhile in Chapter 5, PLC program implementation will be discussed. This chapter will go thorough entire function that developed in order to complete this project. Chapter 6 will discuss about HMI implementation. In this chapter HMI design and development will be discussed. Chapters 7 will focus on drive implementation. In this chapter drive configuration and programming will be discussed briefly. Chapter 8 will discuss results and discussion regarding this project and finally Chapter 9 is conclusion and recommendations.

20 99 REFERENCES 1. Erickson, K. T. (2005). Programmable Logic Controllers: An emphasis on design and application. Dogwood Valley Press, LLC, 1604 Lincoln Lane Rolla, MO, USA. 2. Bolton, w., Programmable Logic Controllers: An Introduction, Butterworth- Heinemann, Clements-Jewery, K., Jeffcoat, W., The PLC Workbook; Programmable Logic Controllers made easy, Prentice Hall, Siemens AG. S7-400 and m7-400 programmable controllers - hardware and installation., September URL 5. Fieldbus technology, June URL 6. Profibus - profibus & profinet., June URL 7 Lenze Drive Configuration Manual, June 2009.URL Knowledge_Base/Application_Knowledge_Base.com.jsp?cid=0b0164e

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