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
iii Dedicated to my beloved wife Dr Rokiah Binti Khalid Son, Yasir Adham Ali Parents, Janathul Nisa & Mohd Yaseen
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.
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.
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.
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 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
viii 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
ix 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
x 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 REFERENCES 99
xi 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
xii 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
xiv 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
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.
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.
3 Figure 1.1 : Gantry Robot Structure Figure 1.2 : Loading Station
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
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.
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, 1997 3. Clements-Jewery, K., Jeffcoat, W., The PLC Workbook; Programmable Logic Controllers made easy, Prentice Hall, 1996. 4. Siemens AG. S7-400 and m7-400 programmable controllers - hardware and installation., September 2004. URL http://www.siemens.co.jp/simatic/japan/as/plc/data/400/424ish\_e.pdf. 5. Fieldbus technology, June 2009. URL http://murray.newcastle.edu.au/users/students/1999/c9518176/fieldbuste 6. Profibus - profibus & profinet., June 2009. URL http://www.profibus.com/profibus.html. 7 Lenze Drive Configuration Manual, June 2009.URL http://www.lenze.com/lenze.com_en_active/040_services/060_application_ Knowledge_Base/Application_Knowledge_Base.com.jsp?cid=0b0164e0800 91546