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

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Dedicated to my beloved wife

Dr Rokiah Binti Khalid

Son,

Yasir Adham Ali

Parents ,

Janathul Nisa & Mohd Yaseen

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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.

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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.

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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.

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TABLE OF CONTENTS

CHAPTER TITLE PAGE

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENTS iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES xi

LIST OF FIGURES xii

LIST OF ABBREVIATIONS 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

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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

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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

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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

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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

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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

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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

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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

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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.

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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.

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Figure 1.1 : Gantry Robot Structure

Figure 1.2 : Loading Station

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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

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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.

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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

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