Lab Manual of Computer Integrated

Manufacturing

Prepared By:
Dr. syed Farhan Raza Rizvi

Industrial & Manufacturing Engineering Department

University of Engineering & Technology Lahore
 Table of Contents

Experiment No.01..................................................................................................................................1
Title....................................................................................................................................................1
Objective............................................................................................................................................1
Outcome:............................................................................................................................................1
Apparatus...........................................................................................................................................1
Theory................................................................................................................................................2
a) Introduction of RV-2AJ:...........................................................................................................2
b) Workspace..............................................................................................................................2
c) Robot kinematics....................................................................................................................2
d) Specifications..........................................................................................................................2
PLC Programming............................................................................................................................4
Conclusion..........................................................................................................................................4
Experiment No.02..................................................................................................................................5
Title....................................................................................................................................................5
Objective............................................................................................................................................5
Outcome:............................................................................................................................................5
Apparatus...........................................................................................................................................5
Theory................................................................................................................................................6
a) Introduction............................................................................................................................6
b) Sensors....................................................................................................................................6
c) Working Procedure of Robotic Cell..........................................................................................7
Specifications.....................................................................................................................................8
Conclusion..........................................................................................................................................8
Experiment No.03..................................................................................................................................9
Title....................................................................................................................................................9
Objective............................................................................................................................................9
Outcome:............................................................................................................................................9
Apparatus...........................................................................................................................................9
Procedure...........................................................................................................................................9
Comments........................................................................................................................................12
Experiment No.04.................................................................................................................................13
Title..................................................................................................................................................13
Objective..........................................................................................................................................13
Outcome:..........................................................................................................................................13
Apparatus.........................................................................................................................................13
Procedure.........................................................................................................................................13
Comments........................................................................................................................................15
Comparison between Experiment No.03 and 04...............................................................................15
Experiment No.05, 06, 07, 08................................................................................................................16
Case Study........................................................................................................................................16
Sections............................................................................................................................................16
a) Industry details:....................................................................................................................16
b) Layout...................................................................................................................................16
c) Automation...............................................................................................................................16
d) Material Handling.....................................................................................................................16
e) Material Storage System:..........................................................................................................16
f) Automatic Identification and Data Capture (AIDC)....................................................................16
g) Group technology (GT) and Cellular manufacturing..................................................................16
Concerned Person...........................................................................................................................17

Students Names:..............................................................................................................................17
Experiment No.09.................................................................................................................................18
Case Study........................................................................................................................................18
Objective..........................................................................................................................................18
Organization.....................................................................................................................................18
Department:.....................................................................................................................................18
Task:.................................................................................................................................................18
Exposure...........................................................................................................................................18
Outcome:..........................................................................................................................................18
Existing Automation in industry........................................................................................................18
Suggestions for automations............................................................................................................18
References............................................................................................................................................19
 List of Figures

Figure 1: RV-2AJ side view......................................................................................................................1

Figure 2: RV-2AJ Front view....................................................................................................................1
Figure 3: FESTO Robotic work cell...........................................................................................................5
Figure 4: Part feeder of FESTO robotic cell..............................................................................................5
Figure 5: Working diagram of capacitive proximity sensor......................................................................6
Figure 6: Infrared sensor.........................................................................................................................7
Figure 7: Driving Base.............................................................................................................................9
Figure 8: Double Bumper......................................................................................................................13
 List of Tables

Table 1: Specifications of RV-2AJ............................................................................................................3

Table 2: Specifications of work cell.........................................................................................................8
Table 3: Concerned persons in interwood.............................................................................................17
 List of Abbreviations

PLC Program Logic controller

FESTO Company Name
IR Infrared
LEGO Robotic Kit name
 Experiment No.01
Titl
e: To study the degrees of freedom of RV-2AJ Mitsubishi robotic arm.
Objective:
 To understand the robotic arm movement.
 To analyze the work space of robotic arm.
 To learn about kinematics related to robotic arm.
Outcome:
Students will be able to understand the robotic arm movement and angular & linear workspace
and also the safety assessment related to work space of robotic arm.
Apparatus:

Figure 1: RV-2AJ side view

Figure 2: RV-2AJ Front view

1
Theory:
a) Introduction of RV-2AJ:
RV-2AJ has five degrees of freedom and each degree is controlled by motor that may be
controlled electrically or pneumatically. Degrees of freedom are important to determine the
workspace of robotic arm. It has a base motor at the bottom and end effector which is basically
manipulator that can be easily detachable. Teach pendant is used to control robotic arm. PLC
programming is used to operate the robotic arm which works on matrices.
b) Workspace:
In this arm, angular workspace depends upon base motor of arm and 60° is not access able by
robotic arm, hence angular workspace of robotic arm is 300°. While the linear workspace
depends upon the length of end effector therefore the maximum workspace of arm is 410mm
and minimum is 220mm radius with respect to base motor.
c) Robot kinematics:
Robot kinematics applies geometry to the study of the movement of multi-degree of
freedom kinematic chains that form the structure of robotic systems. [1]
Types of kinematics:

 Forward kinematics:
In this type, joint angles determines the reach of robotic arm.

 Inverse kinematics:
In this type, position is given to robotic arm and we can determine the joint angles to reach the
position.
d) Specifications: [2]

Model Units RV-2AJ

Degree of freedom of motion 5
Structure Vertical, multiple-joint type
Drive system AC servo motor
Type Absolute encoder
Shoulder
0
shift
Arm length Upper arm mm 250
Fore arm 160
Elbow shift 0
Wrist length 72
J1 300 (-150 to +150)
 J2 180 (-60 to +120)
J3 230 (-110 to +120)
Motion range J4 Degree -
J5 180 (-90 to +90)
J6 400 (-200 to +200)
J1 180
J2 90
J3 135
Speed of motion J4 Degree/s -
J5 180
J6 210
Maximum resultant velocity mm/s Approx. 2100
Maximum 2
Load capacity kg
Rating 1.5
Position repeatability mm ±0.02
Ambient temperature ºC 0 to 40
Mass kg Approx. 17
J4 -
Allowable J5 2.16
Nm
moment
J6 1.10
J4 -
Allowable inertia J5 kg m2 3.24 × 10-2
J6 8.43 × 10-3
Arm reachable radius
mm 410
(front p-axis center point)
Four input signals (Hand
section),
Four output signals (Base
Tool wiring
section),
Motorized hand output (Hand
section)
Supply pressure MPa 0.5 ±10%
Table 1: Specifications of RV-2AJ
PLC Programming: [3]

A PLC is primarily used to control machinery. A program written for a PLC consists basically of
instructions to turn on and off outputs based on input conditions and the internal program. In
this respect, it is similar to how a standard computer application is used.
Once a PLC program is activated, however, it will typically run continuously as a loop for an
indefinite period. Most commonly, a PLC is found inside of a machine in an industrial
environment. A PLC can run an automatic machine for years with little human intervention.
They are designed to withstand most harsh environments.
Different cycles in PLC programming:
 Scan Cycle.
 Overhead
 Input cycle.
 Logic execution.
 Diagnosis and communication.
 Output scan.
Conclusion:
This session was interesting as we come to know about working, degrees of freedom,
kinematics and controller of robotic arm. Understanding the working of Robotic Arm gives us a
great exposure w.r.t understand the arm thoroughly and its parts.
Comments:
Comments should be based on what students have learnt from this experiment and compare
the perception of automation before and after the experiment? What is the main role of this
equipment in industry?
Experiment No.02
Title
:
To study the operation of a FESTO Robotic Work cell.

Objective:
 To understand the working of robotic work cell.
 To know about sensors and gauging method of work cell.
Outcome:
After this experiment, student will come to know about the working of robotic cell, role of infrared and
capacitive sensor, gauging techniques used by work cell and applications of robotic work cell.

Apparatus:
 Figure 3: FESTO Robotic work cell

Figure 4: Part feeder of FESTO robotic cell

Theory:

a) Introduction:

FESTO is a German company who is manufacturing robotic work cell. This robot is an industrial
robot. It performs drilling operation after that it measures the hole’s diameter and depth with
the help of go and not go gauges and differentiate the parts w.r.t color of part with the help of
capacitive and infrared sensors. Its control are pneumatic.

b) Sensors:

There are two types of sensors that are used in this cell:

1: Capacitive proximity sensor: [4]

Capacitive sensing is a noncontact technology suitable for detecting metals, nonmetals, solids,
and liquids, although it is best suited for nonmetallic targets because of its characteristics and
cost relative to inductive proximity sensors. In most applications with metallic targets, inductive
sensing is preferred because it is both a reliable and a more affordable technology.

Figure 5: Working diagram of capacitive proximity sensor

The sensor consists of four basic components:

 A capacitive probe or plate
 An oscillator
 A signal level detector
 A solid-state output switching device
 An adjustment potentiometer

Capacitive proximity sensors are similar in size, shape, and concept to

inductive proximity sensors. However, unlike inductive sensors which use
induced magnetic fields to sense objects, capacitive proximity generate an
electrostatic field and reacts to changes in capacitance caused when a target
enters the electrostatic field. When the target is outside the electrostatic
field, the oscillator is inactive. As the target approaches, a capacitive
coupling develops between the target and the
capacitive probe. When the capacitance reaches a specified threshold, the oscillator is
activated, triggering the output circuit to switch states between ON and OFF.

The ability of the sensor to detect the target is determined by the target’s size, dielectric
constant and distance from the sensor. The larger the target’s size, the stronger the capacitive
coupling between the probe and the target. Materials with higher dielectric constants are easier
to detect than those with lower values. The shorter the distance between target and probe, the
stronger the capacitive coupling between the probe and the target.
2: Infra-red sensor: [5]
An infrared sensor is an electronic instrument which is used to sense certain characteristics of
its surroundings by either emitting and/or detecting infrared radiation. Infrared sensors are also
capable of measuring the heat being emitted by an object and detecting motion.
1. Thermal infrared sensor.
2. Quantum infrared sensor.
Principle of operation of IR Sensor: [6]
IR Sensors work by using a specific light sensor to detect a select light wavelength in the Infra-
Red (IR) spectrum. By using an LED which produces light at the same wavelength as what the
sensor is looking for, you can look at the intensity of the received light. When an object is close
to the sensor, the light from the LED bounces off the object and into the light sensor. This results
in a large jump in the intensity, which we already know can be detected using a threshold.

Figure 6: Infrared sensor

c) Working Procedure of Robotic Cell:

 Firstly, Work piece is fed from part feeder to rotatory table.
 Then, Drilling is performed at this point.
 After that, go and not go gauge check the diameter and depth of hole.
 Then, RV-2AJ picks the part from that place to capacitive proximity sensor which detects
whether the work piece is metal or non-metal on the behalf of capacitance.
 Then, from capacitive sensor work piece is placed in front of infrared sensor where color
of work piece is detected and IR sensor on for a specific time period and gets off after
that time.
 And finally, work piece is stored in specific storage area for a particular part.
Specifications: [7]
Sr. no Elements Details
1 Maximum working stroke Y axis is 1900mm and z axis is 50mm
2 Max. speed 5 m/s
3 Max. acceleration 50 m2/s
4 Repetition accuracy +/-0.1mm
5 Absolute accuracy +/-0.5mm
6 Contour accuracy +/-0.5
7 Rated load for max. dynamic 4 kg
response
8 Motor Stepper motor
Table 2: Specifications of work cell

Conclusion:
This session was really informative as it gives a lot of information related to robotic work cell,
working of work cell and also the applications of sensors such as capacitive sensor, infrared
sensor. And also the use of robotic arm in material handling was also studied. Although this
equipment was not workable due to some technical problems but overall session was
informative.
Comments:
Comments should be based on what students have learnt from this experiment and compare
the perception of automation before and after the experiment? What is the main role of this
equipment in industry?
Experiment No.03
Title
:

To assemble the robotic driving base from Robot Assembly Kit (LEGO).
Objective:
 To learn about assembly of robot using block.
 To analyze the different assembly techniques.
 To understand 5s technique.

Outcome:
After this experiment, students will be able to learn different assembly techniques while
working on robotic kit and they will be able to analyze their mental skills. They were also able to
know about Lego software used by these robotics.
Apparatus:
 Figure 7: Driving Base

Procedure:

1. Firstly, sort and organize all the parts.

2. Then, assemble the parts according to the instructions given in manual.
3. Then, robotic driving base is ready.

Step by step pictures and description is given below:

Step no.01 and 02 Step no.03 and 04

Step no.05 Step no.06

Step no.07 and 08 Step no.09 and 10

Step no.11 and 12 Step no.13 and 14

Comments:
Comments should be based on what students got from this experiment in terms of their
experience and interest. How this experiment was different from other experiments? What
were the difficulties they faced while performing this experiment and how to avoid those
difficulties? What are the possible errors that occurred during this experiment and how to avoid
them? If any fault was present in this apparatus then what is the reason of fault?
Experiment No.04
Titl
e: To assemble the robotic double bumper using Robot Assembly Kit (LEGO).
Objective:
 To learn about assembly of robot using block.
 To analyze the different assembly techniques.
 To understand 5s technique.

Outcome:
After this experiment, students will be able to learn different assembly techniques while
working on robotic kit and they will be able to analyze their mental skills. They were also able to
know about Lego software used by these robotics.
Apparatus:

Figure 8: Double Bumper

Procedure:

1. Firstly, sort and organize all the parts.

2. Then, assemble the parts according to the instructions given in manual.
3. Then, robotic driving base is ready.
Step by step pictures and description is given below:
Step no.01 and 02 Step no.03 and 04

Step no.05 and 06 Step no.07 and 08

Comments:

Comments should be based on what students got from this experiment in terms of their
experience and interest. How this experiment was different from other experiments? What
were the difficulties they faced while performing this experiment and how to avoid those
difficulties? What are the possible errors that occurred during this experiment and how to avoid
them? If any fault was present in this apparatus then what is the reason of fault?

Comparison between Experiment No.03 and 04:

In experiment no.03 we assembled the Driving Base and in experiment no.04 we developed
double bumper. Driving base is used in all the experiment as a base to assemble other parts.
Different techniques are used to assemble both the kits but to assemble driving base too much
time was consumed as it takes too much time as compared to Double bumper. Double bumper
was assembled on base drive and it takes much less time to assemble.
Experiment No.05, 06, 07, 08
Case
To suggest automation in any industry.
Study:

Sections:
a) Industry details:
Briefly explain the industry, type of industry (Small, Medium, and Multi-national), its products, in
which countries they supply their products.
b) Layout :
Discuss the layout of industry whether it is job shop, process type or product type layout. What
are flaws in the layout and suggest the corrections in layout.
Draw the layouts in Auto Cad or Paint etc. (Both Current and Suggested)
c) Automation:
Observe the automation level in that industry. Whether they are using Fixed, Programmable
automation etc. Also take pictures and make videos. Also suggest the automation in that
industry.
d) Material Handling:
Observe the material handling system they are utilizing and make pictures and videos of that
material handling system. Also suggest the correct material handling system for them.
e) Material Storage System:
Observe the material storage system they are utilizing and make pictures and videos of that
material storage system. Also suggest the correct material storage system for them if any flaw
exists in there system.
f) Automatic Identification and Data Capture (AIDC):
Observe what kind of AIDC system they are using and what are the suggestions for AIDC are in
order to improve their AIDC system?
g) Group technology (GT) and Cellular manufacturing:
Observe whether the concerned industry is using GT and cellular manufacturing or not. If yes,
then which level of GT and cellular manufacturing they are using and what the suggestions for
their GT and cellular manufacturing.
h) Flexible Manufacturing System (FMS):
Analyze which type of FMS industry is using and what is the level of FMS. What are the
suggestions to improve their FMS?
 i) Manual and Automated Assembly Lines:
Observe how many Manual and automated assembly lines the concerned industry is using. And
what are the suggestions to improve their assembly line whether through automation or
manual work.
Concerned Person:
Name Contact No. Designation
Manger XYZ XYZ
Mangaer XYZ XYZ
Table 3: Concerned persons in interwood

Students Name Roll Number

Names:
Name Roll Number

Experiment No.09
Case
Study:
To write an internship report to suggest automation in any industry.
Objective:
 To summarize what you have learnt in your internship?
 Existing Automation in companies.
 Suggestions about automation that can be implemented.
Organization:
In which organization you did summer internship and what was the duration of
your internship?
Department:
In which department you worked during internship?
Tas
k:
Which type of tasks you performed during your internship?
Exposure:
What type of Exposure did you get from that industry?
Outcome:
What did you learn from that organization during internship?
Existing Automation in industry:
What type of automation is present in that industry?
Suggestions for
automations: What are the suggestions that you will give to the organization in
order to improve their productivity?
 References

1. https://en.wikipedia.org/wiki/Robot_kinematics. Accessed on 2/20/2015.

2. http://www.mitsubishirobots.com/robot%20specification/rv-2aj.html. Accessed on
2/20/2015.
3. https://en.wikibooks.org/wiki/Introductory_PLC_Programming. Accessed on 2/20/2015.
4. http://www.ab.com/en/epub/catalogs/12772/6543185/12041221/12041231/Capacitiv
e-Proximity-Sensing.html. Accessed on 2/20/2016.
5. http://www.azosensors.com/Article.aspx?ArticleID=339. Accessed on 2/20/2016.
6. http://education.rec.ri.cmu.edu/content/electronics/boe/ir_sensor/1.html. Accessed on
2/20/2016.
7. https://www.festo.com/net/SupportPortal/Files/373466/Handlingsysteme_en_S.pdf.
Accessed on 2/20/2016.