LAB NO: 06

OBJECTIVE: Introduction

To demonstrate and learn the process of controlling individual stations

THEORY

What is CIM system?

A CIM cell is an automated assembly line that uses a network of computers to control robots,
production machines and quality control devices. The CIM cell can be easily programmed to
produce custom parts and products. Educational CIM cells are used to simulate the production
cycle and enable control and analysis of various aspects of the cycle, from the planning through
production.

Main Components of CIM

All CIM systems generally share the following components, which are necessary for most
production processes:

Robotic Arms: CIM systems are fully automated, and robotic arms are critical components in
these automated systems. In CIM, robotic arms perform tasks that would otherwise require
human intervention, thus enabling the system to be fully automated. Examples of tasks
performed by robotic arms include the picking and placing of parts in/from machines, removing
of parts from storage, assembling of parts and handling of parts for quality control. In later
activities, you will be introduced to some of the robot types and robot tasks used in CIM.

Storage: A storage stationis used to store raw

materials prior to production, as well as finished
products following the production process. Such
stations are fully automatic and controlled by
robotic arms.

A typical CIM storage station includes a machine

known as an ASRS or Automated Storage and
Retrieval System. The ASRS is a robotic storage device used to store and retrieve parts in a
CIM cell. The ASRS is used as the main source of raw material for the cell, and can also serve
as a warehouse for parts in various stages of production. Storage cells in the ASRS contain
templates, either empty or containing parts. A CIM cell may contain any number of ASRS
Stations.

Machines: “Machine” is a generic term used to describe a

wide variety of production devices, such as CNC machines and laser engravers. Such machines
require that parts be inserted or placed into them, usually by a robotic arm. The inserted parts
are predefined size and nature. The machine is programmed in advance to process a particular
part, ensuring precise and exact part production.

Quality Control (QC): This group of equipment includes measuring devices, such as optical
systems, laser scan meters and CMMs (Coordinate Measuring Machines). The purpose of these
devices is to determine whether a product meets the quality control specifications defined prior
to the production process.

QC components include high precision measuring tools that the

system uses to determine whether the product should advance
to shipment or be rejected. Following the rejection of a product,
the system must be capable of adjusting itself so that it does not
automatically reject subsequent parts.

Closed Loop Conveyor : By nature, CIM components tend to be located in multiple

production stations that are physically distant from one another. This requires a system that
moves parts from one robotic station to another (for example from an ASRS to a CNC
machine). A closed loop conveyer with stop stations controlled by PLC is typically used for
this purpose. Stop and release units (i.e. stop stations) are located on the conveyor in front of
each production station. The stop stations are controlled by the PLC and enable the robot to
pick apart from the conveyor and place the part on it.

Technologies:
 • FMS, (flexible manufacturing system)
• ASRS, automated storage and retrieval system
• AGV, automated guided vehicle (mobile robot )
• Robotics
• Automated conveyance systems

This system consists of 5 stations and 5 station controller.

All stations are controlled by the CIM manager which configures all station
simultaneously. CIM manager maintains sequence of all the stations.CIM manager is
used for on-line production and manufacturing.
Station # 1 ASRS (Automatic Storage and Retrieval System): it picks and place the
raw material or finished goods.
Station #2 CNC lathe & robot Er4u is a 6 axis robot and it picks the parts from the
conveyor and places it in the CNC lathe and CNC mill.
Station # 3 QC robot Er4u: It is also a 6 axis robot and it picks the material places it on
QC station where it is measured by a digital Vernier caliper pneumatically operated. It
also picks and places the pallet with raw material from buffer to AGV.
Station # 4 Quality control: At the QC station material is inspected by using a digital
camera when defects are identified by digital image processing.
Transportation and Verification: The material is transported to all the stations by a
conveyor system where it is placed on pallets. The material transportation and
identification is controlled by a PLC.

TASK
Q1: Refer to the actual SCORBOT-ER 4u robot. In the figure on the worksheet, mark
the following parts of the robot:
• Robot joints: base, shoulder, elbow, wrist pitch, wrist roll
 • Gripper
• Motors and encoders

Q2: What are the three key elements in the definition of a robot?

Q3: To work on station 1, which software you will operate?

Q4: what is difference between station 3 and station 4?

LAB NO: 07

OBJECTIVE:

SCORBASE Er-4u Software demonstration + pick & Place program training.

EQUIPMENT:

SCORBOT-ER 4u Robot and Controller USB

♦ Computer with SCORBASE for ER 4u software
♦ Experiment Table
♦ Gray Conveyor Belt (24V) with photoelectric sensor
♦ Gravity Parts Feeder with micro switch
♦ Parts Bin
♦ 6 Round blocks: 4 large, 1 medium, 1 small
♦ 4 Square blocks: 2 large, 1 medium, 1 small

TECHNICAL DESCRIPTION:

Number of axes: Two axes are required to reach any point in a plane; three axes are required
to reach any point in space. To fully control the orientation of the end of the arm (i.e. the wrist)
three more axes (yaw, pitch, and roll) are required. Some designs (e.g. the SCARA robot) have
trade limitations in motion possibilities for cost, speed, and accuracy.

Degrees of freedom: This is usually the same as the number of axes.

Working envelope: The region of space a robot can reach.

Kinematics : The actual arrangement of rigid members and joints in the robot, which
determines the robot's possible motions. Classes of robot kinematics include articulated,
Cartesian, parallel and SCARA.

Carrying capacity or payload : How much weight a robot can lift.

Speed – how fast the robot can position the end of its arm. This may be defined in terms of the
angular or linear speed of each axis or as a compound speed i.e. the speed of the end of the arm
when all axes are moving.

Acceleration - how quickly an axis can accelerate. Since this is a limiting factor a robot may
not be able to reach its specified maximum speed for movements over a short distance or a
complex path requiring frequent changes of direction.

Accuracy – how closely a robot can reach a commanded position. When the absolute position
of the robot is measured and compared to the commanded position the error is a measure of
accuracy. Accuracy can be improved with external sensing for example a vision system or
Infra-Red. Accuracy can vary with speed and position within the working envelope and with
payload (see compliance).
Repeatability - how well the robot will return to a programmed position. This is not the same
as accuracy. It may be that when told to go to a certain X-Y-Z position that it gets only to within
1 mm of that position. This would be its accuracy which may be improved by calibration. But
if that position is taught into controller memory and each time it is sent there it returns to within
0.1mm of the taught position then the repeatability will be within 0.1mm.
PROCEDURE:

• Open the software ScorBase for Scorbot ER4U ST2.

• HOME the robot and click on ON iconin tool bar.

• Select STAND ALONE in operation mode.

• Press PICK AND PLACE command
open the window RUN PICK AND PLACE
• select part ID i.e. MILL PROD 2
• select source ID i.e. RACK 1
• Put source index i.e. 1
• Target ID same as SOURCE ID
• Put the value of target index i.e. 3
• press ok

CONCLUSION:

This system makes:

• Reduced manufacturing times,

• Lower cost per unit produced,

• Greater labor productivity,

• Greater machine efficiency,

• Improved quality,

• Increased system reliability,

• Reduced parts inventories,

• Adaptability to CAD/CAM operations.

• Shorter lead times

Precautions:

• Set up a protective screen or guard rail around the robot.

• Make sure the robot base is properly bolted to a table or pedestal. Otherwise, the robot
may become unstable and topple during operation.
• Do not use physical force on the robot arm to change its position, or for any other
reason.
• Be sure the robot arm has sufficient space in which to operate freely, especially during
homing.
• Before connecting any input or output to the controller, and before approaching or
handling the robot, make that the controller’s main power switch is turned off.
• Before opening the controller housing, be sure to unplug the controller power cable
from the AC power outlet. It is not sufficient to switch off the power; the power supplies
inside the controller still contain dangerously high voltages.
• Before removing any fuses, be sure to turn off the controller and unplug the controller
power cable from the AC power outlet.

LAB NO: 08

OBJECTIVE

Demonstrate and learn the process of CNC base spectral light 0200 software and flexible
manufacturing system.

EQUIPMENTS:
CNC milling machine system
SCORBOT-ER 4u Robot
Controller-USB
Computer with SCORBASE software
Teach Pendant.

TECHNICAL DESCRIPTION:

The spectra LIGHT Mill is a CNC tabletop milling machine. Like other mills, it has a spindle,
which holds the cutter. A pneumatically y operated vise, mounted on a cross slide, holds the
work piece. Motors move the cross slide horizontally (X and Y) while other motors move the
spindle vertically (Z) and rotate the cutter.

The Controller is connected between the computer and the mill. The controller houses the
electronics that interpret part programs and send them to the mill in a form the mill can
understand.

Computer loaded with the WSLM Control Program; used to create and run CNC programs.

Parts Feeder: This device supplies parts by means of gravity. The feeder includes a micro
switch sensor whose signal indicates to the robot controller that a part is available for pickup.

Collection Bin: This box is used to collect and palletize parts.

PROCEDURE:
• Open the software MILL CAM designer.
• Select depth 1.5mm, Cutter parameter 2mm, Step 5 inch.
• Select text and type “CIM LAB”
• File saves as CIM LAB.
• To create G-code Select make file and click on create G-code and press OK.
• Open software CNC BASE SPECTRAL LIGHT 0200 MACHINING CENTRE.
• To open the file goes to FILE--- open --- C drive--- Denford --- Data --- cimlab.fnc.
• Edit the program by inserting line numbers.
• Open the folder Click on green icon.
• Control speed and feed rate with the help of jog control.

CONCLUSIONS:
• Reduced manufacturing times,
• Lower cost per unit produced,
• Greater labor productivity,
• Greater machine efficiency,
• Improved quality,
• Increased system reliability,
• Reduced parts inventories,
• Adaptability to CAD/CAM operations.
• Shorter lead times

SPECTRA LIGHT MILL SAFETY:

• Make sure you know how to stop the mill in an emergency:

• Push the Emergency Stop button on the front of the mill.
• Simultaneously press the [Ctrl] key and the spacebar on the computer key
• Keep the safety shield closed whenever the mill is operating.
• Press the Emergency Stop button before opening the safety shield.
• Release the Emergency Stop button only after closing the safety shield.
• Make sure you have the correct tool for the job. Make sure the cutter is surmounted.
• Make sure the work piece is securely clamped.
• Never make adjustments while the mill is operating.
• Remove all loose parts and pieces from the machine.
• Remove all tools and wrenches from the machine and work area.
• Make sure the mill is plugged into a three-hole grounded outlet.
• Do not operate the mill in a damp or wet location.
• Before running a new part program on a CNC mill:
• Verify new part programs by means of the computer simulation.
• Make sure the machine is properly initialized.
• Dry run the program on the mill without a work piece.
• Use a brush to remove chips after the mill has completely stopped.

LAB NO: 09
OBJECTIVE

Demonstrate and learn the process of Automated Storage and Retrieval System (ASRS).

EQUIPMENT:

ASRS 36/36x 2 Storage Units

Templates
ASRS Robotic Arm
Controller-USB
Teach pendant

TECHNICAL DESCRIPTION:

ASRS 36/36x2 Storage Unit: A floor-mounted automated storage and retrieval system that
contains 36 (or72) storage cells arranged in a 6x6 (or 6x6 + 6x6) array. Storage cells in the
ASRS contain templates (either empty or loaded with parts). The unit is used to store these
templates containing raw materials prior to production as well as finished products following
the production process and serves as warehouse for parts in various stages of production.

Templates: Templates are plastic trays which can hold various types of parts. They allow parts
to be transported on the conveyor. A template contains a matrix of holes in which pins are
placed to fit the dimensions of a part. Each arrangement of pins defines a unique template type.
Each part may only be held by its assigned template. The handle, located on top of or in front
of the template, facilitates grasping by a robot’s gripper.

ASRS Robotic Arm: The ASRS robotic arm is fully controlled by the controller and performs
various pick and place tasks to transfer parts between storage cells and conveyor pallets stopped
at the ASRS station. The ASRS robotic arm performs these tasks using a forklift gripper which
is connected to the robotic arm. The robotic arm moves the gripper within the ASRS robots
work envelope.

Controller-USB: Controls the ASRS robot using the SCORBASE application that supports
the SCORBASE language (an advanced robotic programming language). The SCORBASE
program accesses the Controller-USB through the PC USB interface.

Teach pendant: A hand-held terminal used for controlling the robot and axes connected to the
controller. The Teach Pendant contains function keys, and its LCD display shows the current
status of the controller, the current user command, and system messages.

PROCEDURE:
• Open desktop icon Loader of ws1.
• Click on green icon.
• Click on home icon and home all axis of robot.
• In operation mode select STAND ALONE procedure.

LAB NO: 10
OBJECTIVE

To demonstrate and learn the Process of quality control by using Vernier caliper

EQUIPMENT:

• Robotic Arm
• AGV mobile robot
 • Vernier caliper

TECHNICAL DESCRIPTION:
AGV mobile robot:
Automated Guided Vehicles can be used in a wide variety of applications to
transport many different types of material including pallets, rolls, racks, carts, and
containers. AGVs excel in applications with the following characteristics:
• Repetitive movement of materials over a distance
• Regular delivery of stable loads
• Medium throughput/volume
• When on-time delivery is critical and late deliveries are causing inefficiency
• Operations with at least two shifts
• Processes where tracking material is important

Vernier Caliper:

• The Vernier caliper is an extremely precise measuring instrument; the reading error
is 1/20 mm = 0.05 mm.
• Close the jaws lightly on the object to be measured.
• If you are measuring something with a round cross section, make sure that the axis
of the object is perpendicular to the caliper. This is necessary to ensure that you are
measuring the full diameter and not merely a chord.
• Ignore the top scale, which is calibrated in inches.
• Use the bottom scale, which is in metric units.
• Notice that there is a fixed scale and a sliding scale.
• The boldface numbers on the fixed scale are centimeters.
• The tick marks on the fixed scale between the boldface numbers are millimeters.
• There are ten tick marks on the sliding scale. The left-most tick mark on the sliding
scale will let you read from the fixed scale the number of whole millimeters that the
jaws are opened.

LAB NO: 11
OBJECTIVE:

Control the continuous flow of water by using a servo motor.

THEORY:

Servomotor
A servomotor is a rotary actuator or linear actuator that allows for precise control of angular or
linear position, velocity and acceleration. It consists of a suitable motor coupled to a sensor for
position feedback. It also requires a relatively sophisticated controller, often a dedicated
module designed specifically for use with servomotors.

A PID Controller is used in this experiment.

PID: Proportional, Integral and Derivative.
PID
A proportional integral derivative is a closed loop feedback mechanism. A (PID) controller
continuously calculates the error value as the difference between desired set point and
measured process variable and applies the correction based on PID terms.

Proportional Response
The proportional component depends only on the difference between the set point and the
process variable. This difference is referred to as the Error term.

The proportional gain (Kp) determines the ratio of output response to the error signal. In
general, increasing the proportional gain will increase the speed of the control system
response. However, if the proportional gain is too large, the process variable will begin to
oscillate. If Kp is increased further, the oscillations will become larger and the system will
become unstable and may even oscillate out of control.

Integral Response
The integral component sums the error term over time. The result is that even a small error
term will cause the integral component to increase slowly. The integral response will
continually increase over time unless the error is zero, so the effect is to drive the Steady-
State error to zero. Steady-State error is the final difference between the process variable and
set point. A phenomenon called integral windup results when integral action saturates a
controller without the controller driving the error signal toward zero.

Derivative Response
The derivative component causes the output to decrease if the process variable is increasing
rapidly. The derivative response is proportional to the rate of change of the process variable.
Increasing the derivative time (Td) parameter will cause the control system to react more
strongly to changes in the error term and will increase the speed of the overall control system
response. Most practical control systems use very small derivative time (Td), because the
Derivative Response is highly sensitive to noise in the process variable signal. If the sensor
feedback signal is noisy or if the control loop rate is too slow, the derivative response can
make the control system unstable

Closed Loop:
Closed loop is such an operation in which there is feedback from output to input by the help of
sensors. In this way the error of measured process variable from set point could be easily
reduced by carrying out certain actions according to the nature of the process.

Open Loop:
Open loop is incapable of sending back the feedback of the measured value back
to the input to improve it.

The main aim of the experiment is to control the flow of water and bring the water level to a
constant level (which is a preset value).

PROCEDURE:
• The water level in a tank is being maintained by the help of PID controller which senses
the measured value at every instant of time and provides feedback to the input which is
controlled by the servo valve.

• The water in the tank flows from the servo valve into it and at the same time is being drained
into the secondary tank and guided back to the primary tank to make a continuous flow.
• The desired value of the water level in the primary tank is entered into the computer that is
connected to the PID controller.

• The measured value is sensed by a sensor and is also displayed on the computer interface
along with the preset value. The preset value line remains constant but the measured value
line keeps fluctuating showing us the error present.
• The value of the measured value can be observed by the PID controller.

• Now as we apply the proportional band value, the measured value line comes closer to a
straight line. It may be below the preset value line or above but it’s preferred to keep it
below the preset value.

• In these cases we have to take the measured line as close as possible to the preset value as
possible once it has attained a constant value. This is done by applying integration.

OBSERVATION:
We need to control is the proportional band once we are getting the values of measured
values at every instance of time after the graph stabilizes.
For the first iteration, we need to enter a small value of PB and see the output. It should
decrease the amplitude of the oscillations of the measured value line. Then we apply second
value which is bigger value. If the amplitude decreases further then we need to increase the
PB value and keep on increasing till we get a constant line. If the amplitude increases on
entering the second value then it means that we have to reduce the PB value to obtain the PB
value at which the line becomes straight.

Second thing is to set the value of the integral band which takes the straight line obtained by
tuning PB value, closer to the set point.

There can be different combinations of PB and IB values for an experiment. The values our
group used for PB and IB were for set point 30 cm height for the primary tank was:

PB 6
IB 15

CONCLUSION:
Through Proportional, derivative and Integral inputs, the PID effectively controls the water
level and maintains it with minimum deflection at provided correct conditions. The PID
controller is an extremely efficient method for these kind of closed loop applications which
requires a feedback system for improving the output and maintain it to a preset value. The
line following robot can be a prime example of its use. The robot has a preset destination
point and the measured point is one to which it reaches. So as the feedback is sent to PID
controller the robot improves its accuracy and goes towards the right location.

LAB NO: 12
OBJECTIVE:
Control water level via ON/OFF solenoid valve.
THEORY:
 SOLENOID VALVE
A solenoid valve is an electromechanically operated valve. The valve is controlled by
an electric current through a solenoid. In the case of a two-port valve the flow is switched on
or off. Solenoid valves are the most frequently used control elements in fluidics. Their tasks
are to shut off, release, dose, distribute or mix fluids. They are found in many application areas.
Solenoids offer fast and safe switching, high reliability, long service life, good medium
compatibility of the materials used, low control power and compact design.
PROCEDURE:
The procedure for this experiment is relatively easy because it does not require continuous
monitoring by a human to set the values for PB and IB.
• We just have to set a set point for our primary tank where we want our water level to be
maintained.
• Solenoid valve is a part of the whole process which also includes other components such
as float level switch which works in conjunction with the solenoid valve.
• We set our desired set point for the primary tank and the water is being drained out of it by
a certain flow rate into the secondary tank.
• The outflow from the primary tank is also controlled by the user.
• As the water level strikes the float level switch, the float level switch opens the circuit and
as a result the electrically operated solenoid valve is closed (OFF) preventing the water
flow into the primary tank. But at the same time the water is also being drained so the float
level switch closes the circuit and solenoid valve is ON now allowing water to flow into
the primary tank.
• In this manner solenoid valve and float level switch work together to maintain the water
level.

OBSERVATION:
The set point we used in this practical was 50 cm in the primary tank.
CONCLUSION:
The more the fluctuation of the water level in the primary tank, there will be gradual ON/OFF
conditions for solenoid valve which results in inaccuracy and errors. This is caused by the large
flow rate of the drained water. These are largely used in irrigation sprinklers, washing machines
and dishwashers.

LAB NO: 13
OBJECTIVE:
Control water level via float level switch.
THEORY:
FLOAT LEVEL SWITCH:
Float level switches are sensors with an electrical contact output at a specific liquid level. All
float operated liquid levels controls on the basic buoyancy principle. A float switch is a
device used to detect the level of liquid within a tank. The switch may be used to control
a pump, as an indicator, an alarm, or to control other devices.
PROCEDURE:
This experiment is to show us the working principle of the float level switch. Basically the
procedure for this experiment is relatively easy because it does not require continuous
monitoring by a human to set the values for PB and IB.
• We have to set a set point for our primary tank where we want our water level to be
maintained.
• Float level switch is a part of the whole process which also includes other components such
as solenoid valve which works in conjunction with the float level switch.
• We set our desired set point for the primary tank and the water is being drained out of it by
a certain flow rate into the secondary tank.
• The outflow from the primary tank is also controlled by the user.
• Now as the water level strikes the float level switch, the float level switch opens the circuit
and as a result the electrically operated solenoid valve is closed (OFF) preventing the water
flow into the primary tank. But at the same time the water is also being drained so the float
level switch closes the circuit and solenoid valve is ON now allowing water to flow into
the primary tank.
• In this manner solenoid valve and float level switch work together to maintain the water
level.

OBSEVATION:
The set point we used in this practical was 50 cm in the primary tank.
CONCLUSION:
The error caused is by the level we set. The higher the set point, the more error are introduced
due to fluctuations. This type of level switch is widely used in household water tanks to prevent
the water level rising from a certain level so that the water does not overflow. They can also be
found in heaters and high or low level alarms.