INTRODUCTION
BACKGROUND OF THE RESEARCH
In recent years, the trend of automation in the manufacturing and assembly industries has gained significant popularity Implementing robots and automated machines on production lines enhances efficiency, minimizes errors, and boosts overall productivity By transitioning from manual tasks to automated processes, companies can achieve faster and more precise operations, resulting in increased production output and reduced costs.
Recent advancements in drug classification within the pharmaceutical industry have been driven by the integration of vision systems and automation lines, enhancing efficiency, accuracy, and standardization at high speeds to boost productivity These vision systems can analyze vast amounts of data, identifying drugs with potential side effects or interactions, thereby assisting medical professionals in prescribing safer and more effective medications As these trends continue to evolve, further improvements across various industries are anticipated.
REASON TO CHOOSE THE PROJECT
Research in technical aspects is crucial for engineering students, as they are responsible for monitoring and maintaining production systems that primarily utilize PLC controllers and vision systems.
User safety must be prioritized in drug production, as the process involves the precise manufacturing and transportation of pharmaceuticals This requires swift identification of errors, including barcode checks, drug name verification, and expiry date assessments, to ensure only qualified vials are packaged while defective products are discarded Given the complexities involved, relying solely on manual labor is inefficient and costly Thus, implementing advanced technology, such as an Industrial Vision System for confirming medicine bottle labels, can effectively address these challenges.
RESEARCH OBJECTIVES
Establish communication between project devices using SSCNET III, Ethernet, and CC-Link, incorporating components such as the Q04UDEHCPU, QD75MH4, QJ61BT11N, QY41P, and QX80 Utilize servo drivers MR-J3-10B and MR-J3-40B alongside servo motors HF-KP43 and HF-KR13 for optimal performance.
HG-KR053B, HG-KP053, Driver Brushless Motor BLED6C; and Brushless Motor BLEM46-GFS, digital sensors, Camera Cognex 5110
Position Interpolation Control and operate as required
The project successfully integrates both the electrical panel and mechanical model to operate motors that transfer bottles along a conveyor system This system efficiently transports bottles to a rotary table where a Cognex camera sorts and arranges them precisely along the XYZ axes into designated positions within a box.
Control and monitor the industrial vision system through SoftGOT 2000.
RESEARCH CONTENT
With the objective set above, our graduation thesis is constructed as follows:
This chapter indicates the background of the research, reason to choose the research, research objective, research content, project layout and the limit of the project
This article explores the theoretical foundations of key components in automation systems, focusing on the Mitsubishi Q Series PLC, AC Servo Motors, and their control methods, which include drivers, encoders, and sensors It also examines barcode technology and communication networks such as SSCNET III, Ethernet, and CC-Link Chapter 3 delves into the calculations, design, and construction of the model, emphasizing the integration of these technologies for efficient automation solutions.
This chapter outlines the equipment calculation and layout for the panel and model selection Following the calculations, suitable devices for the system are chosen The project details the entire process, encompassing mechanical construction, electrical wiring, and system control, from parameter setup to program activation, addressing the identified challenges.
Chapter 4: Algorithm and Control Program
The Vision System project necessitates a specific algorithm for effective regulation and control, guiding the process step by step This chapter focuses on the software components integral to the Vision System's functionality.
Chapter 5: The outcome of the research
This chapter outlines the research findings in relation to the initial objectives, highlights the challenges encountered during the study, and reflects on the lessons learned and insights gained throughout the process.
Conclusion after accomplishing the model and discuss about the merits and disadvantages of the overall project and recommendation to develop the project.
THE LIMITATION OF THE PROJECT
The project carried out on the medium-sized model compared to the actual automation line in any factory and regulates based on only the given requirements
The system is designed to recognize medicine bottles only when their labels are positioned correctly within the camera's detection area, and it requires a slow rotation of the table to ensure the camera lens can accurately read the labels.
THEORETICAL BASIS
GENERAL INTRODUCTION ABOUT PLC
A Programmable Logic Controller (PLC) is a digital computer essential for industrial automation and control systems It monitors and controls machinery and processes across various environments, including factory assembly lines, power plants, and water treatment facilities The core function of a PLC involves receiving input signals from sensors, processing this data, and generating output signals to manage actuators and motors Its programmability allows customization of behavior through specialized programming languages, enabling tailored logic and sequencing instructions.
The CPU is the "brain" of the PLC It processes instructions, coordinates the activities of other components, and communicates with external devices
PLC CPUs vary in processing speeds, memory capacities, and communication capabilities based on their model and manufacturer Advanced PLC CPUs offer multitasking support, enabling the simultaneous or time-shared execution of multiple programs.
The CPU performs various functions including program execution, data processing, communication, I/O handling, timing and synchronization, system diagnostics and memory management
A PLC's memory is categorized into two primary types: program memory and data memory Program memory is designated for storing user-programmed instructions, whereas data memory is utilized for holding variables, timers, counters, and other essential data required during the execution of the program.
The memory capacity of a PLC varies by model and manufacturer, making it crucial to assess available memory when designing PLC programs to ensure they are appropriately sized for the allocated space.
PLCs can enhance their storage capacity through additional memory expansion options like memory cards or modules, enabling the accommodation of larger programs and the retention of historical data and logs.
These modules play a crucial role in receiving signals from a variety of sensors, switches, and devices in the field They effectively convert physical input signals into digital data, enabling the PLC's CPU to process the information efficiently.
These features could be listed as signal conversion, various input types, signal isolation, various input channels, wiring connection support, input status indication and hot-swapping
Output modules serve as the critical link between the PLC and field devices, transforming control signals into the necessary format to activate various output devices These modules encompass a range of components, including digital and analog output cards, motor drives, and solenoid valves, facilitating effective communication and operation within automation systems.
Key features include signal conversion, multiple output types and channels, current and voltage ratings, wiring connection support, output status indication, short-circuit and overload protection, and hot-swapping capabilities.
Properly mapping the PLC's output channels to the corresponding variables in the PLC program is crucial for ensuring accurate control signals are sent to the appropriate output devices, which facilitates effective operation and management of industrial processes.
The power supply of a Programmable Logic Controller (PLC) is crucial for delivering the necessary electrical power to the entire system, ensuring reliable and consistent operation It converts input voltage from an external source to the specific voltage levels required by the PLC, which can vary by model and application Common input voltage ranges for PLC power supplies include 110-240 volts AC (alternating current) and 24 volts DC (direct current).
An AC power supply is designed to accept input from the main power grid and includes essential components such as transformers, rectifiers, and voltage regulators These components work together to convert the alternating current (AC) voltage into the direct current (DC) voltage levels required by programmable logic controllers (PLCs).
DC power supplies are essential for certain PLC systems utilized in industrial automation, typically operating on a 24 volts DC input These power supplies often incorporate components such as filters and voltage regulators to provide a stable and clean power source, ensuring optimal performance for industrial control systems.
PLCs are equipped with integrated communication ports that facilitate connections to various devices and networks These ports enable seamless data exchange with human-machine interfaces (HMIs), supervisory control and data acquisition (SCADA) systems, programming devices, and other PLCs, ensuring efficient inter-device communication.
Programmable Logic Controllers (PLCs) feature various communication ports that differ by model and manufacturer Common types include serial ports like RS-232 and RS-485, Ethernet ports, USB ports, wireless communication options, fieldbus ports, and expansion ports.
A programming device, such as a personal computer or handheld programmer, is used to develop the control program and configure the PLC
It provides an interface for programming, testing, and troubleshooting the PLC system
The rack or chassis serves as a physical enclosure for the various modules of the PLC, offering essential mechanical support and facilitating electrical connections that enable communication between the modules.
2.1.2 Characteristics and Function of PLC:
SERVO MOTOR AND DRIVER SERVO
A servo motor is a rotary actuator designed for precise control of angular position, widely utilized in numerous applications This closed-loop system employs feedback signals to continuously regulate its rotational position, speed, and torque, ensuring accurate performance.
A servo motor consists of three main components: a motor, a position sensor (typically a potentiometer or encoder), and a control circuit The control circuit interprets a pulse-width modulation (PWM) control signal that indicates the desired position or speed It then compares the actual position, detected by the position sensor, with the target position and adjusts the motor's output accordingly Additionally, the servo motor's control circuit includes a built-in amplifier to enhance the control signal, enabling precise movement of the motor, which is often a DC or brushless DC motor known for its high torque and accuracy.
Servo motors are essential in applications demanding precise motion control, including robotics, industrial automation, CNC machinery, and remote-controlled vehicles Their benefits include a high torque-to-size ratio, rapid response times, and exceptional position accuracy.
Servo motors come in various types, including DC servo motors, AC servo motors, brushed and brushless servo motors, linear servo motors, continuous rotation servo motors, high-torque servo motors, and micro servo motors Among these, AC servo motors and DC servo motors are the most widely used in industrial applications due to their efficiency and reliability.
DC motors consist of a stator (stationary part) and a rotor (rotating part) The stator usually contains field coils, while the rotor has permanent magnets or windings
A DC servo motor utilizes a position sensor to deliver feedback on its current position, allowing for precise adjustments to align with the desired position This feedback mechanism often involves components such as potentiometers and encoders, ensuring accurate control and performance.
The control circuit plays a crucial role in processing control signals and feedback from the position sensor By comparing the desired position with the actual position, it generates an appropriate control signal to drive the DC motor This circuit can be designed using either analog or digital control techniques, ensuring precise motor operation.
DC servo motors are often favored for applications that require high torque and precise control at lower speeds
AC servo motors operate with an AC power supply, which is readily available in most electrical systems
The control circuit for AC servo motors is generally more intricate than that of DC servo motors, utilizing advanced control algorithms and techniques to ensure precise position and speed regulation.
AC servo motors commonly use position sensors such as encoders or resolvers to provide feedback on the motor's actual position This feedback information is used
30 for accurate control and positioning AC servo motors offer good torque characteristics across a wide range of speeds They can provide high torque output at high speeds as well
AC servo motors tend to be more power-efficient compared to DC servo motors They can provide higher power output for a given input power
AC servo motors are preferred for applications that demand dynamic control, high- speed operation, and a wider range of speeds
Mitsubishi Electric offers a wide range of servo motors to cater to various industrial needs
HF-KP/KP2R Series: Compact and lightweight servo motors suitable for space- constrained applications, providing high-speed and high-precision control
HF-KP/HF-JP Series: Compact servo motors offering high torque and high-speed performance, suitable for applications requiring precise control
HG-KR/KRT/KP/KPN Series: Servo motors with a compact design and high torque output, suitable for a variety of applications including robotics and automated machinery
Figure 2 5: Series HF Servo Motor
The AC servo system is engineered for precise position control, ensuring it accurately maintains a specified position It operates by receiving a desired position signal, which it then compares to the feedback signal generated by the encoder.
AC servo systems enable precise velocity control of motors by allowing users to set a desired speed The control system actively adjusts the motor's operation to achieve and maintain this specified velocity, ensuring optimal performance.
Acceleration and Deceleration Control: AC servo systems can control the acceleration and deceleration of the motor to achieve smooth and precise motion
The AC servo system employs a feedback loop to constantly track the motor's position, velocity, and acceleration By comparing the feedback signal with the target values, a Proportional-Integral-Derivative (PID) control algorithm fine-tunes the motor's performance, effectively reducing any discrepancies.
Feedforward Control: It involves providing additional control signals to compensate for anticipated disturbances or changes in the system
AC servo systems excel in trajectory planning by adhering to predefined motion profiles The control system meticulously calculates the optimal path for the motor, ensuring precise adjustments to its operation for accurate trajectory execution.
2.2.1.4 Structure of an AC Servo motor:
The stator is the stationary component of an electric motor, featuring a core constructed from laminated steel sheets It includes a configuration of three-phase stator windings arranged in a precise pattern, essential for the motor's operation.
The rotor, a crucial component of the motor, is the rotating part that connects to the driven load Depending on the motor design, it can either be a permanent magnet rotor or one equipped with windings.
Stator Windings: The stator windings are three-phase windings placed in specific locations around the stator core These windings create a rotating magnetic field when energized with AC current
Rotor Windings or Permanent Magnets: The rotor may have either windings or permanent magnets, depending on the type of AC servo motor
AC servo motors depend on position sensors for accurate rotor position feedback, which is essential for precise control Common types of position sensors include optical encoders, resolvers, Hall effect sensors, and magnetic sensors.
Motor Controller or Drive: The motor controller or drive is responsible for providing the necessary power and control signals to the motor
AC servo motors produce heat during operation, particularly when running at high speeds or under substantial loads To manage this heat and ensure optimal performance, these motors are typically equipped with cooling systems, which may include fans or liquid cooling mechanisms.
ENCODER
An encoder, often referred to as a rotary or shaft encoder, is an electromechanical device that translates the angular position or movement of a shaft into either an analog or digital output signal This technology is essential for monitoring motor parameters such as position, travel direction, and speed by counting the shaft's revolutions.
Figure 2 9: Encoder structure Figure 2 10: Linear Encoder
Encoders come in various types, including optical, magnetic, capacitive, inductive, and Hall effect encoders; however, they all fundamentally fall into two main categories.
Incremental encoders are essential devices that offer insights into relative motion or position changes by generating pulses as a shaft or object rotates or moves They consist of a disk with evenly spaced slots or marks, known as pulses, and a sensor that detects these pulses The resolution of the encoder is defined by the number of pulses per revolution or per unit of linear motion By counting these pulses, the system can accurately determine the relative position or speed of the object being measured.
Absolute encoders deliver precise information regarding the absolute position of a shaft or object They generate a distinct binary or digital code corresponding to each position within their measurement range, often utilizing multiple tracks or a combination of methods for enhanced accuracy.
Absolute encoders utilize 36 tracks to represent various segments of binary code As the object rotates or moves, the binary code updates, allowing the encoder to accurately ascertain its precise position Notably, absolute encoders can retain this position information even in the event of a power loss.
Absolute encoders deliver precise absolute position data, removing the necessity for homing or reference point initialization This capability is vital in applications requiring accurate position maintenance, particularly following power loss or system restarts As a result, they allow for immediate and accurate positioning without recalibration.
AC Servo positioning control
Unit setting: The first setup for positioning control, using mm when the axis is controlled with lead screw and using degree when the axis is control for rotation
The number of pulses per rotation is crucial for achieving the desired accuracy in servo motor control This value indicates the number of pulses needed for the motor to complete one full revolution, which is determined by the encoder disk's specifications For an 18-bit encoder, this equates to 262,144 pulses per revolution, ensuring precise motor performance.
The movement distance for each rotation should be configured according to the mechanical mechanism linked to the motor shaft, such as lead screws, linear systems, or turntables This distance can be measured in millimeters for reciprocating motion, degrees for rotary systems, or pulses for specific applications.
Forward and reverse rotation pulse train
- The number of revolutions as well as the rotation speed depend on the pulse signal
- The reversible rotation signal is independent of the command pulse to control the direction of rotation
- When port A receives pulse then the motor rotates follow clockwise, input B receives pulse then opposite
- By choosing the dimension to follow can be installed in parameter or transmit command from control to servo driver
A-phase pulse train b-phase pulse train
- Direction of rotation control difference between 2 pulse output - Turn forward when phase B phase delay than phase A 90 degrees - Reverse rotation when phase A phase delay than
Input signal logic: The input digital signal can be chosen by one of two types Positive logic or Negative logic
Speed limit value: Based on limit of servo motor used, which can be lower when declaring in the parameters, but not higher
To properly set the rotation direction of a servo motor, it is essential to note that the reverse rotation is not the default setting The correct rotation direction is defined as either clockwise or counter-clockwise Thus, to configure the servo controller, the motor must be adjusted to rotate in the positive position value direction, indicating forward rotation, while the opposite direction signifies reverse rotation.
The OPR method involves selecting a starting position for work, which includes the near-point dog method, data set method, and count method When configuring these parameters, it is crucial to specify the direction and speeds for returning to the OPR position.
Figure 2 13: Return Home using Near-point dog method
To safeguard against damage and unforeseen issues caused by incorrect control, it is essential to establish a maximum travel stroke for the system This can be achieved in two ways: first, by configuring the upper and lower limit parameters within the servo driver's software, and second, by utilizing limit switches or sensors to restrict the motor's displacement.
Figure 2 14: Movement limit of the structure
Before operating the system, it's crucial to establish the predetermined home position, which is typically set to a value of 0 This Zero Point Return ensures accurate functionality and alignment during operation.
SENSOR
A sensor is a crucial device that detects and measures physical phenomena or environmental conditions, converting them into electrical signals Widely utilized across engineering, science, medicine, and consumer electronics, sensors can monitor various variables, including temperature, pressure, light, humidity, motion, acceleration, proximity, pH, gas, and magnetic fields These devices are essential for gathering data from the environment, enabling the processing, analysis, and application of information for diverse purposes.
Figure 2 15: Optical sensor Omron SX674A
Many types of sensors are distinguished based on its ability
- Volatile Organic Compound (VOC) Sensors pH Sensors: - Glass Electrode pH Sensors
- Ion-Selective Field Effect Transistor (ISFET) pH Sensors
Force and Load Sensors: - Strain Gauge Sensors
Magnetic Sensors: - Hall Effect Sensors
Chemical Sensors: - pH Sensors (also mentioned earlier)
- Gas Sensors (also mentioned earlier)
An NPN sensor employs an NPN (Negative-Positive-Negative) transistor as its output device, which is a three-layer semiconductor consisting of a base, emitter, and collector Typically, an NPN sensor integrates this transistor with additional components, including a sensing element or detector that identifies specific physical quantities or environmental conditions The detected information is converted into an electrical signal, which is then amplified and processed by the NPN transistor, enabling accurate measurement and response.
Figure 2 17: NPN 3-wire sensor wiring
A PNP sensor is a type of sensor that utilizes a PNP (Positive-Negative-Positive) transistor as its output device This three-layer semiconductor device comprises a base, collector, and emitter, and is often paired with additional components like a sensing element or detector Like NPN sensors, PNP sensors are designed to detect specific physical quantities, making them essential in various applications.
43 or environmental condition and produces a corresponding electrical signal This signal is then amplified and processed by the PNP transistor
Figure 2 18: PNP 3-wires sensor wiring
BARCODE SCANNER
A barcode is a machine-readable optical representation of data, featuring a series of parallel lines, spaces, and numbers It enables quick and accurate scanning of information using a barcode scanner or reader.
Barcodes play a crucial role in product identification, inventory management, and point-of-sale transactions By encoding information in a machine-readable format, they streamline data entry processes and minimize human error.
The most widely utilized barcodes are UPC, EAN, Code 39, Code 128, and QR codes, each with unique formats, encoding rules, and data length limitations These barcodes can be printed on diverse surfaces, including product labels, packaging, tickets, and identification cards.
Barcodes offer significant advantages such as rapid and precise data capture, enhanced inventory management, efficient checkout processes, and improved visibility in the supply chain They are essential components of contemporary business operations, facilitating effective tracking, traceability, and data management.
Barcode technology has significantly evolved, incorporating innovations such as color barcodes, high-density barcodes for small products, and smartphone app scanning These advancements enhance the functionality and versatility of barcode applications.
When a barcode is scanned, the scanner captures the reflected light and converts it into a digital signal, allowing for the extraction of encoded information This information is utilized for various purposes, including price lookup, inventory management, and shipment tracking Barcodes have streamlined processes across industries such as retail, logistics, healthcare, and manufacturing, enhancing data capture efficiency and accuracy They play a crucial role in modern business operations by improving inventory control, supply chain management, and overall operational efficiency.
Advanced encoding techniques utilize dot matrix patterns for 2D codes, enabling the storage and definition of extensive information These codes comprise small dots that form intricate patterns, similar to those produced by dot-matrix printers, which are interpreted during scanning Additionally, they can incorporate various shapes and circular designs beyond the traditional format.
Laser barcode scanners are the most prevalent type of barcode reader, utilizing a laser beam to scan and decode barcodes from a medium distance These scanners operate by emitting a laser that sweeps across the barcode, analyzing the reflected light to extract the encoded information.
CCD (Charge-Coupled Device) barcode scanners utilize a series of small light sensors to capture barcode images by illuminating them with LED lights and measuring the reflected light intensity Known for their cost-effectiveness and reliability, CCD scanners excel at reading 1D barcodes from close distances.
Image-based barcode scanners utilize a camera or image sensor to capture and decode barcodes through image processing algorithms Capable of reading both 1D and 2D barcodes, these scanners excel in interpreting damaged or poorly printed barcodes, offering superior performance compared to traditional scanners.
Pen-type barcode scanners, commonly referred to as barcode wands, are handheld devices designed to read barcodes by swiping across them These scanners utilize a light source and a photodiode to detect reflected light, allowing them to decode data based on the scanner's movement.
2D imagers are sophisticated barcode scanners capable of reading both 1D and 2D barcodes, along with capturing images and signatures Utilizing advanced image sensor technology, they produce high-resolution images of barcodes, ensuring exceptional scanning performance.
Mobile barcode scanners are integrated into smartphones and tablets, leveraging the device's camera and software applications for barcode scanning By utilizing image processing algorithms and the processing capabilities of mobile devices, these scanners effectively capture and decode various barcodes.
Cognex specializes in machine vision and industrial barcode reading technologies, utilizing advanced image capture and processing techniques to efficiently read barcodes on diverse surfaces like labels and packages Renowned for their speed and reliability, Cognex scanners excel at reading damaged or poorly printed codes With ergonomic designs, these scanners can be seamlessly integrated into production lines, handheld devices, or fixed-mount setups, and many models offer connectivity options including USB, Ethernet, and wireless interfaces.
Cognex offers a variety of scanner products that cater to different barcode reading and machine vision applications
The DataMan series features advanced handheld and fixed-mount barcode readers optimized for rapid reading and decoding These high-performance scanners are essential in various industries, including manufacturing, logistics, and healthcare, facilitating critical applications such as product tracking, sorting, and identification.
Ethernet Network
Ethernet is a prevalent technology for local area networks (LANs), enabling wired communication between devices It standardizes the transmission of data packets among various network-enabled devices, including computers, servers, routers, and switches.
Ethernet networks provide numerous benefits, such as high data transfer speeds, minimal latency, and exceptional scalability and reliability Their robustness and compatibility with various devices make them ideal for use in home and office environments, data centers, and industrial applications.
An Ethernet network typically consists of several components:
Ethernet networks utilize twisted pair or fiber optic cables for data transmission between devices, with the most prevalent types being Category 5e (Cat 5e) and Category 6 (Cat 6) cables These cables feature RJ-45 connectors that easily connect to Ethernet ports on various devices.
Ethernet switches serve as central hubs in a network, enabling multiple devices to connect and communicate efficiently They receive data packets from one device and direct them to the correct destination based on the MAC (Media Access Control) address, ensuring seamless data transmission.
Network Interface Cards (NICs), also referred to as Ethernet adapters or network adapters, are essential hardware components that enable devices to connect to Ethernet networks These cards are commonly integrated into computers, laptops, and servers, but can also be installed as separate expansion cards to enhance connectivity options.
Ethernet networks rely on protocols to manage data transmission and reception, with Ethernet II (or Ethernet Version 2/DIX Ethernet) being the most prevalent protocol in use today This protocol outlines the structure of Ethernet frames and specifies the format of MAC addresses, ensuring efficient communication within the network.
Effective network configuration for Ethernet networks involves assigning unique IP addresses to devices and establishing essential parameters such as subnet masks, default gateways, and DNS settings These configurations are crucial for ensuring seamless communication between devices and facilitating their connection to the broader network, including the internet.
CC-Link
CC-Link, also known as CC-Link Industrial Networks, is a family of open fieldbus and industrial Ethernet technologies used for communication in industrial automation systems
Developed by Mitsubishi Electric Corporation in 1997, CC-Link has gained global popularity as a versatile communication protocol It effectively connects a wide range of devices, including programmable logic controllers (PLCs), human-machine interfaces (HMIs), and sensors, enhancing automation and control in various industrial applications.
CC-Link is a high-speed communication network designed for real-time data exchange and control in manufacturing and industrial environments, supporting 49 actuators and various automation components This versatile network offers multiple variants to cater to diverse automation needs.
CC-Link (Control & Communication Link) is a foundational technology that operates on a master-slave communication model, enabling high-speed data transfer It ensures deterministic and synchronized communication, making it ideal for control applications.
CC-Link/LT (Lite): This variant is a simplified version of CC-Link designed for smaller-scale applications It is suited for applications where cost and simplicity are important factors
CC-Link Safety enhances the CC-Link network by integrating safety functionalities, allowing for the seamless connection of safety devices with standard control and communication systems This integration facilitates safe communication and effective monitoring of safety-related information.
CC-Link IE is a high-speed, Ethernet-based network that supports gigabit transmission rates, making it ideal for handling large data volumes Its design allows for seamless integration with existing Ethernet infrastructure, enhancing communication efficiency in industrial settings.
Figure 2 22: CC-Link Industrial Network
Openness: This fosters interoperability and allows for the integration of devices from different vendors, providing flexibility and choice to users
High Performance: CC-Link offers high-speed communication and deterministic data transfer, ensuring real-time control and synchronization of devices
CC-Link is renowned for its robustness and reliability in industrial environments, offering fault-tolerant communication and automatic error detection and recovery mechanisms It efficiently manages large volumes of data with low latency, significantly enhancing the overall stability of the system.
CC-Link networks offer excellent scalability, enabling easy expansion to support an increasing number of devices With the ability to utilize various network topologies such as star, line, and ring configurations, they provide flexibility in both system design and future growth.
Flexibility: CC-Link offers flexibility in terms of wiring options, allowing both copper and fiber optic cables to be used for network connections
CC-Link Safety is a specialized version of CC-Link that facilitates the smooth integration of safety devices and systems within a network This technology ensures safe communication and effective monitoring of safety-related data, thereby safeguarding both personnel and equipment.
CC-Link networks provide user-friendly maintenance features, including diagnostics and monitoring capabilities that facilitate quick troubleshooting, device status tracking, and predictive maintenance.
CC-Link has achieved significant global adoption, backed by a wide range of manufacturers and organizations This extensive international presence guarantees access to compatible devices, reliable technical support, and a robust user community.
SYSTEM CALCULATION, DESIGN AND CONSTRUCTION
SYSTEM REQUIREMENT
An industrial automation system utilizes the Cognex vision system to classify and sort medicine bottles into pre-prepared boxes, effectively eliminating the need for manual labor This project addresses the challenge of precise and synchronous control of the production line, where the Cognex vision sensor processes images to identify different bottle types The Cartesian coordinate robot, featuring three main axes that operate in unison with a rotary table, efficiently transfers the bottles to designated positions within the boxes.
Minimum number of products in 1 minute:
The speed of the conveyor is 300rpm through the gearbox 1
15 where the velocity of the shortest distance between products is 2cm
The number of revolutions in 1 second is: 300 0.33
60 *15 (r/s) With the circumference of the conveyor's rotation axis is: 2 4 251.2mm
The conveyor belt travels in 1 second: 251.2 0.33 82.9mm
It takes time for the product to travel 2 cm: 2 8.29 0.241s
The deceleration and delay time of sensor and conveyor :0.2+0.8=1s
Time for Z axis to go from ready position to product position: 30-4&mm
At a speed of 1200 mm/min = 20mm/s and the distance is 26mm the time is: 26 1.3
20 s The time it takes to get from the pick-up position to the turntable is: 283-11.5'1.5mm
So at a speed of 1200mm/min mm/s s and the distance is 271.5mm the time is:
Time for the table to rotate 1 revolution at a speed of 2000degree/min is:
=>360 : 33.3 10.8s The distance traveled by the product from the turntable to the sorting position is:
At a speed of 3000mm/min= 50mm/s and the distance 24.8mm the time is: 0.496s The time it takes for a product to be classified is:0.24+1+1.3+1.36+10.8+0.496.2s
In 1 minute 3 products have been completed classification
Maximum number of products per minute is: 15.2-10.8=4.4s
In 1 minute 13 products have been completed classification
Our system is divided into two key components: mechanical and electrical We have successfully installed and configured both parts to ensure the project integrates seamlessly into an industrial automation line The mechanical components are constructed entirely from aluminum, while the electrical elements are mounted on an aluminum composite panel.
The system features four Mitsubishi Servo Motors and one Oriental Brushless Motor, with three servo motors synchronously activating the principal axes Additionally, one servo motor operates the rotary table, while the brushless motor regulates the conveyor This configuration highlights the mechanical requirements essential for optimal performance.
Aluminum Base Product for Camera mounting
Bars, frames for mounting equipment on the panel
Engine support frame, conveyor belt and product stop bar
XYZ Axes and Rotary Table
Mechanical axes and pedestals for mounting X, Y, Z axes
Y-Axis, Z-Axis aluminum base plate
3.3.1.3 Model parameters and Design Drawing
Mechanical parameters are chosen based on requirements of the system:
Aluminum Plate for whole system: ́́84x98x1 cm
XYZ-axes and Rotary conveyor frame and drive pedestal, support frame
Aluminum Plate for XYZ axes: 41x22x1.2 cm
The Aluminum composite panel: 68x56 cm
Figure 3 2: Lead screw X-Axis parameters
Figure 3 4: Lead Screw Y-Axis parameters
Figure 3 6: Lead Screw Z-Axis parameters
The model's electrical system comprises several key components, including the power block, central processing unit, position control block, CC-Link module block, driver servo motor block, driver brushless motor block, sensor block, and camera block.
Functions of each block in the system are as follows:
The 220VAC power source serves as the primary supply for the entire motor driver and the PLC, while a 24VDC switching power supply is utilized for the control circuit, powering sensors, relays, and I/O modules.
Central Processing Unit Q04UDEHCPU Positioni ng Module QD75M
Proximity Sensor XYZ Axes and
CC-Link Module QJ61BT11N
The sensor block system employs proximity sensors to accurately determine the positions of the upper and lower limits, the home position of the servo linear motor, and the location of the medicine bottle on the conveyor It utilizes Azbil APM-D3A1 and Omron EE-SX674A sensors, operating within a supply voltage range of 10VDC to 24VDC with NPN output, which connects to the positioning module Additionally, the conveyor is equipped with an OMDHON E3F-DS30C4 sensor, also featuring NPN output and powered by 10V to 24V, linking to the QX80 module input via a relay.
The central processing block, known as Q04UDECPU, is responsible for generating control signals for various system components It executes calculation and processing algorithms necessary for synchronous operation and facilitates communication with peripheral devices, including sensors, cameras, and motor control pulse outputs This block plays a crucial role in managing the interaction with attached peripheral devices, ensuring efficient system performance.
Motor Driver Block: This block has the function of carrying a synchronous shaft to help move the axes in the model This block receives pulses from the QD75MH4 module
The servo motor block serves as the core component of the system, featuring four motors mounted on shafts It utilizes MR-J3 10B and MR-J3 40B drivers, which receive communication pulses via the SSCNET network to fulfill control commands effectively.
3.3.2.3 Choose devices and system design 3.3.2.3.1 PLC Station
Input Module Device Q38B Q61P Q04UDE QD75MH4 QJ61BT11N QY41P QX80
Table 3 1: Modules in PLC station
It is necessary to mount the devices on the base, our group choose the base unit Q38B, which suits the need of slots and Q series
The Q61P module is compatible with the Q3xP unit base and Melsec Q-Series, providing a single power supply for PLC modules It supports a wide input voltage range of 100 to 240VAC, making it ideal for use in households with a standard voltage of approximately 220VAC.
The Q04UDEHCPU PLC offers robust support for functional modules and accommodates a large number of I/O inputs, along with an SD card backup feature, making it ideal for expanding analog systems Additionally, it simplifies the management and operation of devices in the factory through easy integration with Remote I/O and industrial CC-Link IE Field Network connectivity.
Communication port: RS232, USB, Ethernet
Memory: SRAM card, Flash card, ATA card
Built-in many high-speed CPUs
Our system is equipped with four servo motors that require a positioning module capable of controlling four drivers It operates with precision, allowing for positioning in both millimeters and degrees while utilizing interpolation control for enhanced accuracy.
2/3/4 axes linear interpolation, 2 axes circular interpolation
Control unit: mm, inch, degree, pulse
Control system: Point to point control, control, path control, speed control, speed- position switching control, position-speed switching control in incremental and absolute system
In speed-position switching control/position- speed switching control:
In speed-position switching control
Other axis is in operation: 1.5
Table 3 5: Positioning Module QD75MH4
The output module regulates the electromagnet to position the medicine bottle vertically It operates on a 24V DC supply, consistent with the other modules in the system.
The input module is used to receive signal from NPN proximity sensor on the conveyor The module also take 24VDC supply, which is the same as other modules
3.3.2.3.8 CC-Link module QJ61BT11N
The module is used to control the brushless motor of the conveyor with CC-Link network
Figure 3 14: Module CC-Link QJ61BT11N
Base on the hardware setup, the Auto Cad 2D drawing of the PLC modules is designed with one power supply module and five modules on the right side
The station has four Servo Driver including three modules Servo MR-J3-10B and one module Servo MR-J3-40B
MR-J3-B series is specialized for general closed control systems, interpolated multi- axis motion systems and especially servo control networks with fiber optic lines
Rated Output Power: 100W for MR-
Control System: sine wave PWM/ current control
Communication others or Motion CPU by SSCNET III
Communicate with computer by USB cable
Table 3 7: Servo Driver MR-J3-10B Parameters
Rated Output Power: 400W for MR-
Control System: sine wave PWM/ current control
Communication others or Motion CPU by SSCNET III
Communicate with computer by USB cable
Table 3 8: Servo Driver MR-J3-40B Parameters
Our team has created a detailed 2D drawing of the Driver Servo modules, which are designed to connect via SSCNET III This system is controlled by the QD75MH4 positioning module and features four AC Servo motors for enhanced performance.
In this system, Servo motors are used which must suits the Driver Servo Base on the table 3.6, the servo motors are chosen below:
Parameters X-Axis Y-Axis Z-Axis Rotary Table
Model Servo HF-KP43 HG-KR13 HG-KR053B HF-KP053
Encoder (bit) 18 bit 22 bit 22 bit 18 bit
Protection IP65 IP67 IP65 IP65
Our system uses camera Cognex In-Sight 5110, which suits the requirements of the system
Figure 3 20: Camera Cognex In-sight 5110
The In-Sight 5110 COGNEX helps measure parts, check critical dimensions, and measure components, parts, and arrangements Especially taking pictures and decoding 1D and 2D barcodes
Electronic shutter speed 16às-1000ms
Figure 3 22: Driver Brushless Bled6C-CC
Table 3 11: Brushless DC Driver BLED6C-CC parameters
The model employs multiple soft limits to define the working distance of the XYZ axes and establish the home position for both axes and turntables To detect objects on the conveyor, the system utilizes nine proximity sensors, specifically requiring sensors for the X and Y axes.
2 limit sensors and 1 near-point dog sensor, where z axis and turntable need near-point dog sensor, 1 proximity sensor for locating medicine bottles on conveyors
Type NPN transistor open collector
NO Light-On/Dark-On NO
The limit sensor and the x-axis near-point dog sensor will utilize the Omron EE-SX674A sensor For identifying objects on the conveyor, an Omdhon proximity sensor will be employed, while all other sensors will be the Azbil APM-D3A1 model.
Figure 3 23: 2D Sensors connecting QD75MH4
Positioning Module with Driver Servo cable:
System Construction
Figure 3 41: Conveyor and Motor Base construction
Figure 3 42: Z-Axis construction beyond Y-Axis
Figure 3 43: XYZ-Axes and Rotary table
Figure 3 44: Soft limit switch for X-Axis
Figure 3 45: Wiring motors and sensors of all motors and axes
Figure 3 46: Electromagnetic, Camera Base and Limit Sensor Y-Axis construction
Once the mechanical components are completed, aluminum composite panels are utilized to house all electrical devices The electrical construction begins with the completion of the circuit breaker (CB) block, followed by the wiring of AC lines for the drivers, PLC, and switching source.
Figure 3 48 AC servo and sensor wiring
Figure 3 49 Electrical panel and switching source
Figure 3 50: CB,Relays and AC Servo
Figure 3 51 PLC modules and domino wiring
ALGORITHMS AND PROGRAMS
SYSTEM DESCRIPTION
The system comprises two main parts:
The composite panel houses essential control devices such as the Q04UDEHCPU, QD75MH4, QX80, QY41P, and QJ61BT11N, alongside driver servos like the MR-J3-10B and MR-J3-40B Additionally, it includes vital electrical components such as circuit breakers, relays, dominos, and switching sources, while a camera is securely mounted on an aluminum base product for optimal functionality.
The motion axes of the support frame are equipped with the HF-KP43 servo motor for the X-axis, the HG-KR13 servo motor for the Y-axis, the HG-KR053B servo motor for the Z-axis, and the HF-KP053 servo motor for the rotary table Additionally, a Brushless DC Motor BLEM46-GFS is mounted on an aluminum base, while peripheral devices such as sensors and electromagnets are securely attached to brackets made of aluminum and mica.
The PLC is designed to manage four servo motors via the Positioning Module and SSCNET III network, as well as a DC Brushless motor using the QJ61BT11N module and CC-Link network The brushless motor drives the conveyor shaft through an intermediate shaft Product identification is facilitated by the In-Sight 5110 camera, which captures data outside the xyz-axis working range The PLC processes signals from the camera to retrieve the barcode and drug name, subsequently directing the QD75MH4 position control module to accurately position and sort the products on the conveyor All operations are monitored and controlled through Mitsubishi's SoftGot display.
SYSTEM OPERATION AND ALGORITHMS
The model features three operational modes: Stop, Manual, and Auto In Stop mode, the conveyor, servo, and other devices are turned off Manual mode requires the operator to input speed and position data, as well as jog speed, to facilitate the testing of motors and equipment In Auto mode, it is crucial for the operator to return the motor to its home position to accurately establish the initial position, preventing incorrect movements that could trigger the limit switch Once the home position is set, the operator can simply press Run, and the conveyor will begin moving the product automatically.
In this project, we implemented a system for detecting and reading barcodes and characters on vials using Insight Explorer support software Initially, the vials are transported on a conveyor belt after being labeled and capped Once a sensor detects a vial, an arm mechanism moves it to a turntable position where a camera inspects the label and reads the barcode and characters Based on this information, the vials are classified and sorted into pre-arranged compartments according to their type and quantity After sorting, the arm structure returns to its original position, completing the process.
4.2.2.1 Algorithm to process information from images of objects:
When the camera scans an object on the turntable, it transmits two key pieces of information to the PLC: the 1D code and the name of the medicine bottle This data is stored for processing The device array is pre-defined and organized along the XYZ axes for precise placement in the box Once the object is fully absorbed and released by the magnet mechanism, its information is removed from the associated data array, marking it as processed.
Interpolation in position control enables the simultaneous operation of multiple axes by referencing the speed of a designated origin axis, eliminating the need for individual control of each axis to achieve the target position To address this requirement, the manufacturer has developed a position control module featuring a built-in interpolation mode, which is organized by data with independent parameters.
The 3-axis linear interpolation algorithm necessitates the input of destination coordinates (X2, Y2, Z2) and the main axis speed, measured in mm/min Upon function invocation, the dataset is accessed and processed to execute movement along the X, Y, and Z axes.
The Positioning Module will control the X, Y, and Z axes, calculating actuator coordinates from the reference origin at position 0 (Home) during OPR mode A position interpolation run will occur when there are at least two sets of parameters, using the current position coordinates (X1, Y1, Z1) and destination coordinates (X2, Y2, Z2) to execute the movement.
A flowchart is a crucial step in the programming model development process The team has created a control flowchart based on the chosen control method and algorithm This flowchart outlines the steps necessary for programming, aligning closely with the initial requirements and specifications.
Figure 4 2 State diagram in main function
The main function serves as the primary control mode of the system, consisting of four key components: Stop, Manual, Auto, and Alarm This setup features multiple buttons that allow for seamless switching between these modes.
Figure 4 1 Interpolation algorithms of X,Y,Z, axis
97 between modes together as well as change the screen mode on the HMI to make it easier for the operator
Upon entering the Main function, the system defaults to Stop mode until the manual or auto button is activated Users can seamlessly switch between manual and auto modes using the respective buttons If an error occurs in either mode, the system automatically transitions to alarm mode to address the issue Operations can only resume once the fault is rectified, reverting back to Stop mode Additionally, in Auto mode, an emergency stop button is available; when pressed, it immediately disconnects the devices, which will only resume operation after the reset button is pressed and the error is corrected.
Figure 4 3 State diagram of Stop mode
Stop mode is when the servo and all devices in the system are in the OFF state
Figure 4 4 State diagram in manual mode
In manual mode, the operator has the flexibility to test axes and devices by inputting specific speed and velocity settings to operate in the preferred mode Conversely, in auto mode, the system automatically manages these parameters for optimal performance.
In the automode state diagram, the initial step involves determining the home position for the system Once the home position is successfully established, the system will operate automatically, moving the jar to the turntable, which rotates at a speed of 2000 degrees per minute If the jar remains on the turntable for over 12 seconds without the cam receiving it, the system will classify the item as faulty; otherwise, it will proceed to the classification program.
Figure 4 6 State diagram in sub function classify
In Classify mode, the system captures the barcode and characters to convert them into binary code, which is then utilized to compare different products.
Figure 4 7 State diagram in sub function Berberin, Vitamin,VITAMIN
In this mode, each subroutine sequentially places items at specified coordinates while simultaneously tracking time during the potion sorting programs.
Figure 4 8 State diagram sub function error
In auto mode, if the camera remains undetected after the designated time has passed, the error mode will systematically organize the error positions into their pre-established locations in a sequential manner.
Figure 4 9 State diagram sub function alarm mode
The alarm mode activates when a servo axis encounters an error, requiring the operator to address the issue and reset the program before returning to stop mode Additionally, error notifications will be displayed as warnings in alarm mode, allowing the operator to identify the frequency of errors for timely corrections.
Figure 4 10 State diagram sub function emergency
System program installation software
The engineering software GX Works2 deploys the global mainstream concepts of
"grouping" and "structuring" for fundamental improvement of programming efficiency The world-standard engineering style begins with GX Works2 Here are some characteristics:
The all-in-one GX Works2 package consolidates all essential capabilities for PLC engineering, including intelligent function module configuration and simulation functions This comprehensive solution supports the entire engineering process, encompassing system design, programming, debugging, and maintenance.
Make full use of MELSEC PLC modules: GX Works2 enables full use of high- function and high-performance CPUs and modules
Inherits customer assets: Existing GX Developer program assets can be used in GX
GX Works2 allows for seamless integration, enabling programs written for programmable controllers to be read using GX Developer This means that data created with GX Developer on a production site’s PC can also be utilized with GX Works2 on a development office’s PC, ensuring compatibility and flexibility across different environments.
GX Works2 has integrated advanced functions from GX Developer, enhancing operability and performance for smoother, more responsive user experiences Compliant with the international standard IEC 61131-3, GX Works2 supports structured programming with grouped components and allows the use of multiple programming languages, including SFC, ST, and ladder logic, within a single application This continuous improvement in operability aims to meet diverse customer applications effectively.
Create a new workspace and declare the CPU:
Figure 4 12 Configuration of Gx works2
Go to Parameter PLC Parameter I/O Assignment to
Declare the modules included in the project as: QD75MH4, QJ61BT11N, QY41P, QX80 with points each module is 32 points
CC-link connection between QJ61BT11N modules and Bled6C-CC Driver:
To establish a connection, navigate to the Network Parameter and select the CC-Link folder Specify the number of connected modules, along with the locations for remote inputs, outputs, and registers, as well as any special relays and registers.
Figure 4 14 Declare to connect CC-link
Then we declare the station for driver BLED6CC-C: CC-Link Configuration Setting, and select intelligent device station for driver BLED6CC-C and master station for CPU
Figure 4 15 Choose Station for CC link module
Basic parameters to control the speed of the motor after connecting to the PLC
Figure 4 16 Manual terminal name of CC-link
To control the conveyor to rotate forward or backward, we need to set X based on the remote input we declared in the CC-Link module and driver setup section
Figure 4 17 Information default of BLE series
With the BLE series, we have speed setting range and default time acceleration when deceleration is 300r/min and setting range is 0.2s
Connect and declare the parameters of Modules QD75MH4 and Mitsubishi Servo Drivers:
Select PLC Parameter Intelligent function module QD75MH4.Parameter:
In GX Works2 supports a lot of parameters to help users easily control, in this project we need to pay attention to a few parameters such as:
Unit, number of pulses required for 1 rotation, Movement amount per rotation, Speed limit value, Software stroke limit and Jog speed value
With the parameter set home, we need to set the following parameters: OPR direction, OPR speed, Creep speed, OPR retry
The OPR direction indicates the path the servo will take when returning to the home signal Speed refers to how quickly the motor moves back to this home position, while creep speed is the reduced speed at which the servo stops after making contact with the dog The OPR retry mode is activated when the servo attempts to locate the dog again after hitting the limit switch.
Figure 4 19 Confit OPR basic parameters
Servo Parameters: Servo's Series declaration is MR-J3B and Force stop changes to Invalid
Figure 4 20 Confit Servo amplifier series
Position Axis Data: Here are a few ways to call data used in the project
Operation pattern: there are 3 modes End, Cont, Location
End mode is the end of data, Cont will start data and run continuously until there is data end, then data will end
Control system: there are many modes, in this project we use data with INC and ABS modes with the ability to control 1 and 2 axes
Positioning address: the position where the desired axes travel at the speed entered in Command speed
Dwell time: is the delay time between data
Figure 4 21 Data Axis1 in project
To effectively call data and store values in a register for desired position and speed, refer to the specified memory areas in the manual For axis 1, the memory range is from 2000 to 7999; for axis 2, it spans from 8000 to 13999; and for axis 3, the designated range continues accordingly.
Figure 4 22 Positioning data in axis 1
To effectively monitor servo positions and operational errors, it is essential to declare register values that will store this information These values can then be utilized for display on the screen, facilitating easy observation and correction of any errors encountered during operation.
Figure 4 23 The data of the buffer memory
To reset error we need to do the following:
Figure 4 24 The data of buffer memory for reser error
GT Designer3 is a powerful software tool designed for creating screens for the GOT2000 series, included in the comprehensive "GT Works3" software package by Mitsubishi Electric This software simplifies the screen design process for HMIs, offering useful functions that facilitate the creation of well-organized screens with ease.
The GT Designer3 interface is organized by function, allowing for quick identification of target items For comprehensive information on each function, please consult the GT Designer3 (GOT2000) Screen Design Manual.
Figure 4 26 Introduce task bar in GT Designer3
You will place switches, lamps, numerical displays, or other parts on the screen design area in GT Designer3 Such screen parts are referred to as "objects"
Figure 4 27 Setting lamp in GT Designer 3
In a project, the settings are categorized under the "Project," "System," or "Screen" tabs By switching between these tabs, you can easily locate specific setting items, streamlining the process of finding your desired configuration.
Figure 4 28 Window of Project, Screen, System
Easily choose your preferred screen design from various options, which can be applied to all displays, including base, window, and mobile screens This streamlines the process by eliminating the need to configure settings for each individual screen Additionally, you can adjust the gradation to enhance the stylish appearance of your screens.
Figure 4 29 Type of screen in GT Designer3
To place an object, simply select it and click anywhere in the design area For advanced configuration, double-click the object to access the settings dialog, where you can check the status of the lamp, switch, or other elements through the displayed image.
Figure 4 30 Setting bit switch in GT Designer3
Design the HMI screen in the project:
To enhance security and prevent unauthorized access, we will implement a security window in the interface This step is crucial for ensuring that users fully understand the machine's functionality before interacting with it.
After declaring the buttons and the number bar to enter the password with the memory area of gd300, we set up the login button as follows:
Figure 4 33 Confit script in login button
In the Script section, select "Use Object Script" for the button's own script and choose the User ID associated with it Activate the trigger type and align the memory area with that of the m4400 button Next, input the script for the button to fulfill specific requirements, where gd100 represents the page-turning device, GD101 indicates the current page memory, and GD300 is designated for the password Entering the password "123" will deactivate the current page and set pass to 0 Additionally, configure the Cancel button accordingly.
Figure 4 34 Confit scipt in cancel button
To disable page transitions, set the command line parameter GD101=0 in the Script section Once the first button is configured, simply invoke the push button using the designated memory area.
GD 101 to switch pages and add it to Base green to set up security, at the setting value we choose the value = 1:
Figure 4 35 Creat button for switching screen
Figure 4 36 Firt Screen in HMI project
EXPERIMENT RESULTS, COMMENT AND EVALUATION
RESULT
Figure 5 1 Pick,place and arrange product in to the correct position
1 The control system meets the following requirements:
Run Jog and run Data to the standby position
The XYZ-axes system automatically returns to the standby position if the object processing is completed to continue the next process
The conveyor runs with CC-Link network, while the speed can be set independently
Press EMC to turn off entire system
2 The system operates smoothly and stably
3 The camera can scan objects in the frame at a moderate speed and can't scan defective products
4 The group aligned the right distance and speed to get the object onto the turntable from the conveyor
5 The medicine bottles are arranged in the positions in the box
6 The SoftGOT display actives well, which contains all simple information for regulation users
7 When completely build the project, the number of products random direction sorted in the packet is 11 products
Figure 5 2 Complete arrange bottles in the box
COMMENT AND EVALUATION
After a period of researching, designing and programming the operating supervision for the model, our team has collected predetermined results The model has the following advantages and disadvantages:
Control up to 4 servo motors, can run all three axes interpolation
Camera works stably, no interference
The axes work stably, the medicine bottles are properly dropped into the boxes
Flexible model can run many different modes
The mechanical details also have a little deviation leading to the operation not reaching 100% accuracy However, small errors can be ignored
The camera's hardware limitations restrict its effective range to objects positioned at least 40cm away, resulting in a small active area Additionally, the camera's processing power hinders its ability to quickly capture images, impacting overall performance.
Items must be spaced 10 cm apart on the conveyor to reach the correct magnet position
Limited z-axis distance from smoking the bottle and putting it on the turntable
Operating speed is not high
The distance to recognize the object of the limit and dog sensors is quite small Limit in this project:
+The distance of the each bottle on the conveyor must be more than 2 cm for sensor to detect
+The distance for camera Cognex to recognize objects must be more than 40 cm
+The speed of the rotary table must be smaller than 6 rpm for camera to handle
+The barcode of vitamin bottle type 1 is sometimes missed by the camera
CONCLUSION AND RECOMMENDATIONS
CONCLUSION
The team has successfully achieved its initial goals by developing a fast and stable control algorithm for the model, which can be applied to various fields, including product classification by codes and other industrial challenges While some limitations related to the mechanical structure remain, the team has worked diligently to minimize these issues.
The team gained a thorough understanding of servo motor operating principles and position control theory, while also deepening their knowledge of Encoder theory They learned to communicate effectively between modern devices, including the COGNEX camera, QD75MH4 position control module, and CC-Link module with PLC Additionally, during the construction of mechanical models, the team acquired essential skills such as reading mechanical drawings and processing metal.
The hardware features a robust aluminum construction, ensuring durability under high-frequency operations Its design allows for easy disassembly, prioritizing operator safety, while also minimizing the impact of external factors on system performance.
The SoftGOT display system is user-friendly and fully programmed, allowing operators to easily monitor the system's operational status It effectively displays speed and location parameters, enhancing convenience in monitoring.
RECOMMENDATIONS
Enhance the mechanical structure to increase the accuracy of the model
Can change other types of code such as QR code, Matrix code, PDF417 code, etc to increase the processing range of barcode types
Can change to more advanced image processor to increase responsiveness when moving objects at high speed, reducing response time
Towards product classification with the application of speed synchronization between the pick-and-drop mechanism and the conveyor, so that objects can be
141 caught from the conveyor without stopping to increase the working efficiency of the model
It is possible to use motors with larger capacity and change the sliders accordingly to increase the load capacity
[2] https://www.manualslib.com/products/Cognex-In-Sight-5110-8986527.html
[3] https://shop.sapo.vn/cac-loai-ma-vach-thong-dung
[4] http://www.omonr.com/download/OMRON-EE-SX674A Manual-EE-
`[5] https://www.relianceprecision.com.au/absolute-encodersmultiturn
[6] https://www.mitsubishielectric.com/app/fa/download/search.do?mode=manua l&kisyu=/plcq
[7] https://support.cognex.com/en/downloads/in-sight/software-firmware
[8] https://www.mitsubishielectric.com/fa/assist/e-learning/pdf/eng/2-
GTW3_GTD3_Basics_Screen_Design_Introduction_na_eng.pdf
[9] http://dl.mitsubishielectric.com/dl/fa/document/manual/servo/sh030113/sh030
[10] https://www.azbil.com/products/factory/download/catalog-spec/APM.pdf
[11] https://dl.mitsubishielectric.com/dl/fa/document/manual/plc/sh080016/sh0800
[12] https:/online.com/m/d/a53ecc792bcb54c8710cf1134a1211ed.pdf
[13] https://dl.mitsubishielectric.com/dl/fa/document/manual/plc/sh080042/sh0800
[14] https://www.orientalmotor.com/products/pdfs/opmanuals/HM-5109-3E.pdf
[15] https://catalog.orientalmotor.com/item/es-shop-online-components-speed- control-components/speed-control-motors/blem46m2-gfs-gfs4g200
YE JOG Forward Axis Rotate
YF JOG Reverse Axis Rotate
M15,M16,M17,M18 INC MANUANAL MODE AXIS X,Y,Z,ROTATE
M1923,M21M22,1924 INC MANUAL MODE AXIS X,Y,Z,ROTATE
U0\G2004,…, U0\G2214 ADDRESS FOR INPUT SPEED DATA
0,…,DATA 22 IN THE X AXIS U0\G2006, , U0\G2216 ADDRESS FOR INPUT POSITION DATA
0,…,DATA 22 U0\G8004,…, U0\G8214 ADDRESS FOR INPUT SPEED DATA
0,…,DATA 22 IN THE Y AXIS U0\G8006,…, U0\G8216 ADDRESS FOR INPUT POSITION DATA
0,…,DATA 22 IN THE Y AXIS U0\G14004,…, U0\G14214 ADDRESS FOR INPUT SPEED DATA
0,…,DATA 22 IN THE Z AXIS U0\G14006,…, U0\G14216 ADDRESS FOR INPUT POSITION DATA
0,…,DATA 22 IN THE Z AXIS U0\G20004,…, U0\G20214 ADDRESS FOR INPUT SPEED DATA
0,…,DATA 22 IN THE ROTATE AXIS U0\G20006,…, U0\G20216 ADDRESS FOR INPUT SPEED DATA
0,…,DATA 22 IN THE ROTATE AXIS U0\G1502, U0\G1602, U0\G10702,
U0\G1802 ADDRESS FOR RESET ERROR SERVO
The camera captures and stores the area memory of barcode data from D1016 to D1021 Additionally, it records the location memory of the characters "VITAMIN" from D1024 to D1027, and the characters "Berberin" from D1028 to D1031 and D1037 Furthermore, the camera also retains the location memory for the characters "Vitamin" from D1032 to D1036.
D308,D10000,D10004,D10008,D10012 The location memory for the total number of 3 type bottles