---GRADUATION PROJECT SCHEDULEStudent's Name: DO MANH HUNG Class: 19H40301 MSSV: 41900405 Title of the topic: The product sorting system using gantry robot 1 Receive the topic and identi
OVERVIEW OF TOPIC
Introduction to the topic
Modern healthcare grapples with critical challenges in pharmaceutical inventory management, such as human error, increased time and labor requirements, and heightened complexity due to facility expansion These challenges result in resource wastage, diminished efficiency, and obstacles in ensuring accuracy.
In 2023, the Ministry of Health revealed that 15% of medications expire each year, leading to significant financial losses Bach Mai Hospital discards 10% of its drugs annually due to damage or expiration, while Cho Ray Hospital faces drug shortages that delay treatment for 8% of patients, adversely affecting their health Additionally, the World Health Organization estimates that 50% of medication errors are attributed to human factors, and 30% of stored drugs remain underutilized.
Implementing intelligent management systems (IMS), barcode systems, and automated storage and retrieval systems (AS/RS) effectively addresses inventory challenges by enhancing control, reducing errors, and increasing efficiency Additionally, the integration of robotics in drug management further automates processes, minimizes human errors, and ensures accurate storage and handling.
This approach saves time, reduces costs, and improves healthcare quality,benefiting both patients and medical staff while optimizing resources and enhancing treatment outcomes.
Statement of the problem
Developing a robot system with flexible operational capabilities is essential for efficient drug distribution tailored to specific usage needs This system must be designed to accommodate various drug sizes while ensuring compliance with user requirements, ultimately optimizing work performance and enhancing overall efficiency.
Design product sorting system using gantry robot Executor : Do Manh Hung
Objectives of the Thesis
The objective of the thesis is to research, design and complete a robot model capable of handling goods with the main functions including:
Control and monitor operations via HMI interface.
Scopes of the Thesis
In this project, I aim to design a scaled down model of real industrial systems.
My model is designed with a reduced drug storage capacity and robot payload, making it ideal for small and medium-sized applications This focus on a low-cost solution does not compromise the accuracy and reliability of the system Ultimately, I aim to advance robotic technology in this field.
Research methods
I am conducting research on robot storage systems through the following methods:
Collecting and analyzing scientific articles, reports, and specialized books from reputable sources such as IEEE Xplore, ScienceDirect, and SpringerLink.
Studying manuals from leading manufacturers to understand the features, operating principles, and programming of robots.
Surveying robot storage systems currently used in industrial environments to observe actual operating methods and control applications.
Using controllers to improve the performance and flexibility of the system and designing new control programs when needed based on the results of research and surveys.
THEORETICAL BASIS
Types of pharmaceutical storage facilities
Cold storage is a specialized environment designed to store perishable items, pharmaceuticals, and other sensitive products under tightly controlled low temperature conditions.
Key features of cold storage include:
Temperature control: Maintains a stable temperature between 2-8°C.
Applications: Suitable for storing vaccines, antibiotics, insulin, and other biological products.
Figure 2-1: Cold Storage for Pharmaceutical Preservation
Conventional storage generally refers to standard storage solutions used for everyday storage needs Here are some of the key features of this method:
Applications: Suitable for storing most tablets, capsules, syrups, ointments and products that do not require special storage conditions.
Ease of implementation: Conventional storage requires minimal infrastructure and is compatible with standard storage equipment, making it a practical choice for many facilities.
Design product sorting system using gantry robot Executor : Do Manh Hung
Figure 2-2: Regular Storage for Pharmaceuticals
Dry storage is a dedicated space or area for storing goods and items in dry conditions Some of the main features of this type of storage include:
Humidity control: The ambient humidity is usually maintained below 60%.
Application: Suitable for storing pharmaceuticals that are susceptible to damage or loss of effectiveness when exposed to high humidity.
Secure storage ensures maximum protection for valuable items, featuring access control, surveillance, and professional security It is ideal for storing high-value pharmaceuticals, narcotics, and psychotropic drugs.
Storage by dosage form pertains to the tailored guidelines and procedures for preserving pharmaceutical products according to their specific dosage types Key categories include:
Solid forms: Such as tablets, capsules, and powders.
Liquid forms: Including syrups, injectable solutions, and suspensions.
Gaseous forms: Such as aerosols and inhalers.
Methods of medicine management
A manual inventory process involves handling the tracking of goods' inflow and outflow by individuals or small businesses without relying on automated systems or specialized professional services
No need for advanced technology or complex systems.
Prone to human error, such as entering incorrect quantities or information
Easy to apply and operate for small warehouses or when managing small quantities of drugs.
Time consuming and labor intensive, especially when handling large quantities of drugs.
Difficulty in accurately tracking and controlling inventory.
Table 2.1: Advantages and disadvantages of manual inventory processes
Design product sorting system using gantry robot Executor : Do Manh Hung
Enterprise Resource Planning (ERP) is a comprehensive software solution that streamlines and automates essential business functions It encompasses various applications and modules that facilitate key processes, including procurement, manufacturing, finance, human resources, inventory management, and sales.
Figure 2-5: Drug Management Using Software
Manage your entire business process, from procurement and inventory management to sales.
The initial investment and maintenance costs of ERP software are very high.
Minimize errors and improve management efficiency.
ERP systems are complex and require highly skilled personnel to operate. Easily generate reports and analyze data to support decision making.
It takes time to deploy and integrate the system into business operations.
Table 2.2: Advantages and disadvantages of using Pharmaceutical Management Software
Robots used in pharmaceutical import and export operations help improve accuracy and efficiency, reduce errors and optimize processes, although they require appropriate investment and technical training.
Figure 2-6: Robots working in a pharmaceutical storage warehouse
Robots can perform import and export tasks quickly and continuously without rest.
The cost of purchasing and installing an automated robotic system is very expensive.
The ability to operate 24 hours a day, 7 days a week significantly increases import and export productivity.
Robot maintenance and repair require significant costs.
Robots are capable of tracking and managing inventory in detail and accurately, updating information immediately into the management system.
The system may experience technical problems, affecting the import and export process.
Minimize occupational accidents and exposure to hazardous substances, especially in warehouses storing addictive or toxic drugs.
Staff need to be trained to operate and manage the robotic system, which is time consuming and costly.
Table 2.3: Advantages and disadvantages of using Robots for drug management
Design product sorting system using gantry robot Executor : Do Manh Hung
Popular commnunication protocols
Modbus RTU, utilizing the RS-485 connection, is a widely used industrial communication protocol that facilitates direct data transmission between PLCs and step drivers through register read and write commands.
Modbus TCP/IP: A version of Modbus that operates over the Ethernet, providing faster communication speeds and easy integration into large-scale industrial networks.
Ethernet/IP is a standard Ethernet-based industrial protocol popular in automation applications It supports high-speed communication and provides real- time control between PLCs and step drivers.
Profinet is an Ethernet-based industrial communication protocol developed bySiemens This protocol supports real-time communication and is particularly suitable for complex motion control applications with step drivers.
Technological requirements
To enhance system management and monitoring, I implemented an HMI screen that offers a user-friendly interface for controlling equipment and tracking essential details about the location, status, and quantity of goods in the warehouse This implementation boosts management efficiency, optimizes operations, and ensures timely compliance with import and export requirements.
Figure 2-7: Operating system via HMI
Tehnology process
We have crafted a detailed proposal for the technological process that aligns with the evaluated system requirements and operating model This proposal highlights essential stages of system operation, such as hardware integration, software implementation, and workflow optimization, to ensure seamless functionality among all components Additionally, it addresses scalability, efficiency, and adaptability to fulfill both current and future operational needs.
Figure 2-8: The import process for goods
Figure 2-9: The export process for goods
Design product sorting system using gantry robot Executor : Do Manh Hung
HARDWARE DESIGN
Tehnology process
The hardware design process can be divided into five stages as follows:
Step 1: Collect the requirements and necessary technical information.
Step 2: Evaluate the applicable solutions and technologies.
Step 3: Develop the overall system diagram and block diagram and select appropriate materials and equipment to meet the identified technical requirements. Step 4: Test and optimize the design to ensure it fully meets the technical requirements, and perform tests and adjustments to improve performance, reliability and safety.
Step 5: Proceed to assemble and complete the system.
System requirement
Each medicine box is barcoded to contain product information, making management easier.
The robot must function autonomously and adaptively across all axes in various scenarios, demonstrating the ability to handle specified loads Additionally, it is essential for the robot to precisely follow commands issued by the operator.
Robots must efficiently and accurately automate the picking and placement of prescriptions into storage, handling multiple orders from various suppliers simultaneously They are required to multitask and operate continuously without interruptions, remaining unaffected by fatigue or lapses in concentration.
Mechanical design
I designed a medicine box using Formex paper, tailored to specific drug sizes and budget constraints for system implementation The box features eight compartments of varying sizes to accommodate different medications effectively.
7 compartments for classifying drugs of 15x15 mm.
1 compartment for issuing prescriptions of 15x15 mm
This design helps to organize and store medicines of different sizes neatly and efficiently.
Figure 3-1: 2D Drawing of the Pill Container
Figure 3-2: 3D Drawing of the Pill Container
Design product sorting system using gantry robot Executor : Do Manh Hung
DC motors offer a versatile and economical solution for conveyor systems, making them a popular choice in production lines and warehouses Their straightforward design, coupled with high efficiency and reliability, ensures effective material transportation while also simplifying maintenance tasks.
DC motors are a suitable solution to power conveyors without requiring a large investment Therefore, our team decided to use DC motors for conveyor systems.
In industrial applications, there are many types of robots used for warehouse storage Below, I will present some advantages and disadvantages of current industrial robots.
Types of Robots Advantages Disvantages
SCARA SCARA robots are highly efficient, making them perfect for rapid assembly and sorting operations.
SCARA robots are typically not ideal for tasks that involve covering large areas or managing extensive
The 4-axis design of SCARA is well-suited for working in limited spaces. inventory.
Because of their design, SCARA robots may not provide high accuracy when picking and placing items.
Delta SCARA robots’ function at very high speeds, ensuring excellent productivity.
The robot’s straightforward design makes it easy to maintain.
The robot's reach is restricted by the length of its arms.
Delta robots are mounted at a fixed height, limiting flexibility in installation options.
Gantry Gantry robots can cover a wide area, making them ideal for automation systems that involve transporting and storing goods across large spaces.
Featuring a sturdy frame and precise control system, Gantry robots offer excellent accuracy in picking and placing objects, ensuring correct positioning without
Gantry robots often require a higher initial investment, particularly for operations involving large-area coverage.
They are not ideal for tasks that require flexible assembly processes.
Design product sorting system using gantry robot Executor : Do Manh Hung mistakes.
Table 3.1: Analyzing the advantages and disadvantages of different types of robots
After careful analysis, the Gantry Robot emerged as the best choice for medicine box storage, thanks to its extensive mobility, exceptional precision, and efficiency in maximizing storage space.
With the medicine box design, model scale, and cost considerations, I selected the 3- axis XYZ Gantry Robot to implement the project. b) Motor selection
In designing a drug storage system, ensuring accuracy and responsiveness is crucial for effective inventory management To achieve this, I opted for a stepper motor to drive the robotic system, as these motors are favored for their stability and responsiveness This choice aligns with the stringent standards of healthcare environments, guaranteeing high levels of accuracy and reliability.
The flexible nature of the stepper motor allows precise control of the robot's position and speed, which is important for safe and efficient handling of drug boxes.
In addition, stepper motors are durable and reliable, minimizing disruptions in critical applications such as pharmaceutical storage, where efficiency and accuracy are paramount. c) Proposed motion method
In industry, there are many transmission methods applied Below, I will present some advantages and disadvantages of common transmission methods that the group has analyzed.
Rack and Pinion - Easily adjustable transmission ratios enable precise control of the robot's movement speed.
- Offers high durability with minimal maintenance
- The accuracy is relatively lower compared to alternative methods.
- Operation can result in higher noise levels. needs.
- Provides consistent and reliable accuracy.
Worm gear and Belt - Allows for simple adjustment of the transmission ratio with minimal noise.
- Offers excellent durability and a long service life.
- Provides consistent accuracy over time.
- Accuracy can be compromised if the belt loosens or stretches.
- Ongoing maintenance and adjustments are necessary to ensure optimal performance.
Lead Screw - Offers high accuracy, making it ideal for precision tasks like pick and place.
- Provides strong transmission force and excellent load-bearing capacity.
- The transmission ratio is fixed and cannot be adjusted like rack and pinion or belts.
- Regular lubrication is needed to maintain the performance and extend the lifespan of the acme screw.
Table 3.2: Analyzing the advantages and disadvantages of drive methods e) Proposing abasic layout for the robot
The robot's robust frame is constructed with aluminum profiles, ensuring enhanced rigidity and stability It features a three-axis XYZ motion system that incorporates stepper motors and linear guides for smooth and precise movement To achieve optimal performance, the drive system utilizes high-performance stepper motors.
Design product sorting system using gantry robot Executor : Do Manh Hung torque and speed, providing accuracy, repeatability and the ability to handle large loads at high speeds.
Figure 3-4: Basic layout for the Gantry Robot
1 The motor for the X- axis
2 The motor for the Y- axis
3 The motor for the Z- axis
5 Lead nut 10 Pillow block bearing
The layout design includes three axes for the robot's movement: the X-axis enables horizontal movements, measuring 600mm to accommodate the size of the medicine boxes and ensure operational accuracy The Y-axis facilitates vertical movements, also designed at 600mm for precise handling of the boxes Finally, the Z-axis supports height adjustments with a length of 250mm, ensuring high-precision operations during the handling of medicine boxes.
Electrical design
When choosing robotic equipment, it's crucial to consider key criteria such as performance, flexibility, and safety The equipment should ensure stable operation, accommodate various tasks, and be compatible with other robot components Additionally, its size must align with the robot's overall design and the available workspace Finally, cost-effectiveness is essential to maintain a balance between usability, value, and quality By adhering to these criteria, we can select the most suitable equipment for robotic applications.
3.4.2 Device Selection a) CHiNT NXB-63 Circuit Breaker
To protect the model from faults such as overload or short circuit, I decided to use CHiNT NXB-63 Circuit Breaker as the main circuit breaker for the system.
Design product sorting system using gantry robot Executor : Do Manh Hung
Ensures a high degree of safety.
Offers outstanding durability and an extended lifespan.
Designed to handle heavy electrical loads effectively.
Operates without the need for an external power source.
Simple to install and operate.
Accuracy may be limited in specific scenarios.
Larger in size compared to alternative models.
Suitable for power distribution networks.
Well-suited for backup power systems.
Commonly used in R&D for electrical protection solutions. b) 24V honeycomb power supply
I use 24V honeycomb power supply with 24VDC output to supply power to the devices in the system.
Input voltage range: AC110/220VAC ± 15%
Weight: 420g c) TB6600 Stepper Motor Driver Circuit
After evaluating multiple options in line with our controller selection plan, we chose the TB6600 stepper motor driver circuit This decision was based on a careful assessment of the performance requirements and the driver's compatibility with our system.
The TB6600 stepper motor driver is renowned for its reliable and robust design, making it ideal for applications requiring precise motor control It offers a versatile range of input voltages and current settings, allowing for tailored configurations to suit specific operational needs With advanced features like micro-stepping capabilities and built-in overcurrent and overheat protection, the TB6600 ensures smooth, efficient motor performance while protecting the system from potential damage.
By selecting the TB6600, we aim to achieve high levels of accuracy and stability
The design of a product sorting system utilizing a gantry robot, overseen by Do Manh Hung, focuses on essential motor control for optimal robotic performance This selection meets our project's technical specifications while ensuring a cost-effective and dependable solution for sustained operation.
Figure 3-7: TB6600 Stepper Motor Driver Circuit
Input has optical isolation, high speed.
Built-in over-current and over-voltage measurement.
Dimensions: 96 * 71 * 37mm. e) Roller Limit Switch
I decided to use roller limit switches to determine the initial position for the XYZ axes.
Figure 3-8: Roller Limit Switch f) PLC S7-1200 1214c DC/DC/DC controller
I have chosen the PLC S7-1200 1214c DC/DC/DC central controller to perform the main processing task.
Figure 3-9: PLC S7-1200 1214c DC/DC/DC controller
The CPU 1214C acts as the central component of the system, overseeing program execution and data management.
Includes integrated memory for storing user programs and temporary data.
Delivers high-speed processing to efficiently manage complex automation tasks.
Digital Inputs/Outputs (DI/DO): Compatible with diverse sensors and
Design product sorting system using gantry robot Executor : Do Manh Hung actuators, making it suitable for a variety of automation applications.
Analog Inputs/Outputs (AI/AO): Ensures precise control for tasks involving analog signal processing.
Comes with built-in PROFINET ports for Ethernet-based communication.
Supports integration with HMIs, SCADA systems, and other industrial networks.
Can be expanded with additional communication modules to enhance connectivity.
Works seamlessly with TIA Portal (Totally Integrated Automation) software for efficient programming.
Offers support for various programming languages, such as Ladder Logic (LAD), Function Block Diagram (FBD), and Structured Text (ST), catering to different user needs.
Designed to support additional signal modules, communication modules, and other extensions to meet specific project requirements.
Suitable for both basic and advanced automation systems.
Includes built-in diagnostic capabilities for real-time system monitoring and fault detection.
Provides instant feedback on system performance, enabling quick troubleshooting and maintenance.
Its compact size allows for easy installation in control panels with space constraints.
Engineered to endure tough industrial environments, ensuring consistent and reliable operation.
Widely utilized in small to medium-scale industries for various automation systems
Figure 3-10: Datasheet PLC g) WEINTEK HMI Display
To enhance the robot's operational and monitoring efficiency, I incorporated a WEINTEK HMI into the system Its sleek, compact design and responsive touch screen facilitate swift interactions, offering a superior user experience This user-friendly interface allows operators to easily manage control and monitoring tasks, significantly improving overall functionality.
Design product sorting system using gantry robot Executor : Do Manh Hung
Display: Features a 7-inch TFT LCD with an 800 x 480-pixel resolution.
Communication Ports: Supports RS232, RS485, Ethernet, and USB interfaces.
Operating System: Runs on Windows CE 6.0 and is compatible with widely used HMI software.
Brightness and Contrast: Offers 400 cd/m² brightness with a 500:1 contrast ratio.
Ethernet Connectivity: Enables seamless communication over a network.
Expandability: Allows control of devices through connection modules.
Water and Dust Protection: Rated IP65, making it ideal for industrial settings.
Responsive Touchscreen: Supports multi-touch functionality for smooth operation.
Advanced Communication Protocols: Works with Modbus and OPC standards.
Rugged Design: Engineered for durability in demanding environments.
Ease of Use: Features intuitive programming tools for user-friendly interaction.
Reliable Performance: Delivers fast and stable processing speeds.
Monitoring and Control Systems: Ideal for managing production lines and industrial equipment.
Manufacturing Facilities: Facilitates monitoring and control of production operations.
HVAC Systems: Used to regulate temperature and humidity in environmental control systems. h) Proximity sensor E3F-DS30C4 NPN
I chose the E3F-DS30C4 NPN proximity sensor to detect the medicine box.
Figure 3-12: Proximity sensor E3F-DS30C4 NPN
SPECIFICATIONS OF INFRARED OBSTACLE SENSOR E3F-DS30C4
Outer diameter size: 18mm (mm) Detection: infrared obstacle
Working voltage: DC 6-36VDC NPN output i) DC Mini Conveyor
Based on the plan for choosing the motor, I decided to use a DC motor to control the conveyor.
The technical specifications of the relay:
Maximum switching voltage: 250 Vac; 125 Vdc
Design product sorting system using gantry robot Executor : Do Manh Hung l) Lead Screw T8 Thread Pitch 2mm
Figure 3-14: Lead Screw T8 m) YHD 1100D Barcode Scanner
To ensure accurate product identification and storage, I chose the YHD 1100D barcode scanner.
Figure 3-15: YHD 1100D Barcode Scanner n) Switch Ethernet TL-SF1005D
I chose Ethernet Switch TL-SF1005D to split Ethernet ports for HMI, PLC, and barcode scanner.
Figure 3-16: Switch Ethernet TP-Link LS1005Advantages:
Quick and hassle-free installation without requiring configuration.
Reliable data transmission speed, perfectly suited for automation applications.
Energy-efficient design ensures cost-effective performance.
Space-saving compact structure, ideal for installation in confined areas.
Facilitates seamless connectivity between barcode scanners, HMIs, and PLCs in industrial control and monitoring systems, ensuring synchronized and efficient device functionality. o) Module S7-1200, Digital I/O SM 1223 8DI/8DO
I selected the S7-1200 Module with the Digital I/O SM 1223 (8DI/8DO) to enhance the system's input and output capabilities This module offers 8 digital input and 8 digital output ports, providing flexibility for connecting various sensors, actuators, and peripheral devices Its compact design and smooth integration with the S7-1200 PLC ensure reliable performance and efficient communication, making it a perfect choice for improving system functionality and scalability.
Design product sorting system using gantry robot Executor : Do Manh Hung
Figure 3-17: Module S7-1200, Digital I/O SM 1223 8DI/8DO p) Step motor
A stepper motor functions by advancing in precise, incremental steps, allowing for accurate control of position and direction Typically, these motors have common step angles of 1.8° or 0.9°, which equate to 200 or 400 steps for a full rotation.
When current passes through the stator coils of a stepper motor, it generates a magnetic field that interacts with the rotor, resulting in its rotation The rotor's speed and direction are determined by the sequence and phase of the current supplied to the coils Stepper motors can be designed with unipolar or bipolar coils, each necessitating distinct control methods.
Stator: Contains coils that produce a magnetic field when energized.
Rotor: Typically constructed from permanent magnets or magnetic materials.
Shaft: Transfers mechanical motion to connected components.
When electric current passes through the stator coils, it creates a magnetic field that interacts with the rotor, resulting in its rotation in distinct steps The direction of rotation is dictated by the sequence in which the coils are energized, allowing for control over the rotor's movement By changing the energizing pattern, the rotor can be directed to turn either clockwise or counterclockwise.
Accurate Positioning: Stepper motors provide precise motion control without requiring encoders.
Smooth Operation: Deliver stable movement with minimal vibrations, especially at low speeds.
Simple Control: Compatible with drivers like the TB6600 for adjusting speed, current, and microstepping.
Durable and Reliable: Brushless design ensures a longer lifespan and reduces maintenance needs.
Automation Systems: Widely used in robotics, 3D printers, and CNC machinery.
Medical Equipment: Ensures precision in devices such as scanners and surgical tools.
Industrial Use: Commonly employed in conveyor belts, packaging systems,and measurement devices.
Design product sorting system using gantry robot Executor : Do Manh Hung
SOFTWARE DESIGN
Software Design Process
The software design process consists of 7 stages as follows:
Stage 4: Design the user interface (HMI)
Stage 6: Implement and maintain the system
Stage 7: Evaluate and improve the system
Design requirements
The development of PLC programs is crucial for the effective operation of drug storage systems utilizing PLC-controlled gantry robots These programs must be carefully designed to ensure precise control of gantry robot movements, efficient management of drug storage and retrieval, real-time inventory monitoring, and adherence to safety standards throughout the operation.
The HMI must feature a user-friendly interface that displays critical information, including system operating status, medication storage details, alerts, and safety-related data Additionally, it is essential to adhere to information security and safety standards by implementing robust data protection and access management solutions.
PLC control programming
I have developed a program diagram for a storage system utilizing gantry robots, tailored to meet specific design requirements This program is optimized to ensure high performance and stable operation of the storage system.
The robot needs to be supplied with a stable 220V power supply to ensure continuous, reliable operation and avoid interruptions due to power failures.
For optimal robot performance, it is crucial to maintain a stable and error-free connection between the Programmable Logic Controller (PLC) and the inverter, ensuring that the robot receives precise instructions for task execution.
A stable connection must be maintained between the Human Machine Interface (HMI) screen and the robot to ensure effective communication, allowing the operator to monitor and control the robot smoothly.
Accurate determination of a robot's initial position is crucial for operational precision, as this reference point underpins all future movements and tasks.
Design product sorting system using gantry robot Executor : Do Manh Hung
To ensure seamless integration, precise task execution, and enhanced reliability of the gantry robot, I have established operating principles grounded in the system software requirements These principles outline the robot's command processing, data analysis from sensors, decision-making capabilities, and efficient movement coordination.
I have created a comprehensive algorithm diagram that illustrates the software's logical flow, detailing how it processes commands from the interface (HMI or PLC) to execute tasks and provide feedback By following these principles and utilizing the algorithm diagram, we can achieve optimal performance within the system's constraints, while also enhancing scalability and maintainability.
My goal is to deliver a robust, efficient gantry robot solution that fully meets operational requirements and exceeds expectations.
Figure 4-2: Flowchart of the Import function
The system operates according to the following principles:
When the "Input Mode" button on the HMI screen is pressed, the robot will automatically move to the waiting position to receive the medicine.
The medicine boxes are transported on the conveyor belt in the specified direction.
When the medicine box passes through the barcode scanner, the information about the medicine type will be transmitted to the PLC for processing.
When the medicine boxes reach the sensor location, the robot will perform the task of picking them up and placing them into the designated containers.
The number of medicines will be updated after each robot loading cycle.
When additional medicine boxes are loaded, the robot will operate continuously; if not, it will automatically return to its waiting position to prepare for the next batch.
I have established a drug output process similar to the drug import mode, illustrated by the accompanying algorithm diagram This diagram clearly outlines the sequential steps in the drug output process, which include retrieving data from the storage system, verifying information against inventory records, and executing distribution to ensure accurate order fulfillment.
By implementing a systematic approach, I enhance the efficiency and accuracy of drug output processing while reducing errors and delays This method ensures consistency and reliability within the pharmaceutical system, even during peak demand periods.
An organized approach significantly improves operational efficiency and minimizes waste while ensuring compliance with regulatory standards and quality assurance protocols like Good Distribution Practice (GDP) This method also enhances traceability and transparency, allowing for the seamless tracking of drug movements within the system, which is essential for upholding trust and accountability in pharmaceutical operations.
Design product sorting system using gantry robot Executor : Do Manh Hung
Figure 4-3: Flowchart of the Export function
The system operates based on the following principle:
When the "Export" button on the HMI screen is pressed, the robot will automatically return to the standby position to prepare for drug export.
After the order is received, the robot will move to the designated container, pick up the required drugs and transport them to the delivery location.
The order processing is carried out under the direction of the staff.
After each delivery is completed, the quantity of drugs in stock will be updated.
The robot efficiently executes shipping tasks when given consecutive commands and will return to standby mode once all tasks are completed, remaining ready to operate upon receiving new instructions.
Manual operation mode, commonly known as manual mode, is essential in various automation systems, acting as a dependable backup and support mechanism This feature serves two primary purposes.
Quality assurance is crucial, as automated systems can sometimes fall short of achieving the desired quality due to unforeseen deviations or limitations By incorporating manual mode, operators can directly intervene to inspect, adjust, and uphold quality standards This human oversight guarantees that high-quality standards are consistently maintained, even in challenging situations.
In rare or complex scenarios that surpass the automated system's capabilities—such as unique customer needs, system failures, or unexpected environmental challenges—manual intervention becomes essential Operators can quickly step in to analyze and resolve these issues, ensuring effective and accurate responses that minimize downtime and prevent potential losses.
Additionally, manual mode serves as a valuable tool during system commissioning,
The design of a product sorting system utilizing a gantry robot, developed by Do Manh Hung, incorporates a manual mode for maintenance and troubleshooting This feature enables technicians to independently test individual components and processes, ensuring operations can proceed seamlessly during automation failures The dual functionality of the manual mode significantly enhances the system's flexibility, reliability, and robustness.
The system operates based on the following principles:
When the button to return the robot to its original position is pressed, the robot will automatically return to the pre-set position.
The initial position status and current position of the robot are displayed on the screen through the indicator light system.
Press the vacuum mode activation button to start the vacuuming process.
Hold down the conveyor control button, the conveyor will move towards the container.
Hold down the navigation button, the robot will move forward.
Hold down the navigation button, the robot will move backward.
Hold down the navigation button, the robot will move right.
Hold down the navigation button, the robot will move left.
Hold down the navigation button, the robot will move forward and turn right.
Hold down the navigation button, the robot will move forward and turn left.
Hold down the navigation button, the robot will move backward and turn right.
Hold down the navigation button, the robot will move backward and turn left.
Can control the speed of 3 XYZ axes
HMI Interface Design
4.1.1 Introduction to easybuilder pro software
EasyBuilder Pro effectively enhances the capabilities of Weintek HMI devices, featuring an intuitive interface that caters to both seasoned automation experts and newcomers This user-friendly software simplifies the creation of intricate and innovative HMI projects, allowing users to optimize their time and effort throughout the development process.
Figure 4-6: Main screen of system
Design product sorting system using gantry robot Executor : Do Manh Hung
On the Import mode screen, users will find a button to toggle between Import and Export modes, along with separate buttons to start and stop the drug box conveyor.
When drug boxes are scanned, the system captures and displays their information on the screen A status indicator light is positioned on the right side, while the central area of the screen presents detailed information about the imported drugs.
In Export mode, users can specify the quantity for each type of medicine, while the screen simultaneously shows the number of prescriptions being processed by the robot.
The Manual Mode Screen boasts a user-friendly interface that enables precise control and monitoring of the system Equipped with indicator lights, it displays real-time status and positions of the three axes, offering operators immediate feedback on the robot's current state.
A Home Button to reset the robot to its initial home position, ensuring a reliable starting point for operations or troubleshooting.
An Emergency Stop Button for immediate system shutdown in case of emergencies, prioritizing safety and preventing potential damage to the equipment or products.
Dedicated buttons to control the vacuum motor and conveyor, allowing users to turn these components on or off as required for specific tasks, adding flexibility to the system's operation.
Navigation buttons to manually move the robot to the desired position, enabling precise adjustments and intervention when needed.
The Manual Mode Screen features status messages and alerts that inform operators of system errors, maintenance requirements, and operational conditions, thereby improving situational awareness Its intuitive design allows operators to interact with the system swiftly and efficiently, minimizing downtime.
Design product sorting system using gantry robot Executor : Do Manh Hung and improving overall efficiency.
The Password Screen serves as the primary security layer for the system, allowing access to the Main Screen only for authorized personnel who enter the correct code Key features include password masking for privacy, a reset option for forgotten passwords, and a limited number of login attempts to deter unauthorized access Furthermore, the screen logs access attempts and generates alerts for failed logins, significantly enhancing the system's security and accountability.
The main screen is designed to provide all the essential features for efficient robot monitoring and control Key elements include:
LED Indicator: Displays the readiness status of the XYZ axes for operation.
Status Light: Reflects the robot's current operating mode.
Coordinate Display: Shows the XYZ axes' coordinates, providing the robot's real-time position.
Emergency Stop Button: Allows immediate power shutdown of the entire system in case of emergencies.
Navigation Panel: Positioned below the screen, enabling users to seamlessly switch between various pages as needed.
Visual Studio
Visual Studio, a robust integrated development environment (IDE) by Microsoft, streamlines the development of various software solutions such as desktop applications, mobile apps, websites, and cloud systems With its extensive suite of powerful tools, it empowers developers to efficiently write, test, and debug code.
Support for Multiple Languages: Compatible with various programming languages such as C++, C#, Python, JavaScript, and more.
Design product sorting system using gantry robot Executor : Do Manh Hung
Smart Code Editor: Includes advanced IntelliSense for intelligent code suggestions, syntax highlighting, and error identification.
Advanced Debugging Tools: Provides live debugging, breakpoints, and other features to simplify error resolution.
Integrated Git Support: Facilitates version control through built-in Git tools within the IDE.
Rich Extension Library: Offers a wide selection of plugins and extensions available in the Visual Studio Marketplace to expand functionality.
A comprehensive suite of tools covering all aspects of the software development lifecycle.
Intuitive interface, suitable for both novice and seasoned developers.
Frequent updates and a strong developer community ensure consistent enhancements.
High system resource usage, which can affect performance on less powerful hardware.
Some features are exclusive to the paid version, though the free Community Edition is available for individual users.
Ideal for developing web applications, desktop programs, mobile apps, and cloud-based solutions.
Widely used in enterprise environments for managing large-scale software projects.
Visual Studio is a powerful and versatile integrated development environment (IDE) designed to meet diverse development requirements across various platforms and programming languages Its comprehensive features and solid reputation establish it as a preferred option for developers globally.
Development and Implementation of Electrical Circuits
Utilize EPLAN Electric software to create and design electrical circuits tailored for the system.
EPLAN Electric is a comprehensive software solution for designing electrical circuits and systems, providing engineers with a robust platform that enhances design workflows With its diverse array of tools and features, EPLAN Electric significantly improves efficiency and produces high-quality documentation for professional electrical engineering projects.
EPLAN Electric provides an advanced environment for efficiently creating and editing electrical schematics.
Automated documentation generation minimizes manual effort and reduces the likelihood of errors.
Enables the development of reusable templates, macros, and components to standardize designs.
Ensures compliance with industry standards and regulatory requirements.
Automatically produces comprehensive reports, such as bills of materials, terminal layouts, and wiring diagrams.
Delivers accurate and clear documentation critical for manufacturing, installation, and maintenance activities.
Easily integrates with other engineering tools and PLM platforms, facilitating interdisciplinary collaboration and data sharing.
Offers interfaces with ERP and production systems to ensure a smooth transition from design to manufacturing.
Design product sorting system using gantry robot Executor : Do Manh Hung
Includes advanced validation and error-checking tools to detect and resolve design issues early in the process.
Reduces the risk of expensive mistakes and rework during production and installation.
Features like automatic wire numbering and cross-referencing significantly cut down on time compared to manual methods.
Accelerates the design process, allowing engineers to concentrate on more complex and innovative tasks.
EPLAN Electric can be quite expensive, especially for individuals or small businesses.
Requires investment in software licensing, staff training, and customization to suit user needs.
The software is highly complex and possesses a diverse set of tools, resulting in a steep learning curve.
Requires users to spend time training and practicing using it proficiently.
A powerful computer system is required to ensure efficient operation, especially when handling large and complex projects.
Regular updates and maintenance may be necessary to maintain optimal performance.
Heavy dependence on software during the design process can become a disadvantage if technical problems occur or the software stops working.
Regular data management and backups are important to avoid the risk of data loss.
EPLAN Electric is an advanced tool for electrical circuit design, offering significant advantages like enhanced performance, standardized processes, comprehensive documentation, and minimized errors Despite its high cost and the learning curve involved, the software's value makes it essential for electrical engineers and designers managing intricate systems.
The following is the PLC signal convention table:
Table 4.1: PLC input signal convention
Design product sorting system using gantry robot Executor : Do Manh Hung
Table 4.2: PLC output signal convention
Figure 4-16: Wiring Light and Valve, Motor
Design product sorting system using gantry robot Executor : Do Manh Hung
EXECUTION RESULT
Hardware results
The gantry robot boasts a sturdy aluminum frame and 3-axis motion (X, Y, Z) driven by stepper motors and lead screw mechanisms Equipped with a PLC controller, electronic control unit, position sensors, and limit switches, it ensures reliable operation and high accuracy in movement, speed, and payload handling After meticulous assembly, testing, and calibration, the robot is ready for seamless integration and programming in various practical applications.
Figure 5-1: Real-World Model of a Gantry Robot System
Based on the design and model from SolidWorks, our team successfully completed the fabrication of the X-axis.
I have successfully completed the fabrication of the Z-axis using SolidWorks software, ensuring high precision to meet the system's speed and accuracy requirements This milestone is crucial for the development of the project's mechanical system The Z-axis will significantly enhance the precision of warehouse operations, optimizing processes and boosting work efficiency Additionally, thorough quality checks have been conducted to guarantee that the final product adheres to the highest technical standards.
Design product sorting system using gantry robot Executor : Do Manh Hung
I have successfully manufactured the Y axis using SolidWorks software, ensuring it meets precise specifications for high performance and reliability This achievement is a significant milestone in the mechanical development of the project, as the Y axis is essential for facilitating smooth and accurate movements, ultimately enhancing the system's overall efficiency Comprehensive quality checks have confirmed that the final product adheres to the highest technical standards and is prepared for seamless integration into the complete system.
After wiring electrical devices and connecting them to drivers, a comprehensive check of the electrical panel system is essential to ensure all connections function correctly and safely This includes verifying that wires are securely fixed and meet insulation and overload protection standards It's crucial to confirm the technical specifications of each device, assess the mechanical strength of connections, and ensure proper coordination among components Additionally, reviewing safety measures to prevent electrical hazards, such as short circuits and improper grounding, is vital Testing should also encompass the functionality of control systems and the stability of communication between devices Once fully validated, the system will be ready for integration into the overall project, guaranteeing optimal performance and safety.
Design product sorting system using gantry robot Executor : Do Manh Hung
The electrical cabinet is engineered to fulfill the system's technical and operational needs Once the wiring of the electrical components and connections to the drivers are completed, the entire electrical cabinet system undergoes rigorous testing to guarantee both safety and efficient performance.
Figure 5-5 illustrates the detailed design of the electrical cabinet, showcasing the strategic arrangement of internal components This layout is optimized for space efficiency, ease of maintenance, and effective coordination among equipment during operation.
The layout is strategically designed to reduce overheating and component interference, featuring effective ventilation and organized cable management Each device is easily accessible for routine inspections and troubleshooting, allowing for quick and efficient adjustments or repairs.
The electrical cabinet is also equipped with safety features, such as emergency shutoff switches and clear labeling of all connections, to enhance operational safety and compliance with industry standards.
Figure 5-6: Inside the electrical cabinet
Figure 5-7: Outside the electrical cabinet
Design product sorting system using gantry robot Executor : Do Manh Hung
Figure 5.6 illustrates the initial state of the robot when it is placed at the starting position.
Robots work most efficiently when goods are handled according to predetermined rules.
Figure 5-9: Loading medicine boxes onto the conveyor belt properly
Figure 5.8 shows the robot during the "medicine box import" task.
Figure 5-10: How the robot loads goods into the container
Figure 5.9 shows the robot performing the "drug box export" operation.
Figure 5-11: Continuous goods export by the Robot
Design product sorting system using gantry robot Executor : Do Manh Hung
CONCLUSION
Conclusion
Following the hardware design, PLC programming, and HMI control interface development, our team successfully created a robot capable of essential functions including picking, dropping, clamping, and placing drugs The outcomes and evaluations indicate significant progress in our project.
The team successfully designed a robust robot frame specifically optimized for drug transportation, featuring a solid structure and a powerful motor that enhances transportation speed while ensuring high accuracy.
After extensive testing of the PLC program, we discovered that the robot operates with minimal deviations from expected performance The algorithm effectively optimizes time calculations by considering speed, acceleration, and deceleration with high precision, allowing the robot to move swiftly and stop accurately.
Development directions
To optimize, stabilize, and improve performance in diverse environmental conditions, our team proposes the following improvements:
To enhance overall operations in larger scale models, it is essential to optimize the robot's travel time, facilitating a quicker and more efficient loading and unloading process.
Integrate additional camera equipment to support more accurate product identification.
Adjust the tools at the end of the robot arm to be able to handle a variety of products.