Design On CIM Workstation System - LCD Monitor Back Cover Assembly Station.

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Design on CIM Workstation System –

LCD Monitor Back Cover Assembly Station

Thesis submitted in accordance with the requirement of the Universiti Teknikal Malaysia Melaka for the Degree of Bachelor of Engineering

(Honors) Manufacturing (Robotic & Automation)

By

Hoo Lien Tien

Faculty of Manufacturing Engineering May 2007

BORANG PENGESAHAN STATUS TESIS

*

JUDUL: Design on CIM Workstation System – LCD Monitor Back Cover Assembly Station

SESI PENGAJIAN: 2006 / 2007

Saya HOO LIEN TIEN .

(HURUF BESAR)

mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah)* ini disimpan di perpustakaan Universiti Teknikal Malaysia Melaka dengan syarat-syarat kegunaan seperti berikut: 1. Tesis adalah hakmilik Universiti Teknikal Malaysia Melaka.

2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.

4. ** Sila tandakan ( 3 ) SULIT

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972)

TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

Universiti Teknikal Malaysia Melaka

Karung Berkunci 1200, Ayer Keroh, 75450 Melaka. Tel : 06- 233 2323 Faks : 06- 232 2828

TIDAK TERHAD

Disahkan oleh

(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA) Alamat Tetap: _{Cop Rasmi:}

Lot 1970 Taman Ria, Jalan Seremban, 71000 Port Dickson,

Negeri Sembilan, Malaysia

Tarikh: __________________________ Tarikh: _________________________

9

*Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penylidikan, atau disertai bagi pengajian secaraa kerja kursus dan penylidikan, atau Laporan Sarjana Muda (PSM).

** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.

APPROVAL

This thesis submitted to the senate of UTeM and has been accepted as partial fulfillment of the requirement for the degree of Bachelor of Manufacturing Engineering (Robotic and Automation). The members of the supervisor committee

are as follow:

………. EN. SHARIMAN B. ABDULLAH

Main Supervisor (Official Stamp & Date)

DECLARATION

I hereby, declare this thesis entitled “Design on CIM Workstation System – LCD Monitor Back Cover Assembly Station” is the results of my own research except as

cited in the reference.

Signature : ………... Author’s Name : ………... HOO LIEN TIEN

ABSTRACT

This paper presented the development of the assembly station – Back Cover Assembly Station in the Computer Integrated Manufacturing (CIM) systems of assembling the LCD monitor back cover. CIM can be define as the integration of all the processes necessary to manufacture a product through the use of computer technology, tool or method used to improve entirely design, manufacturing process and increase productivity. The outcome idea for this CIM system is an open modular conveyor system with a centralized control unit (OMRON PLC) employing the control methodologies and integration tools. The system is build in used for controls of an automatic product feeder station, a conveyor transfer module, three automatic assembly stations and a vision module which all these stations will be arranged along the conveyor. The assembly process for this assembly station is it starting with the feeder module which it will feed away a piece of LCD monitor back cover to preset location, waiting for the suction system to pick up and transfer it on to the conveyor line and replace it over the half-assemble LCD monitor. The suction system was attached together with the z-axis transfer module as it moves up and downwards together for lifting and placing process (know as pick and paste process). After that, a cylinder will activate to apply force to the surface of back cover, in order to snap fit the back cover with the half-assemble LCD monitor. In this thesis too, a draft PLC program for the station has been purposed, the program has been tested with OMRON Light Training Kit and it does prove it work correctly. The program usage is to be a reference for future studies and development. Finally, it can conclude that this project has fulfills the course outline of Manufacturing engineering, which majoring in the field of Automation. This project involves not only automation skills, but also design, manufacturing and mechanical skills.

ABSTRAK

Kertas kerja ini menerangkan projek bertajuk “Development of Assembly Station – Back Cover Assembly Station in the Computer Integrated Manufacturing (Cim) Systems”. CIM membawa maksud integrasi kesemua prosess yang berkenaan dalam menghasilkan suatu produk dengan penggunaan komputer teknologi, peralatan atau langkah, yang boleh membawa peningkatan dalam prosess penghasilan suatu sistem. CIM sistem ini merupakan sebuah sistem yang terdiri daripada suatu pengawalan unit tengah (Omron PLC) yang berupaya berintegrasi dengan peralatan-peralatan dan sub-sub station di sekeliling conveyor untuk memasang suatu produk iaitu LCD monitor. Sub-sub station ini terdiri daripada station pembekalan, konveyor, tiga buah station pemasangan dan sebuah vision station. Proses pemasangan sistem station ini bermula dari station pembekalan bahan mentah iaitu penutup belakang LCD monitor, ketika penutup belakang ini mencapai lokasi yang ditetapkan, suction sistem yang ada pada station ini akan memegang penutup belakang tersebut ke konveyor. Suction sistem ini dipasangkan bersamaan dengan pergerakan paksi z, dimana ia berkebolehan dalam pegerakan menaik dan menurun. Selepas itu, suatu cylinder akan berfungsi untuk menekan penutup belakang tersebut supaya ia dipasang ketat dengan LCD monitor yang separuh siap dipasang pada station sebelumnya. Dalam kertas kerja ini juga, suatu program kasar PLC untuk station ini juga disertai, dimana program ini telah diuji kebenaran fungsi kerja melalui Omron Light Training Kit.

DEDICATION

To my beloved family

ACKNOWLEDGEMENT

This report inevitably involves many helping hands. First of all, I am extremely grateful and thanks to my supervisor, En. Shariman b. Abdullah, for all the guidance and critics given to me directly or indirectly, and also his scarification in time to teach and explain to me without a word of complains.

Thank and deeply indebted to En Asrul Azwan, who offered a help for guidance and ideas for the products selection in the CIM system. He always is the patience and willingness guy.

I would like to thanks for my friends, the CIM’s comrades, Mohd Faizal, Aizuddin, Hassanul, Khoo, and Najwa, for sharing their ideas and supports, as well as good humor, in helping me to complete my tasks and assignments. I count myself very lucky of having these people around me.

TABLE OF CONTENTS

Abstract i

Abstrak ii Dedication iii Acknowledgement iv

Table of Contents v

List of Figures viii

List of Tables x

List of Abbreviations, Symbols, Sign xi

1. INTRODUCTION 1

1.1 Background Study 3

1.2 Problem Statement 4

1.3 Objectives 5

1.4 Organization 5

2. LITERATURES REVIEW 7

2.1 Literatures 7

2.2 Summary 15

3. METHODOLOGY 17

3.1 Project Planning 17

3.2 CIM Workstation 19

3.2.1 System Overview 20

3.3 Station Design Concept 22

3.4 Module Descriptions 24

3.4.1 3-axis Module 24

3.4.1.1 X-axis System 25

3.4.1.2 Y-axis System 26

3.4.1.3 Z-axis System 26

3.4.2 Suction Module 27

3.4.3 Feeder Module 28

3.4.4 Slotting Module 28

3.4.5 Structure Module 29

3.5 Building Blocks of Automatic Assembly Station 30

3.5.1 Drives 30

3.5.1.1 AC Servo Motor 30

3.5.1.2 AC Reversible Motor 31

3.5.1.3 Stepper Motor 33

3.5.2 Actuators 36

3.5.2.1 Cylinders 37

3.5.2.2 Solenoids 37

3.5.3 Sensors 38

3.5.3.1 Limit Switch 39

3.5.3.2 Proximity Switch 39

3.5.3.3 Thru-Beam Sensor 39

3.5.4 Controller 39

3.5.4.1 Programmable Logical Controller (PLC) 40

3.5.5 Mechanical Device/Element 41

3.5.5.1 Linear Guides 41

3.5.5.2 Ball Screw 42

3.5.5.3 Ball Bearing 43

4. PROPOSED CHARACTERIZATION 46

4.1 Components Analysis 46

4.1.1 Permissible Axial Load and Tensile Compressive Load 46

4.1.2 Axial Load on Horizontal Mount 48

4.1.3 Driving Torque and Backdriving Torque 50

4.1.4 Suction Lifting Capacity 53

4.1.5 Stepper Motor Positioning 54

4.2 Summary 57

5. RESULTS AND DISCUSSION 59

5.1. Results 59

5.1.1.Mechanical Details Drawing 59

5.1.2.Control System 60

5.1.2.1. Process Flow Diagram 61

5.1.2.2. Pneumatic Circuit Diagram 62

5.1.2.3. Electrical Diagram 63

5.1.3.Programming 63

5.2. Machine Hardware 70

5.3. Discussion 71

6. SUMMARY, CONCLUSION AND FUTURE WORK 72

6.1. Summary 72

6.2. Conclusion 73

6.3. Future Work 73

REFERENCES 74

APPENDICES 79

A-1 HIWIN Ball Screw Catalogue A-2 HIWIN Linear Guide Catalogue

B Standard External Circlip European Specification -1400 C-1 Machine Construction System – Aluminum Profile C-2 Machine Construction System – Castor

D Shaft Mounting Method

E Berger Lahr Stepper Motor Drives SD3 Catalogue F Step by Step Using Solid Works

G UTeM Drawing Templates Description H Workstation Pictures

LIST OF FIGURES

1.1 Analysis of the Global LCD and CRT Monitor Markets (Worldwide Monitor Market Tracker, Alexander, 2006)

2.1 Robotic workstations in the CIM-NEGEV laboratory 2.2 The Material Handling System of CIM-NEGEV

2.3 Final Products. Right to Left: Top Row- Rook, Box-Cover; Bottom Row- Sign, Hole-Axis, LEGO

2.4 Robot Workcell for Automatic Lid Assembly

2.5 Drawing of the Grinding Machine for Ultra-Precession Machining 2.6 Gripper Contacts Align the Part for Assembly

2.7 Position Method in Commercial Pallets Using Pins-In-Holes Approach 2.8 Experimental Setup for Measuring Pallet Repeatability

2.9 Commonly Used Vacuum Cups 2.10 The Cup Partly Adheres To the Part 2.11 Flexible Feeding System

3.1 Project Planning Flow Chart 3.2 Provided Conveyor Layout

3.3 The Main Parts of LCD Monitor to Be Assemble

3.4 LCD Monitor Assembly Process. (a) Side Frame Assembly; (b) Back Cover Assembly; (c) Flip-Over; (d) Front Cover Assembly and (e) Finish Product 3.5 Back Cover Assembly Station Design Overview

3.6 3-axis Liner Motion Transfer Design 3.7 X-axis Linear Motion Module Design 3.8 Y-axis Linear Motion Module Design 3.9 Z-axis Linear Motion Module Design 3.10 Pick-and Paste Suction System Design 3.11 The Back Cover Feeder Module Design 3.12 Back Cover Slotting Module Design

3.13 The Structure Module Design

3.14 AC Reversible Motor Operating Cycle 3.15 Stepping Motor System

3.16 Variable Reluctance Stepper Motor 3.17 Permanent Magnet Stepper Motor 3.18 Hybrid Stepper Motor

3.19 Approximate Interrelationship of the Four Basic Categories of Automation Components and Their Interface With the Conventional Process

3.20 PLC conceptual application diagram 3.21 The Structure of Linear Guide

3.22 Ball Screw Assembly 3.23 Types of Ball Screw Starts 3.24 Types of Ball Bearing

4.1 Mounting Method for Ball Screw 4.2 Axial Load Parameter

4.3 Shaft Core Displacement

4.4 Driving Torque Required By the Ball Screw to Move a Load

4.5 Backdriving Torque Required By Ball Screw to Hold the Load in Position 4.6 Motor Control System Principle

4.7 Graph of Motor Operating Pulse Speed versus Period

5.1 UTeM Drawing Template

5.2 Process Flow Chart for One Cycle 5.3 Pneumatic Circuit Diagram 5.4 Electrical Circuit Diagram 5.5 PLC Ladder Diagram

5.6 Workstation under Assembly Progress (a) Isometric View, (b) Front View

LIST OF TABELS

5.1 Assigned Input Address and Address Description 5.2 Assigned Output Address and Address Description 5.3 Bill of Material List

LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED

NOMENCLATURE

IT - Information Technology CE - Computer Engineering

CIM - Computer Integrated Manufacturing LCD - Liquid Crystal Display

CRT - Cathode Ray Tube

CAD/CAM - Computer-Aided Design/Computer-Aided Manufacturing ASRS - Automatic Storage and Retrieval Station

FMS - Flexible Manufacturing Station AGVS - Autonomous Guided Vehicle System CNC - Computer Numerical Control

UTeM - University Technical Malaysia Melaka BMFA - Bachelor in Manufacturing

PLC - Programmable Logic Controller CD - Compact Disc

BOM - Bill of Material

CHAPTER 1

INTRODUCTION

Computer monitor has plays an important role in the Information Technology (IT) and Computer Engineering (CE) industry. The worldwide computer monitor market trends forecast a quantitative growth, especially in the demand of LCD (liquid crystal display) monitor [Alexander, 2006]. A LCD is a thin, flat display device made up of any number of color or monochrome pixels arrayed in front of a light source or reflector. It is prized by engineers because it uses very small amounts of electric power, and is therefore suitable for use in battery-powered electronic devices. Until recently, LCD panels were used exclusively on notebook computers and other portable devices. In 1997, however, several manufacturers began offering full-size LCD monitors as alternatives to CRT (cathode ray tube) monitors. The main advantage of LCD displays is that they take up less desk space and are lighter [Brody, 1997].

As refer to Figure 1.1, we can clearly see that LCD monitors has continually displace CRT monitors across all regions. Industry participant will need effective strategies to maintain the outcome products, in other point of view, which means the manufacturing process of the LCD monitor present a potential and reasonable studies from now, it is possible to develop an automation assembly system to manufacture the LCD monitor, to reach higher production rate objectives along with workers protection, increase the degree of automation in the LCD manufacturing process is crucial [Alexander, 2006].

Figure 1.1: Analysis of the Global LCD and CRT Monitor Markets [Worldwide Monitor Market Tracker, Alexander, 2006]

From Figure 1.1, it shows that the demand for flat screen monitors today is growing strongly, in order to maintain quality, speed new product development, minimizing costs and maximizes flexibility to respond to ever-changing customer desires; a automated assembly workstation is need [Alexander, 2006].

At this point, let consider the tools and materials available in store room at home. Can users really find the tools or materials they need at time they need it to do a job? Have they ever there found that it easier to go to the market and buy new material or even tools to accomplish a job, because it has not been worthwhile to spend the time to find the materials or tools that they know they already have? Carrying the problem a step forward, they may begin a task only to remember that they forgot to pick up a replacement part when they at the store; replace a broken blade or sharpen a tool. Multiply the problems in the store room at home a few thousand times and it will have the complexity of the conventional manufacturing plant.

Many employees spend most of their time communicating and interacting with other employees in an attempt to find out the status of machine, processes, materials, and orders that must be filled. What is needed is an information processing system that ties all of these needs together in an on-line, integrated system – CIM.

There are lots of definitions for conceptual of CIM, but it does not vary in between of them. One of the concept defining CIM as to be the integration of all the processes necessary to manufacture a product through the use of computer technology, tool or method used to improve entirely design, manufacturing process and increase productivity [Kalpakjian, 1995]. The other point of view define CIM as integration of total manufacturing enterprise through the use of integrated systems and data communications coupled with new managerial philosophies that improve organizational and personnel efficiency [Singh and Nanua, 1996]

CIM, as the name implies, the computer is the pivotal element in such system. Through the use of various computer-aided technologies, CIM attempts to pull all of the functional areas of a business into a cohesive, interconnected, interactive and self-aware whole.

1.1 Background Study

Assembly work has a very long history. Ancient people already knew how to create a useful object composed of multiple parts. However, the objective of modern assembly process is to produce high quality and low cost products. Automation assembly planning of a product is a complex problem which involves different artificial intelligence and consideration issues like assembly sequence, execution, flexibility, precise mechanisms, and control, etc. A product is a result of subassemblies being composed into a complete assembly. In order to generate all possible assembly sequences, the determination of an assembly sequence is based on all possible connectivity and relations between parts in a product. These sequences

will be evaluated using the feasibility criteria and optimization criteria to determine the best assembly sequence possible. [Mardanov et al., 1999]

Now, the complete set of valid assembly sequences is explored first. The freedom of separations is defined to determine the possible direction of assembly which must satisfied the feasibility criteria. These criteria are determined by limitations of devices and environment. They are:

(a) Mechanical feasibility, which contain information about the ability for manipulation:

(i) The manipulation directions, (ii) Size and weight properties, (iii) Hardness of the assembly parts.

(b) Connection characteristics, which contains the fit type information

In order to assembly two parts, the part being manipulated must be ready to be manipulated. When considering a product assembly, the scale and accuracy of the task must be defined.

1.2 Problem Statements

Manufacturing Industries are facing stiff competition in every field. Product customerisation is increasing the complexity and variety of products with smaller batch size. Besides, product modification takes place very frequently causing changes in some components. In such situation it becomes important for a centralized point of information to know the material and processes in the plant [Mohsen, 1997]. A conventional manufacturing plant is a widely distributed layout of material and process; it is not uncommon for material and work-in-process to become lost as it is transferred from dept to dept and from person to person. Flexible manufacturing plant consist lot of different assembly stations, dealing with different of the material

handling processes (material feeder, parts assembly, mechanical & vision inspections and etc).

The goals of this CIM workstation are to give students experiences with the following real-world technologies, they are: computer-aided design/computer-aided manufacturing (CAD/CAM), robotics, concurrent design, computer-aided quality control, and CIM integration.

1.3 Objectives

The objectives of this project are the following:

(i) To study the concept and characterization of automation assembly in manufacturing industries.

(ii) To design and fabricated the LCD monitor back cover assembly station in the CIM workstation system.

(iii) To provide support for a variety of hands-on student activities and projects that include the use and integration of various industrial automation components

1.4 Organization

This report is divided into five chapters in addition to introductory one. The material presented in each chapter is presented next.

In Chapter 2, literature review is presented. The chapter includes several research papers that focus on concept of station design, parts transfer and motion problem.

In Chapter 3, an overview of the assembly station design is presented.

In Chapter 4, the design model is analyzed.

In Chapter 5, the station hardware and draft programming is presented.

Chapter 6 includes the thesis summary, conclusions and future work.

CHAPTER 2

LITERATURES REVIEW

The literatures research mainly focuses on the study for fundamental concept of design, product parts feeding and product transfer motion which will be used in the project. The fundamental concept of design is to look after the ideas of product assembly planning, workstation design, and workstations arrangement for the CIM’s LCD monitor assembly. The parts feeding researches are to explore ideas in the product feeding and product alignment system of an automatic feeder system, in order to figure out a suitable design to feed the LCD monitor’s back cover in this project. For the transfer motion problem, it is more on the study of ideas in transferring the parts to the conveyor line. The transferring idea is stick to the concept of flexibility in keeping with the goals of rapid change-over for the products.

2.1 Literatures

Sigal, Yael, and Gad (2003) presents for the CIM-NEGEV system which used for control of four robotic manufacturing workstations: an automatic storage and retrieval station (ASRS), a flexible manufacturing station (FMS) including two lathes and a mill served by a robot on a linear slide base, an automatic assembly station with two robots, and a quality control station with a robot and a vision module that has shown in Figure 2.1. Material handling is conducted by an Autonomous Guided Vehicle System (AGVS) comprised of two Pioneer 2DX automatic guided vehicles (AGV) (Figure 2.2). Five typical products (Figure 2.3) were chosen to demonstrate both single processes, e.g., just milling or just assembly and, combined processes,

e.g., milling and assembly or milling turning and assembly. All products go through quality control tests.

Figure 2.1: Robotic workstations in the CIM-NEGEV laboratory [Sigal et al., 2003]

Figure 2.2: The Material Handling System of CIM-NEGEV [Sigal et al., 2003]

Figure 2.3: Final Products. Right to Left: Top Row- Rook, Box-Cover; Bottom Row- Sign, Hole-Axis, LEGO [Sigal et al. 2003]

Kamnik, Rodic, Mihelj and Bajd (2001) discuss for the automation of the car battery lid assembly operation. In their research, the automatic system aimed for automatic lid assembly needs to provide the lid storage, lid feeding, lid manipulation, and lid assembly functions. The basic requirements for the system are to meet the production line cadence of 100 products per hour, to provide a lid storage for at least half hour production, and to provide flexibility for all battery types in production. When designing the automatic system, the problem of the lid sticking needs to be properly addressed. For successful automation of operation, the system should be able to detect, adequately distinguish and react to the lid assembly faults. A robot workcell performing automatic lid assembly on the battery container is presented. Firstly, the problem of the battery lid assembly operation, treated from a robotic assembly point of view as a peg-in-hole insertion problem, is investigated with theoretical background and practical laboratory evaluation. Secondly, the robot cell setup is presented incorporating for this task specially designed robot gripper and peripheral feeding devices.

will be evaluated using the feasibility criteria and optimization criteria to determine the best assembly sequence possible. [Mardanov et al., 1999]

Now, the complete set of valid assembly sequences is explored first. The freedom of separations is defined to determine the possible direction of assembly which must satisfied the feasibility criteria. These criteria are determined by limitations of devices and environment. They are:

(a) Mechanical feasibility, which contain information about the ability for manipulation:

(i) The manipulation directions, (ii) Size and weight properties, (iii) Hardness of the assembly parts.

(b) Connection characteristics, which contains the fit type information

In order to assembly two parts, the part being manipulated must be ready to be manipulated. When considering a product assembly, the scale and accuracy of the task must be defined.

1.2 Problem Statements

Manufacturing Industries are facing stiff competition in every field. Product customerisation is increasing the complexity and variety of products with smaller batch size. Besides, product modification takes place very frequently causing changes in some components. In such situation it becomes important for a centralized point of information to know the material and processes in the plant [Mohsen, 1997]. A conventional manufacturing plant is a widely distributed layout of material and process; it is not uncommon for material and work-in-process to become lost as it is transferred from dept to dept and from person to person. Flexible manufacturing plant consist lot of different assembly stations, dealing with different of the material

handling processes (material feeder, parts assembly, mechanical & vision inspections and etc).

The goals of this CIM workstation are to give students experiences with the following real-world technologies, they are: computer-aided design/computer-aided manufacturing (CAD/CAM), robotics, concurrent design, computer-aided quality control, and CIM integration.

1.3 Objectives

The objectives of this project are the following:

(i) To study the concept and characterization of automation assembly in manufacturing industries.

(ii) To design and fabricated the LCD monitor back cover assembly station in the CIM workstation system.

(iii) To provide support for a variety of hands-on student activities and projects that include the use and integration of various industrial automation components

1.4 Organization

This report is divided into five chapters in addition to introductory one. The material presented in each chapter is presented next.

In Chapter 2, literature review is presented. The chapter includes several research papers that focus on concept of station design, parts transfer and motion problem.

In Chapter 3, an overview of the assembly station design is presented.

In Chapter 4, the design model is analyzed.

In Chapter 5, the station hardware and draft programming is presented.

CHAPTER 2

LITERATURES REVIEW

The literatures research mainly focuses on the study for fundamental concept of design, product parts feeding and product transfer motion which will be used in the project. The fundamental concept of design is to look after the ideas of product assembly planning, workstation design, and workstations arrangement for the CIM’s LCD monitor assembly. The parts feeding researches are to explore ideas in the product feeding and product alignment system of an automatic feeder system, in order to figure out a suitable design to feed the LCD monitor’s back cover in this project. For the transfer motion problem, it is more on the study of ideas in transferring the parts to the conveyor line. The transferring idea is stick to the concept of flexibility in keeping with the goals of rapid change-over for the products.

2.1 Literatures

Sigal, Yael, and Gad (2003) presents for the CIM-NEGEV system which used for control of four robotic manufacturing workstations: an automatic storage and retrieval station (ASRS), a flexible manufacturing station (FMS) including two lathes and a mill served by a robot on a linear slide base, an automatic assembly station with two robots, and a quality control station with a robot and a vision module that has shown in Figure 2.1. Material handling is conducted by an Autonomous Guided Vehicle System (AGVS) comprised of two Pioneer 2DX automatic guided vehicles (AGV) (Figure 2.2). Five typical products (Figure 2.3) were chosen to demonstrate both single processes, e.g., just milling or just assembly and, combined processes,

e.g., milling and assembly or milling turning and assembly. All products go through quality control tests.

Figure 2.1: Robotic workstations in the CIM-NEGEV laboratory [Sigal et al., 2003]

Figure 2.3: Final Products. Right to Left: Top Row- Rook, Box-Cover; Bottom Row- Sign, Hole-Axis, LEGO [Sigal et al. 2003]

Kamnik, Rodic, Mihelj and Bajd (2001) discuss for the automation of the car battery lid assembly operation. In their research, the automatic system aimed for automatic lid assembly needs to provide the lid storage, lid feeding, lid manipulation, and lid assembly functions. The basic requirements for the system are to meet the production line cadence of 100 products per hour, to provide a lid storage for at least half hour production, and to provide flexibility for all battery types in production. When designing the automatic system, the problem of the lid sticking needs to be properly addressed. For successful automation of operation, the system should be able to detect, adequately distinguish and react to the lid assembly faults. A robot workcell performing automatic lid assembly on the battery container is presented. Firstly, the problem of the battery lid assembly operation, treated from a robotic assembly point of view as a peg-in-hole insertion problem, is investigated with theoretical background and practical laboratory evaluation. Secondly, the robot cell setup is presented incorporating for this task specially designed robot gripper and peripheral feeding devices.