Application Of XY Table Continuous Motion Programming With PC Based Control.

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APPLICATION OF XY TABLE CONTINUOUS MOTION

PROGRAMMING WITH PC BASED CONTROL

ANBALAGAN A/L MUNUSAMY

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

APPLICATION OF XY TABLE CONTINUOUS MOTION

PROGRAMMING WITH PC BASED CONTROL

This report submitted in accordance with the requirements of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing

Engineering (Robotics & Automation) with Honours.

ANBALAGAN A/L MUNUSAMY

FACULTY OF MANUFACTURING ENGINEERING 2009

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PSM

JUDUL:

Applicat ion of XY Table Cont inuous Mot ion Programming Wit h PC Based Cont rol

SESI PENGAJIAN: Semest er 2 2008/ 2009

Saya Anbalagan A/ L Munusamy mengaku membenarkan laporan PSM / t esis (Sarj ana Muda) ini disimpan di Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :

1. Laporan PSM / t esis adalah hak milik Universit i Teknikal Malaysia Melaka dan

penulis.

2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan

unt uk t uj uan pengaj ian sahaj a dengan izin penulis.

3. Perpust akaan dibenarkan membuat salinan laporan PSM / t esis ini sebagai bahan

pert ukaran ant ara inst it usi pengaj ian t inggi.

4. *Sila t andakan (√) SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdar j ah keselamat an at au kepent ingan Malaysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan di j alankan)

(TANDATANGAN PENULIS) Alamat Tet ap:

B170, Jalan Permai Bist ari 7/ 1, Taman Permai Bist ari,

08100 Sungai Lalang, Kedah Darul Aman. Tarikh: 16 April 2009

(TANDATANGAN PENYELIA) Cop Rasmi:

Tarikh: 16 April 2009

* Jika l aporan PSM ini SULIT at au TERHAD, sil a l ampirkan surat daripada pihak organisasi berkenaan dengan menyat akan sekali sebab dan t empoh t esis ini perl u dikel askan sebagai SULIT at au TERHAD.

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DECLARATION

I hereby, declared this report entitled “APPLICATION OF XY TABLE CONTINUOUS MOTION PROGRAMMING WITH PC BASED CONTROL” is

the results of my own research except as cited in the reference.

Signature :

Author’s Name : ANBALAGAN A/L MUNUSAMY

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APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Robotics and Automation) with Honours. The member of the supervisory committee is as follow:

(Signature of Supervisor)

………. (Official Stamp of Supervisor)

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ABSTRACT

The project of application of XY table continuous motion programming with PC based control is divided in two parts. First part of the project is about proposal and the second part is about project implementation. The application of XY table continuous motion programming with PC based control studied and investigated in this project as an improvement of previous research in order to enable the XY table for continuous motion. Further up, for high precision operation automation system the current two axis system is inadequate. Thus the third axis called Z-axis should be designed and added to the current XY positioning system. The continuous motion programming with the third axis may solve the current XY positioning system limitations in order to meet the current industrial automation requirements. This project is will be conducted to modify the current design, improve the current system in term of flow of programming method and mechanical structure. Finally a comprehensive report produced to conclude the findings and results obtained by the implementation of the project.

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ABSTRAK

Projek aplikasi pengaturcaraan pergerakan berterusan meja XY dengan kawalan berasaskan komputer peribadi dibahagikan kepada dua bahagian. Bahagian pertama projek ini berkenaan dengan cadangan dan bahagian kedua adalah berkenaan dengan pelaksanaan projek. Dalam projek ini, aplikasi pengaturcaraan pergerakan berterusan meja XY dengan kawalan berasaskan komputer peribadi dikaji dan diselidik sebagai satu penambahbaikkan daripada kajian terdahulu bagi membolehkan pergerakkan berterusan meja XY tersebut. Tambahan lagi, sistem dua paksi yang sedia ada tidak memadai untuk sistem automasi operasi ketepatan tinggi. Oleh itu, satu paksi ketiga yang dinamakan paksi-Z perlu direkabentuk dan ditambahkan kepada sistem kedudukan yang sedia ada. Pengaturcaraan pergerakan berterusan dengan penambahan paksi-Z boleh menyelesaikan kekurangan yang ada pada sistem kedudukan XY yang sedia ada bagi memenuhi permintaan automasi industri pada masa ini. Projek ini akan dijalankan untuk menambahbaik rekabentuk pada masa ini, untuk memperbaiki system yang sedia ada dari segi kaedah aliran pengaturcaraan dan struktur mekanikal. Akhir sekali, satu laporan yang lengkap dihasilkan untuk merumuskan penemuan dan keputusan yang dicapai daripada aplikasi projek ini.

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iii

DEDICATION

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ACKNOWLEDGEMENTS

It gives me utmost pleasure to express my gratitude to who have directly or indirectly contributed to the fruition of the compilation. They include;

My supervising lecturer, Mr. Shariman bin Abdullah of which we had a excellent working relationship, and who offered tremendous help and encouragement,

My examiner Mr. Zamberi bin Jamaludin, who provide me adequate ideas to complete this project,

My family, who inspired me weather through the storm and carry on, and last but not least

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Abstract……….……….i

Abstrak……….……….ii

Dedication………iii

Acknowledgement………...…iv

Table of Contents……….………....………….…v

List of Tables……….………viii

List of Figures………...…...ix

List of Abbreviations………..……….…xi

1 INTRODUCTION 1

1.1 1.2 1.3 1.4 Background Problem Statement Scope of Project Objectives

1 2 2 3

2 LITERATURE REVIEW 4

2.1 2.1.1 2.2 2.2.1 2.2.1.1 2.2.1.2 2.2.1.3 2.2.1.4 2.3 2.3.1 2.3.2 2.3.3 XY Table

Definition of Specifications Drive Mechanism

Electrical Motor AC Servo Motor Stepper Motor Lead Screws Ball screws PC-based Control PLC versus PC

Benefits of using PC-based control Control System Architecture

4 8 11 12 15 21 25 28 29 30 31 32

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vi 2.3.4 2.3.5 2.3.5.1 2.3.6 2.4 2.5 User Interface Motion Controller

Specifications of PCI-8164 Motion Control Card Control Algorithms

State-of-Art on XY Table Positioning System Summary 33 34 36 38 39 43

3 METHODOLOGY 45

3.1 3.2 3.3 3.4 3.5 3.5.1 3.6

Methodology Flow Chart

Description of Methodology Flow Chart Gantt Chart

Description of Design Improvement

Description of Motion Control Programming User Interface

Project tools and equipments

45 47 49 50 52 52 53

4 DESIGN AND DEVELOPMENT 54

4.1 4.1.1 4.1.2 4.2 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.4 4.4.1 4.4.2 4.4.3 4.5 4.6 Mechanical Design List of Parts

Descriptions of the Structure of the Z-axis

Material Selection for the Components of the Z-axis Development of Z-axis

Back Plate Bottom Plate Pen Gripper Unit Linear Slider Unit Slider Shaft

Pneumatic Drive Mechanism Double Acting Cylinder Directional Control Valve Pressure Supply

Assembly of the Z-axis Components. Electrical Connection 54 56 56 57 59 60 61 62 64 64 65 65 66 67 67 68

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vii

4.7 Motion Control Programming 70

5 RESULTS 72

6 DISCUSSION AND SUGGESTION 79

6.1 6.2 6.3

Project Overview Result Discussion Suggestions

79 80 81

7 CONCLUSION 82

REFERENCES 83

APPENDICES

A Detailed drawings of Z-axis Parts B CN2 Main Connector Pin Assignments C General-purpose Signal SVON

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viii

LIST OF TABLES

3.1

4.1 4.2 4.3 4.4 4.5

Gantt chart for the project PSM 1 and PSM 2

Part List for Z-axis

Material Properties of Aluminum

Material, Mass and Volume of Z-axis Components Cylinder Specifications

SVON Axis and pin number

56 58 59 65 69

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LIST OF FIGURES

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 3.1 3.2 3.3 3.4 4.1 4.2

Main components of XY table XY table

Specifications of XY table

Application requirement terms of XY positioning Graph of efficiency vs. speed curves

Omron AC Servo motor Typical PM servo motors.

Typical servo motor system with either encoder or resolver feedback.

Rotary encoder components and absolute rotary encoder code Lead screw drive system

Lead screw kinematic motion Ball screw drive system

Two types of PC-based control system architecture. Flow of motion control system

XY table user interface

Detailed diagram of Type 2 architecture General layout diagram of the PCI-8164

Methodology flow chart

Initial drafting of Z-axis pneumatic slider Initial drafting of Z-axis lead screw mechanism Example of XY positioning user interface

Complete 3D design of Z-axis Gripper unit with marker pen

5 5 8 10 14 15 17 19 21 26 26 28 32 33 34 35 38 46 51 51 53 55 57

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x 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 5.1 5.2 5.3 6.1

Design of Back Plate

Fabrication process of Back Plate Fabricated Back Plate

Design of Bottom Plate

Fabrication process of Bottom Plate Fabricated Bottom Plate

Design of Pen Gripper Unit parts

Fabrication process of Pen Gripper Unit parts Fabricated Pen Gripper Unit parts

Linear slider unit Slider shaft

Double acting cylinder Solenoid valve

FRL unit

Main air supply port Completed Z-axis

Output circuit for the SVON signal Solenoid valve wire connection User interface for XY table Solenoid valve signal light

The load to the cylinder of XY table

The force exerted by cylinder during extension The force exerted by cylinder during retraction

The improvement done on the XY table

60 60 61 61 62 62 63 63 63 64 65 66 66 67 67 68 69 69 71 71 72 73 74 80

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LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED

NOMENCLATURE

AC - Alternative current

ASIC - Application-specific integrated circuit bps - Bytes per second

CAD - Computer Aided Design

CAM - Computer Aided Manufacturing CLU - Control-loop-unit

CNC - Computer Numerical Control CPU - Central processing unit DC - Direct current

DOF - Degree of freedom DPU - Data-processing-unit FIFO - First In, First Out

FKP - Fakulti Kejuruteraan Pembuatan FRL - Filter, regulator and lubricator HP - Horse power

I/O - Input and output

IT - Information Technology KE - Kinetic energy

LED - Light emitting diode MCU - Machine Control Unit MV - Motor voltage

PC - Personal Computer

PLC - Programmable Logical Controller PM - Permanent magnet

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xii RPM - revolution per minute

SCADA - Supervisory Control and Data Acquisition Servo - Servo motor

SOL - Solenoid

SVON - General-purposed digital output pin VB.NET - Microsoft Visual Basic.NET

% - Percent e.g. - For example etc - and others

µ - Coefficient of Friction rps - Revolutions per second g - gram

mm - millimeter N - Newton F - Force MPa - Mega Pascal p - Pitch

l - Lead

∆θ - Rotational displacement

∆x - Translational displacement N - Net gear ratio

Nls - Effective gear ratio

Jeff - Rotary inertia seen at the input shaft

Wl - Weight of the load

Fl - Load force

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CHAPTER 1

INTRODUCTION

1.1 Background

There are several motivating factors for this particular choice of a project. Programmable coordinate positioning systems employing motor controls have diverse applications and are extensively used in areas where precision linear and or, non-linear traversals are required. These precision machines are widely used in many modern manufacturing processes; a large proportion of these machines require the accurate positioning of some sort of tools or probes with respect to a work piece.

There are multitudes of different manipulators that find themselves attached to the XY positioning rails. Some of which include, lenses for microscope applications, laser heads, plotter heads, plasma cutting heads, robotic grippers for placement of parts, and general robotic manipulation instruments that need latitude and longitude positioning. Moreover, the design and integration of a linear positioning system employs knowledge in the areas of software and hardware design, control systems and power electronics.

However, controlling the XY coordinate positioning system has become a challenging task for engineers for maintaining the accuracy of motion and in reducing subsequent errors in this position. Hence they have introduced the positioning control system which controlled via computers. So, the application of XY table continuous motion programming with PC based control studied and investigated in this project as an improvement of previous research.

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1.2 Problem Statement

The surface area of the XY table can move horizontal or vertical towards X-axis and Y-axis to perform the programmed task. With the existing XY table, an object such as workpiece or tool for machining application can be hold in a fix position. However this system restricts the operation for continuous motion when the positions of the tool or workpiece have to change. So, the tool or workpiece have to move along Z-axis in order to acquire continuous motion. Since there is no movable Z-Z-axis in the current XY table, it has been a significant limitation in PC based positioning control system. In order to meet the current industrial requirement of automation application continuous motion programming is necessitated. Furthermore, for high precision operation automation system the current two axes are inadequate. Thus the third axis called Z-axis should be designed and added to the current XY positioning system. The continuous motion programming and the third axis may solve the current XY positioning system limitations in order to meet the current industrial automation requirements.

1.3 Scope of Project

Current XY table positioning system have two axes that can move horizontal or vertical towards X-axis and Y-axis to perform the programmed task .This mechanism operates in a single mode motion programming system. Therefore, this project is will be conducted to modify the current design, improve the current design in term of flow of programming method and mechanical structure. The research in this project is focused on application of XY table continuous motion programming with PC based control system. A technically improvised mechanical structure of the XY table is also expected to be designed based on the foundation laid earlier.

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1.4 Objectives

The main objectives of this final year project include:-

(a) To design the mechanical structure of the Z-axis

(b) To apply continuous motion programming in current XY table

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CHAPTER 2

LITERATURE REVIEW

This chapter discusses about literature discourse and review of the application of XY table continuous motion programming with PC based control. Throughout the world, there have been many researches about the concept, designs and implementation of many types of XY table positioning system.

2.1 XY Table

In XY table, the X-axis and Y-axis are movable axes and can hold workpiece or tool for machining application. XY tables usually contain motor mounting plates, couplings, lead screws, and a large base and top plate. An XY table is made up of two elements which are a forcer and a platen. The forcer glides over the platen on frictionless air bearings and moves continuously in a linear motion across the platen. This action occurs due to linear motoring modules, typically between two and four, responding to currents. Variations among XY tables include the ways and the drive mechanism. The ways determine load capacity, straight-line accuracy, and stiffness, while the drive mechanisms determine smoothness and speed. Other factors imperative to XY tables are the accuracy, repeatability, and resolution required, as well as the appropriate motor for the application and whether or not an encoder is needed. The example applications of an XY table include CNC machining, milling and welding. All these applications involve automated positioning for time saving and reducing human error. The positioning is mostly controlled by PLC, CNC controller or PC based programming.

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Figure 2.1: Main components of XY table

(Source:Danaher Precision Systems Product Catalogue)

The XY table consists of a travel mechanism, bearings, drive mechanism, motor and motor driver (Hi-Dong Chai, 1998). Figure 2.1 shows the typical components of XY table such as motor, limit sensors, drive mechanism, table, flexible coupling and other components. The characteristics and advantages depend on its appearance of XY table and the body frame of XY table.

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The XY table studied in this project shown in Figure 2.2. The travel distance of this table designed as 1000mm along X-axis and Y-axis respectively. The top plane of the XY of the XY table designed with rows of steel bars so that the workpiece can be clamped. Thus, a variety size of workpiece can be applied for the operation. Each axis consists of two shafts, which are made of steel with these shafts act as guide rail to make a smooth movement and prevention from a vibration. Beside that on the below side of the body of XY table consists of four rollers. With rollers, the XY table is flexible to be moved or placed. Furthermore, this allows easy loading and uploading.

XY tables are most often mounted horizontally. Depending on the specifications, XY tables may also be used in microelectronics assembly, laser machining, and factory automation. The top table can be positioned with high precision and moved at high acceleration and deceleration. The present invention relates to an XY table which is used as a positioning table in semiconductor assembling equipment, machine tools, measurement equipment, etc (Takeo Suzuki,1998).

Otherwise, an automatic XY table used motor to control motion of table surface can be selected if complex project required a precise and skilled movement of the table. This is the other option of moving XY table surface, instead of doing it manually by turning levers. A machine can move table surface on a precise path since it can hook up to computer and the path is programmable. Data input is key in and then the work can be proceeding easily. Hooking up XY table this way can be very effective when looking for a very accurate and precise finish product. There are different ways for XY table built or used to fulfill and fit the requirements of the users.

The standard XY table is usually designed and built from heavy-duty steels including stainless and are meant to last for many years with nominal maintenance. Most XY table working surface are built for toughness in design to get a more rigidity and stressed relieved for minimal environmental effect. Precision rails and bearing blocks are used to give an accurate and repeatable operation. Most basic XY table is accurate. When working on a delicate project vibration need to be concern, thus, vibration control within the table is made for minimal vibration. XY table that

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equipped with proper tools, which combined high precision, high speed and low settling time is regularly been selected to carry out the desired work (Kallmeyer, M.

et al., 1998).

Moreover, an invention of XY table relates to an improved XY table. A plate or the like is cut along imaginary line or a marked line. For example, a thick iron plate cut by a gas torch or plasma torch. The cutting operation may be manual or automatic. It is, however, not easy to handle a heavy iron plate. In addition, a large iron plate cannot be easily cut by a reasonable size of cutting machine (Chen, M. F. et al., 2007).

The objective of this invention is to provide an XY table, which can be easily moved to a desired position for various operations. Specifically, this invention includes an XY table for processing an object such as an iron plate comprising a frame having an opened formed. Thereby, a moving member moving in an X-axis and Y-axis at a right angle to the X-axis, a head for cutting, marking or machining attached to the moving means for processing the object through the opening, and a setting mechanism for detachably setting the frame to the object.

There are a number of selections to make when choosing a motorized XY table. The major components should be considered when choosing XY table are the following (Hussain Z. Tameem, 1999):-

• load capacity

• stiffness

• straight-line accuracy

• the drive mechanism which determines speed and smoothness

• accuracy

• repeatability

• resolution

• the appropriate motor for the application

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1.2 Problem Statement

1.3 Scope of Project

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1.4 Objectives

The main objectives of this final year project include:-

(a) To design the mechanical structure of the Z-axis

(b) To apply continuous motion programming in current XY table

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CHAPTER 2

LITERATURE REVIEW

2.1 XY Table

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Figure 2.1: Main components of XY table (Source:Danaher Precision Systems Product Catalogue)

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equipped with proper tools, which combined high precision, high speed and low settling time is regularly been selected to carry out the desired work (Kallmeyer, M. et al., 1998).

There are a number of selections to make when choosing a motorized XY table. The major components should be considered when choosing XY table are the following (Hussain Z. Tameem, 1999):-

• load capacity • stiffness

• straight-line accuracy

• the drive mechanism which determines speed and smoothness • accuracy

• repeatability • resolution

• the appropriate motor for the application • encoder application

Application Of XY Table Continuous Motion Programming With PC Based Control.

APPLICATION OF XY TABLE CONTINUOUS MOTION

PROGRAMMING WITH PC BASED CONTROL

ANBALAGAN A/L MUNUSAMY

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

APPLICATION OF XY TABLE CONTINUOUS MOTION

PROGRAMMING WITH PC BASED CONTROL

DECLARATION

APPROVAL

ABSTRACT

ABSTRAK

DEDICATION

ACKNOWLEDGEMENTS

TABLE OF CONTENTS

LIST OF TABLES

LIST OF FIGURES

LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED

NOMENCLATURE

CHAPTER 1

INTRODUCTION

CHAPTER 2

LITERATURE REVIEW

CHAPTER 2

LITERATURE REVIEW

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Dukungan

Links

Application Of XY Table Continuous Motion Programming With PC Based Control.

APPLICATION OF XY TABLE CONTINUOUS MOTION

PROGRAMMING WITH PC BASED CONTROL

ANBALAGAN A/L MUNUSAMY

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

APPLICATION OF XY TABLE CONTINUOUS MOTION

PROGRAMMING WITH PC BASED CONTROL

DECLARATION

APPROVAL

ABSTRACT

ABSTRAK

DEDICATION

ACKNOWLEDGEMENTS

TABLE OF CONTENTS

LIST OF TABLES

LIST OF FIGURES

LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED

NOMENCLATURE

CHAPTER 1

INTRODUCTION

CHAPTER 2

LITERATURE REVIEW

CHAPTER 2

LITERATURE REVIEW

Parts

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