Design Of The Robust Gripper Control For Hoisting Mechanism.

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DESIGN OF THE ROBUST GRIPPER CONTROL FOR HOISTING MECHANISM

MUHAMMAD HAFIZ BIN ABD RAZAK

BACHELOR’S DEGREE OF MECHATRONIC ENGINEERING

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“I Hereby declare that I have read through this report entitle “Design of the Robust Gripper Control for Hoisting Mechanism” and found that it has comply the partial fulfillment for awarding the degree of Bachelor of Electrical Engineering (Mechatronic).”

Signature : ……….. Supervisor’s Name : Saleha Bte Mohamad Saleh

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DESIGN OF THE ROBUST GRIPPER CONTROL FOR HOISTING MECHANISM

MUHAMMAD HAFIZ BIN ABD RAZAK

This Technical Report for Final Year Project is submitted to Faculty of Electrical Engineering, Universiti Teknikal Malaysia Melaka In partial fulfillment for Bachelor Degree of Mechatronic Engineering.

Faculty of Electrical Engineering

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

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I declare that this report entitled “Design of the Robust Gripper Control for Hoisting Mechanism” is the result of my own research except as stated in the references. The report has not been accepted for any degree and is not concurrently submitted in candidature of any other degree.

Signature : ……….. Name : Muhammad Hafiz Bin Abd Razak Date : ……….

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To my family, whose love, support and encouragement have helped me navigate the Challenging waters of this project. Thank you.

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ACKNOWLEDGEMENT

First and foremost, I would like to thank Allah S.W.T for the completion the Design of the Robust Gripper Control for Hoisting Mechanism for fulfills the Final Year Project. This prototype concept will be implemented for produce and process the Nata De Coco at Industri Kecil & Sederhana, Bemban, Malacca.

Secondly, I would like to acknowledge my thankful to my Final Year Project Supervisor Puan Saleha Bte Mohamad Saleh who had taken a lot of efforts to meticulously go through my Final Year Project Report and came up with helpful suggestions. Without helping from her, I surely came into deep problem in completing this Final Year Project Report.Very thanks to my supervisor for her cooperation and endless patience in letting me “shadow” her around during fieldwork. Her cooperation indeed make my work became easier and faster.

Besides, I would like to extend my gratitude too to my friends for their kindness and advices to design the prototype with mechanical consideration aspect and spending their time teaching me about how to ensure the design reliable to handling the variety of load and also teach me about PLC controller connection, which seems to be very difficult for me to understand before. Million thanks to all of my friends that giving me so much supports to obtain the output of this project.

And at the same time, I would like to take the chance here to express my deeply thankful to my supplier and vendor for my project component who had taken a lot of effort to advise me and answering all my doubtful concern around field. Finally, I would like to express my heart full gratitude to my family and also lecturers for their support, constructive suggestion and also critism during the completion of my Final Year Project.

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ABSTRACT

The present work aims to describe the “Design of the Robust Gripper for Hoisting Mechanism”. As an overview, this project is developed the gripper for handling or transporting delicately the Nata de Coco jelly blocks, this type of gripper commonly found in the food industry. This project consists of two main parts, which is software and hardware. The goal of this project is to design, build and control a automation robust gripper in small scale and thus, experimentally analyze the load and stability of the robust gripper for handling the Nata de Coco’s steel basket approximately 50 kg as a real implementation in the Nata de Coco processing. Additionally, the overall system was controlled by using the FPO Panasonic Programmable Logic Controller in order to move the gripper linearly. Generally, to perform the mechanism movement for robust gripper, the Induction Motor being implemented as a transmission power in order to move the gripper for forward and backward operation from Platform A (Unload Platform) to water tank for leaching process and lastly to the ending point at Platform B (Loading Platform).

The pneumatic system was applied to control the gripper mechanism for act as a hoisting mechanism by in stroke and outstroke condition of Single Rod Double Acting Cylinder to handling the steel basket. The cage conceptual being implemented for Nata de Coco placement on the leaching tank for neutralization process. Besides that, gripper allow to be lifted indirectly contacted the jelly block surface. It can prevent and reduced the possibilities of damaging the jelly block surface. It was discovered the developed a prototype model and experimentally test the reliability of the gripper to handling the load capacity. As a result of this, it was capable to handling the load until 3kg.

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ABSTRAK

Laporan projek ini menerangkan pembangunan “ Rekabentuk Pencengkam Tegak untuk Mekanisma Pengangkat”. Secara keseluruhannya, projek ini telah merekabentuk pencengkam untuk membawa atau memindahkan Nata de Coco, pencengkam jenis ini kebiasaanya dijumpai di dalam industri pemprosesan makanan. Projek ini terdiri daripada dua bahagian iaitu pembangunan perisian serta perkakasan prototaip. Objektif projek ini adalah merekabentuk, membina dan mengawal automasi pencengkam dalam skala yang kecil dan membuat analisis secara ujikaji bagi menganalisa beban serta kestabilan pencengkam untuk membawa sangkar ataupun bakul berisi Nata de Coco yang seberat 50kg untuk skala yang sebenar kelak. Tambahan pula, sistem ini secara keseluruhannya dikawal dengan mengunakan Pengawal Aturcara Panasonic (FPO Panasonic Programmable Controller) untuk mengawal pergerakan pencengkam secara linear. Secara amnya, untuk melaksanakan mekanisma pergerakan pencengkam, Motor Aruhan (Induction Motor) akan digunakan untuk membawa pencengkam supaya berfungsi secara kehadapan dan juga kebelakang dari Platform A ke tangki air untuk proses pembersihan Nata de Coco tersebut dan juga ke Platform B iaitu destinasi terakhir pergerakan pencengkam dalam satu kitaran.

Sistem kawalan Pneumatik digunakan untuk mengawal mekanisma pencengkam yang bertindak sebagai pengangkat dengan cara menolak serta menarik rod silinder supaya dapat memegang dan membawa sangkar Nata de Coco. Konsep sangkar ini akan digunakan untuk menempatkan Nata de Coco ke dalam tangki cucian untuk proses meneutralkan asid. Disamping itu, pencengkam boleh mengangkat Nata de Coco tanpa sentuhan secara langsung terhadap permukaannya. Ia meliputi pembinaan model prototaip dan ujikaji untuk menentukan kebolehan pencengkam membawa muatan beban berbeza. Sebagai kesimpulannya, prototaip ini telah berjaya membawa Nata de Coco seberat 3kg.

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TABLE OF CONTENTS

CONTENTS TITLE PAGE

SUPERVISOR APPROVAL ii

TITLE iii

DECLARATION iv

DEDICATION v

ACKNOWLEDGEMENT vi

ABSTRACT vii

TABLE OF CONTENTS ix

LIST OF TABLES xiii

LIST OF FIGURES xiv

LIST OF APPENDIX xvii

NOMENCLATURE xviii

CHAPTER 1 INTRODUCTION 1.1 Project Background. 1

1.2 Objective. 3 1.3 Project Scope. 3 1.4 Problem Statement. 6

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CHAPTER 2 LITERATURE REVIEW

2.1 Introduction. 8

2.2 Literature Review 9

2.2.1 Literature Review 1 9

2.2.2 Literature Review 2 13

2.2.3 Literature Review 3 17

2.3 Theory of Material 20

2.3.1 Single Rod Double Acting Cylinder 20

2.3.2 Programmable Controller 25

2.3.2 Rack and Pinion Drive 32

2.3.4 Fiber Optic Sensor 34

2.3.5 Induction Motor 37

CHAPTER 3 METHODOLOGY

3.1 Introduction. . 40

3.2 Methodology of overall project activities 42 3.3 Methodology of Hardware Design and

Development. 47

3.4 Methodology for Software Design and

Development. 49

3.5 Methodology of Analysis 51

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CHAPTER 4 PROJECT DEVELOPTMENT

4.1 Overview 55

4.2 Hardware 56

4.2.1 Robust Gripper Design 56

4.2.2 Prototype of Robust Gripper for

Hoisting Mechanism 59

4.2.3 Steel Basket 62

4.2.4 Installation Electrical Control Devices 63 4.2.5 Internal Wiring of Electrical Component

on Control Panel 64

4.2.6 Pneumatic Connection 67

4.2.7 Installation Sensor 71

4.3 Software 73

4.3.1 GTWIN Software for Programmable

Touch Screen Display 73

4.3.2 FPWIN Software for Programmable Logic

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CHAPTER 5 RESULT AND ANALYSIS

5.1 Overview 81

5.2 Experimental Analysis 82

5.2.1 Experiment 1: Ability and Stability of

Robust Gripper handling different load. 82

5.2.2 Experiment 2: To test the functionality

of Induction Motor. 88

5.3 Theoretical Analysis 93

5.3.1 Overview of Theoretical Analysis 93

CHAPTER 6 CONCLUSION AND RECOMENDATION

6.1 Conclusion 110

6.2 Financial Costing 111

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LIST OF TABLE

TABLE TITLE PAGE

3.1 Project’s Planning Gantt Chart. 54 5.1 Ability of Robust Gripper carries the different load . 86

5.2 Relay B observation. 90

5.3 Relay A observation. 90

5.4 Theoretical Calculation for Permissible Torque of Motor

Gearhead (Newton ). 94

5.5 Theoretical Calculation for Pneumatic Cylinder. 97 5.6 Output Consumption from Anzaq Industries Sdn. Bhd 102 5.7 The Output Consumption by using Robust Gripper

Prototype. 102

5.8 Comparison Outcome Consumption between Anzaq.

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LIST OF FIGURE

FIGURE NO. TITLE PAGE

1.1 Manpower Loads Nata de Coco manually from storage

Tank into leaching tank. 6

2.1 Cylindrical Configuration. 11

2.2 Spherical Grasp Configuration. 11

2.3 Cable Transmission System for The Finger. 9

2.4 Hand Gripper System. 14

2.5 The end effectors of the Robotic Hand Gripper. 15 2.6 Flexible Gripper for Food Product Handling. 18

2.7 Pneumatic Cylinder. 21

2.8 Symbol of Single Rod Double Acting Cylinder 22

2.9 Typical Size of Pneumatic Cylinder 23

2.10 FPO Panasonic Programmable Logic Controller 25 2.11 Programmable Controller Block Diagram 27 2.12 High Speed Execution for PLC Operation 28 2.13 Terminology of Input and Output for PLC 30

2.14 Chain and Gear 32

2.15 Pinion (Gear) and Rack (Chain) arrangement. 33

2.16 Optical Fiber Sensor 34

2.17 Internal Reflection 35

2.18 Internal Reflection Behavior 36

2.19 Part of Induction Motor 37

2.20 Gear head of Induction Motor 38

3.1 Methodology Division 41

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3.3 Flowchart of Hardware Design Activities 48 3.4 Flowchart for Software Design and Development 50

3.5 Flowchart of Analysis Activities 52

4.1 3D View for Robust Gripper 56

4.2 Front View of Robust Gripper Design 58

4.3 Top View of Robust Gripper Design 58

4.4 Robust Gripper Prototype 59

4.5 Flow of Robust Gripper Operation 60

4.6 Detail Dimension of Steel Basket 62

4.7 Top and Front View 63

4.8 Installation Detail Drawing 64

4.9 Overall Devices Location 65

4.10 Internal Wiring Connection. 66

4.11 Pneumatic Interconnection Drawing. 68

4.12 Solenoid Valve Operation 69

4.13 Connection between Cylinders to Solenoid Valve 70 4.14 Connection between Solenoid Valve to Cylinder 70 4.15 Pressure Gauge Connection to Solenoid Valve 70

4.16 Inductive Proximity Sensor 71

4.17 Fiber Optic Sensor 72

4.18 Ladder Diagram of Programmable Display 77 4.19 Ladder Diagram for Indication Input/Output 77

4.20 Homing’s Ladder Diagram 78

4.21 Pick and Place Ladder Diagram 79

4.22 Ladder Diagram of Counting Up and Counting

Down the Position. 80

5.1 The location of Isolator Switch and Start Button 82

5.2 Pick and Place Menu 83

5.3 The 0.5kg of Sample Nata de Coco 84

5.4 Sample Nata de Coco and Steel Basket 84

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Place onto the Tank 1 85

5.6 Robust Gripper Place the Sample Nata de Coco

Onto Tank 1 85

5.7 Internal Wiring system on Control Devices 88

5.8 The Wiring Connection of Relay 89

5.9 Permissible Torque of Induction Motor Gearhead 94

5.10 Pneumatic Cylinder 96

5.11 Push Force Analysis of Pneumatic Cylinder 98 5.12 Pull Force Analysis of Pneumatic Cylinder 99 5.13 Leaching Tank consists of 500kg for each tank 101 5.14 Output Consumption by Robust Gripper Prototype 103 5.15 Comparison Output Between Anzaq Industries

Method and Robust Gripper for Analysis 50kg 105 5.16 Overall hardware prototype 107

5.17 Part for improvement 108

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LIST OF APPENDIX.

APPENDIX NO. TITLE PAGE

APPENDIX A Drawing of Robust Gripper Design 110

APPENDIX B Input and Output Assignment 111

APPENDIX C Programmable Logic Control

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NOMENCLATURE

UTeM Universiti Teknikal Malaysia Melaka. EOAT End of Arm Tooling

Kg Kilogram

PLC Programmable Logic Control. IKS Industri Kecil dan Sederhana. DAQ Data Acquisition Card. D.O.F Degree of Freedom. DSP Digital Signal Processing. CPU Central Processing Unit. LED Light Emitting Diode. I/O Input and Output. AC Alternating Current. DC Direct Current.

D-H Denavit-Hartenberg Algorithm SAC Single Acting Cylinder.

DAC Double Acting Cylinder.

F Force

p Gauge Pressure

A Full Bore Area

d Full Bore Piston Diameter

PB Push Button.

MCB Miniature Circuit Breakers. NA Numerical Aperture

CAD Computer Aided Design.

Mpa Mega Pascal

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CHAPTER 1

INTRODUCTION

1.1 Project Background.

This project title is “Design of Robust Gripper Control for Hoisting Mechanism”. Robust gripper is a type of parts from one location to another and it is driven by using the pneumatic system. The term of robust gripper is one of the mechanical devices that use either rotary or linear actuators to mimic the motion of the human hand or human movement that directly helps convert pneumatic energy into mechanical energy.

This project is developed to design and fabricated a prototype system with a combination of hardware and software to perform a gripper prototype application for handling the delicate Nata de Coco (jelly block) as a real implementation at Anzag Industries Sdn. Bhd, Industri Kecil dan Sederhana Bemban, Malacca. The controller used is FPO Series Programmable Controller by using FPWIN Pro, Panasonic Programming Software.

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The fiber optic sensor technology which is to measure the rotational of the gear teeth system is applied to translate the linear motion of the robust gripper movement. Ideally, an optical fiber is a cylindrica transmits light along its axis, by the process of the Inductive Proximity sensor was applied together to detect the metal for reset the counting numbers of the teeth gear.

In order to set up the mode of the programming for overall process, the Programmable Display is developed which it is provide the interface between user and the machine. Programmable Display is able to display the sequence of the program and act as an operation input device to running the desired sequence and condition of the machines in Manual Mode condition.

The analysis of the project has been done to ensure the ability of the robust gripper to grasp the load without failure. Previously, the robust gripper just used the stepper motor as a transmission device and after series of experimented, the Induction Motor was implemented due to the load torque is much better than stepper motor that has been used previously.

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1.2 Objective.

The objective of this project is to design and developed a gripper prototype for hoisting mechanism. This prototype concept will be implemented in Food Manufacturing Process for Industri Kecil & Sederhana (IKS), Anzag Food Industries Sdn. Bhd to process the Nata De Coco. The objectives of this project are:-

1. To design and fabricated the prototype of gripper mechanism in order to carry the entire Nata de Coco jelly blocks production.

2. To design and fabricated the cage for jelly blocks placement on the leaching tank.

3. To design and develop the controller to control the gripper automation system.

4. To analyze the gripper load capacity as a future improvement for exactly scales of hardware.

1.3 Project Scope.

To perform the functionality of this machine prototype, the project scope should be parallel with the present work aim of this project to Design the Robust Gripper for Hoisting Mechanism. It is important to clarify that, this study of the machine prototype concept does pretend to analyze neither current scale is able to carry the 50 kg load after upscale the size for real implementation. It is the main project scope to describe, in a quantitative way, the results of those actions carried out by robust gripper for hoisting mechanism to improve the previously gripper performance in term of ability to grasp the different load in capability range up from 1 kg to 3 kg for study stage, and 50 kg in real implementation. This general project scope can be split up into the following specific project scope:-

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1. Design and fabricated the gripper prototype by using Solidwork for design and by using Aluminium Profile for fabricated the gripper.

2. Design and fabricated the cage for Nata de Coco placement by using the steel basket.

3. Design a Ladder Diagram Programmed by using FPWIN Pro, Panasonic Programming Software for controller.

4. Conduct an experiment and do the analysis to compare the component specification for future application and implementation.

The scope of this research is to design a gripper prototype for hoisting mechanism by using Solidwork software. This conceptual robust gripper prototype will be implemented after the completion of the studies and researches aspect on the combination between hardware and software including the project analysis in term of the suitability of the component and reliability of the prototype before applying in the real implementation at Industri Kecil & Sederhana (IKS) to leaching process for neutralizes the acid. In order to be automatic grasp the different load, the robust gripper prototype fully controlled by using FPO Series Programmable Controller. The controller uses FPO Series Programmable Controller for efficient controlling related to the automation application and also the maintenance factor.

In this project, the prototypes of the gripper mechanism used the Aluminium Profile as a carrier’s arm for assembling and Single Rod Double Acting Cylinder as a hoisting mechanism for horizontal motion. For gripper prototype, the pneumatic supply was implemented for grasping properly the different of load. The pneumatic systems are widely use in industries especially in automation control system. Besides that, as a safety aspect, the pneumatic system was applied on this robust gripper prototype. It is because, the pneumatic system more clean and suitable for used in food industries processing compared to hydraulic system.

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This prototype used the conceptual cage design to reduce damaging Nata de Coco jelly blocks surface via directly physical contact and reduces the time for load the nata de coco onto the cleaning tank. This is the alternatives way to reduce the manual work by manpower to load the Nata de Coco jelly blocks onto the leaching tanks. The gripper mechanism grasp the cage containing the Nata de Coco to transport delicately to the leaching tank for cycle cleaning process to transform the pH of Nata de Coco from acid to become neutral.

Other than that, this prototype used the FPO Series Programmable Controller as an automation system controller. The ladder diagram was constructed by using FPWIN Pro, Panasonic Programming Software. Additionally, the analysis focused on ability the gripper for handling the a maximum load in range 50 kg for future factory application and to upsizing the prototype scale due to the efficiency, safety and productivity of prototype operation.

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1.4 Problems Statement.

The productivity of Nata de Coco production by Anzag Industries Sdn.Bhd is not being able to achieve the demand of the market. The efficiency of the Industri Kecil dan Sederhana (IKS) to produce the Nata de Coco still unachieved the maximum target due to the traditional method. In other hand, to improve the system in term of productivity and efficiency for Nata de Coco process, the automatic robust gripper was designed to quicken the loading of the nata de coco onto the cleaning tank by manpower. This problem statement can be split up into the following problem factor below:-

i. Manpower Factor.

The common problem in food industry process is manpower. Manpower is required to load the Nata de Coco jelly blocks manually from storage tank to the water tank for cleaning purpose. This method will directly affect the production cost and time to produce the clean Nata de Coco. Figure 1.1, shows the manual works by manpower to clean the Nata de Coco and loading the jelly blocks into the leaching tank for cycle cleaning process to transform the pH of Nata de Coco from acid to become neutral.

Figure 1.1: Manpower loads the Nata de Coco manually from Storage Tank into the Leaching Tank.

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CHAPTER 1

INTRODUCTION

1.1 Project Background.

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1. To design and fabricated the prototype of gripper mechanism in order to carry the entire Nata de Coco jelly blocks production.

2. To design and fabricated the cage for jelly blocks placement on the leaching tank.

3. To design and develop the controller to control the gripper automation system.

4. To analyze the gripper load capacity as a future improvement for exactly scales of hardware.

1.3 Project Scope.

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1. Design and fabricated the gripper prototype by using Solidwork for design and by using Aluminium Profile for fabricated the gripper.

2. Design and fabricated the cage for Nata de Coco placement by using the steel basket.

3. Design a Ladder Diagram Programmed by using FPWIN Pro, Panasonic Programming Software for controller.

4. Conduct an experiment and do the analysis to compare the component specification for future application and implementation.

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de Coco jelly blocks surface via directly physical contact and reduces the time for load the nata de coco onto the cleaning tank. This is the alternatives way to reduce the manual work by manpower to load the Nata de Coco jelly blocks onto the leaching tanks. The gripper mechanism grasp the cage containing the Nata de Coco to transport delicately to the leaching tank for cycle cleaning process to transform the pH of Nata de Coco from acid to become neutral.

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1.4 Problems Statement.

i. Manpower Factor.

Figure 1.1: Manpower loads the Nata de Coco manually from Storage Tank into the Leaching Tank.

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