MANUFACTURING AUTOMATION AND ROBOTICS
Contents
1. power ONLY AFTER all the cable connections are well connected including power lines RS 232 cable etc 2 Turn off power supply BEFORE disconnecting power line and RS 232 cable 3 Don t touch any power source when your hands are wet If any of these rules are violated you will be asked to leave the lab You will receive a grade of 0 for that lab assignment and will not be allowed to make up the lab ENTC 410 Class and Lab Schedule NOTE Topics or labs may not be covered exactly on the date shown and other relevant topics or labs may be covered if time allows You are responsible for attending class to obtain up to date information on topics covered and examination dates VPLC stands for Virtual PLC You can access VLPC materials from my web page at hitp hsieh tamu edu under Virtual PLC weer __tscure peaa _ _tan _ _eupent_ Introduction to Automation Industrial Automation Case Video Control e Role of a PLC in an Study Logix 5550 automated system Automation Controls Notes PLC Hardware Software Control Logix 5550 Programmable Logic Controllers VPLC 1 2 Configuration PLC Structure of a PLC How signal information flows Addressing How programs are executed 3 Numbering system Stenerson C2 PLC Instruction Control Logix 5550 Programming 4 Q1 Overview of PLC Instructions MicroLogix 1000 PLC Instruction Control Logix 5550 Examine On Off User Manual Programming Program structure VPLC 3 4 Bool2. ENTC 410 MANUFACTURING AUTOMATION AND ROBOTICS Revised 8 2015 FALL 2015 Instructor Dr Sheng Jen Tony Hsieh TA Bo Peng Benjamin Email hsieh tamu edu Email bopeng2013 email tamu edu Office Thompson Hall 223 Office Thompson 115CA 002D Office Hours Tues 2 5 pm amp Thur 2 5 pm Phone 845 4985 Web Site http hsieh tamu edu Textbook 1 Lecture notes lab exercises and homework assignments all in one volume is available from Copy Corner on Texas Ave 2 Virtual PLC http nsieh tamu edu References 1 John W Webb and R A Reis Programmable Logic Controllers 6th edition Prentice Hall 2006 2 Frank D Petruzella Programmable Logic Controllers 3 edition McGraw Hill 2005 3 Richard A Cox and Terry Borden Technician s Guide to Programmable Controllers 5 edition Thompson and Delmar Learning 2007 4 Allen Bradley Control Logix 5550 User Manual 2006 5 Jon Stenerson Fundamentals of Programmable Logic Controllers Sensors and Communications 3 Ed Prentice Hall 2005 6 Sabrie Soloman Sensors and Control Systems in Manufacturing McGraw Hill 1994 7 Adept Robot V Programming and Vision System 1990 8 Allen Bradley MicroLogix 1000 and PLC 5 User Manual 2003 Course Objectives To enhance the student s knowledge and skills in the areas of 1 programmable logic controllers PLC 2 sensor technology 3 industrial robotics and 4 design and integration of automated system
3. Studies Case1 WidgetAssembly html http etidweb tamu edu hsieh CaseStudies Case2 Choco Candy html
4. ean algebra Timers Counters MicroLogix 1000 Timer Instructions for Control Logix 5550 e TON TOF RTO User Manual Industrial Process Control VPLC 3 6 Arithmetic Sequencers MicroLogix 1000 Injection Molding M C App Control Logix 5550 e CTU CTD User Manual 1 e ADD SUB VPLC 3 7 Plant Floor Communication Notes Injection Molding M C App Device net and e Layers of communication 2 Control net PLC networking e AB Communication Protocol 8 Q2 Actuators Cylinders Solenoids Notes Actuators and PLC Control Logix 5550 and Relays Integration and Pneumatics e Valves structure functionality categories amp applications e Solenoids structure functionality amp applications week Lectures Readings ta Equipment 9 T2 Sensor Technology Notes Proximity Sensors and PLC Industrial Control amp 10 30 e Temperature sensors VPLC 8 Integration Sensor module and operating principles structure Control Logix 5550 and characteristics Inductive and capacitive proximity sensors operating principles structure and characteristics e PLC wiring 10 Sensor Technology II Notes Optical Proximity Sensors Industrial Control amp e Optical interrupter Optical VPLC 8 Integration and PLC Sensor Module and reflector Control Logix 5550 e Advantages and disadvantages e PLC wiring II 11 Industrial Robots Programming Notes Robot programming for Adept r
5. ing and Interfacing Week 12 Programming Week 13 Demonstration Pao Grades and Changes All quizzes lab reports and exams will be graded and returned as soon as possible Check with me regarding any grading errors immediately upon receiving your graded paper Any request to change a grade after this time will not be considered unless you have an excused absence Your course grade will be calculated as follows Homework Quizzes 10 Monthly Exams 3 45 15 each Lab Assignment 12 Final Exam or Semester Project 20 Lab Final 12 Attendance grade 1 Perfect attendance 1 AMERICANS WITH DISABILITIES ACT POLICY STATEMENT The Americans with Disabilities Act ADA is a Federal anti discrimination statute that provides comprehensive civil rights protection for persons with disabilities Among other things this legislation requires that all students with disabilities be guaranteed a learning environment that provides for reasonable accommodation of their disabilities If you believe that you have a disability requiring accommodation please contact the Department of Student Life Services for Students with Disabilities in room 126 of the Koldus Building or call 845 1637 AGGIE CODE OF HONOR An Aggie does not lie cheat or steal or tolerate those who do For more information about the Aggie Code of Honor please visit the Honor Council Rules and Procedures website at http www tamu edu aggiehonor SAFETY RULES 1 Turn on PLC
6. obot e Industrial robot material handling task l e Configurations e Control system e Programming Industrial Robots Interfacing Robot programming for Micro robots e Applications material handling task II Semester Project Due 12 1 ar Micro robots Automated Systems and PLCs Cell level machine integration Industrial Control amp Software and hardware interface for sensors motors switches Sensor Module robot and PLC robots and PLC Device Net and Control Logix 5550 Machine Vision Lab Final 11 30 to 12 4 Review for Final Exam FinalExam Monday December 14th 8 00 a m to 10 00 a m LAB POLICY COMPLIANCE fully understand the lab policies and safety rules in this Lab Manual If violate the rules will be asked to leave the lab and will not be allowed to make up for the lab By signing below am committed to abide to these rules and policies In addition will go to https howdy tamu edu to complete the lab safety training required by the University Full name UIN Lab session xxx Signature Date LAB REPORT FORMAT _ Title Page Lab Number Name and Date 2 The body of the report should include the following for each task a Problem Statements Task Number b Sequence of operations c Input and output devices and terminal address assignments d Ladder logic program 3 For a detailed example see these web pages http etidweb tamu edu hsieh Case
7. other non class related activities during class If you do one or the above or interfere with a lecture you will be asked to leave the class and be considered absent for that day s class The classroom computers track every online activity you engage in including applications that you launch and web sites that you visit You need to sit on your assigned seat Questions about grading should be addressed after class in my office Team Semesier Project An optional team semester project will involve the application of techniques methodologies discussed in classes and labs such as use of sensors relays robot PLC and interfacing techniques Most previous projects have been in the area of automating a manufacturing process e g egg packaging Therefore an appropriate topic should include an identified product and process The project will begin after the first monthly exam and you will be required to submit reports periodically as the semester progresses If you plan to participate in a project you should begin thinking about topics as early as possible Examples of past student projects will be made available for review An oral presentation and written report will be due on December 1 2015 Each team should consist of two people Examples of previous student projects include 1 Development of a pneumatic driven robot system 2 Use of PLC for injection molding machine control 3 Multiple robot system collaboration for disk drive assembl
8. s e g flexible manufacturing cell In addition students will exercise the above principles and methodologies in close to real world problem solving Prerequisites ENTC 380 383 376 and IDIS 300 or approval of instructor Accreditation Board for Engineering and Technology ABET Outcomes This course will focus on the following three ABET required learning outcomes with moderate M impact 2a Mastery of knowledge techniques skills and modern tools 2e Ability to function effectively on teams and 2f Ability to identify analyze and solve technical problems Attendance Policy Make up Exams Homework and Quizzes Students are expected to attend all lectures and lab classes except for an excused University absence see University Rules In such cases you should provide me a copy of the document that supports your absence Only under this circumstance will any individual be allowed to make up an exam or quiz If you have more than 3 unexcused absences one point will be deducted from your final grade for each class you miss If you maintain perfect attendance one point will be added to your final grade Lab reports are due one week from the assigned date at the beginning of the next lab Late lab reports will not be accepted for grading Class environment It is important that we have a good environment for learning in the classroom Therefore please do not play games check email read newspapers work on puzzles or engage in
9. y 4 Robotic work cell design for egg packaging 5 Automated system for cutting seat belt retractor sleeves 6 Use of vision system for printed circuit board inspection You can find more examples by doing a search for Automated Assembly System on YouTube or by reviewing web sites for the following equipment vendors and system integrators 1 www adept com 2 www motoman com 3 www abb com 4 www fanucrobotics com 5 www doerfer com 6 www atsautomation com 7 www mikron com 8 www ab com 9 www cognex com 10 www grenzebach com index php eng company grenzebach automation gmbh Evaluation criteria for semester projects will be as follows a Written report 20 b Physical model 75 based on working system complexity and creativity c Team member evaluation 5 Format of the report a Introduction b Problem to be solved process to be automated c Construction of Physical model Description of major components CAD drawings parts and sensors d Sequence of operations e I O ports assignments f Overall system schematic g Ladder logic programming explanation of logic h Conclusion and future directions i Appendix bill of materials Milestones a Week 2 Approved 1 page concept paper system layout prefer CAD including the I O devices and part list Fishertechnik parts and other parts such as from Amazon budget lt 100 Week 7 Completion of physical model Week 10 Wir
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