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page 1 Integration and Automation of Manufacturing Systems by: Hugh Jack © Copyright 1993-2001, Hugh Jack page 2 PREFACE 1. INTEGRATED AND AUTOMATED MANUFACTURING . . . .13 1.1 1.2 1.3 2. 13 13 14 16 17 17 19 22 AN INTRODUCTION TO LINUX/UNIX . . . . . . . . . . . . . . . . . . .23 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3. INTRODUCTION 1.1.1 Why Integrate? 1.1.2 Why Automate? THE BIG PICTURE 1.2.1 CAD/CAM? 1.2.2 The Architecture of Integration 1.2.3 General Concepts PRACTICE PROBLEMS OVERVIEW 2.1.1 What is it? 2.1.2 A (Brief) History 2.1.3 Hardware required and supported 2.1.4 Applications and uses 2.1.5 Advantages and Disadvantages 2.1.6 Getting It 2.1.7 Distributions 2.1.8 Installing USING LINUX 2.2.1 Some Terminology 2.2.2 File and directories 2.2.3 User accounts and root 2.2.4 Processes NETWORKING 2.3.1 Security INTERMEDIATE CONCEPTS 2.4.1 Shells 2.4.2 X-Windows 2.4.3 Configuring 2.4.4 Desktop Tools LABORATORY - A LINUX SERVER TUTORIAL - INSTALLING LINUX TUTORIAL - USING LINUX REFERENCES 23 23 24 25 25 26 26 27 27 28 28 29 31 33 34 35 35 35 36 36 37 37 38 40 41 AN INTRODUCTION TO C/C++ PROGRAMMING . . . . . . . . .43 3.1 3.2 3.3 3.4 INTRODUCTION PROGRAM PARTS CLASSES AND OVERLOADING HOW A ‘C’ COMPILER WORKS 43 44 50 52 page 3 3.5 3.6 3.7 3.8 3.9 3.10 3.11 4. STRUCTURED ‘C’ CODE COMPILING C PROGRAMS IN LINUX 3.6.1 Makefiles ARCHITECTURE OF ‘C’ PROGRAMS (TOP-DOWN) 3.7.1 How? 3.7.2 Why? CREATING TOP DOWN PROGRAMS CASE STUDY - THE BEAMCAD PROGRAM 3.9.1 Objectives: 3.9.2 Problem Definition: 3.9.3 User Interface: Screen Layout (also see figure): Input: Output: Help: Error Checking: Miscellaneous: 3.9.4 Flow Program: 3.9.5 Expand Program: 3.9.6 Testing and Debugging: 3.9.7 Documentation Users Manual: Programmers Manual: 3.9.8 Listing of BeamCAD Program. PRACTICE PROBLEMS LABORATORY - C PROGRAMMING 53 54 55 56 56 57 58 59 59 59 59 59 60 60 60 61 61 62 62 64 65 65 65 65 66 66 NETWORK COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . .68 4.1 4.2 4.3 4.4 INTRODUCTION NETWORKS 4.2.1 Topology 4.2.2 OSI Network Model 4.2.3 Networking Hardware 4.2.4 Control Network Issues 4.2.5 Ethernet 4.2.6 SLIP and PPP INTERNET 4.3.1 Computer Addresses 4.3.2 Computer Ports Mail Transfer Protocols FTP - File Transfer Protocol HTTP - Hypertext Transfer Protocol 4.3.3 Security Firewalls and IP Masquerading FORMATS 68 69 69 71 73 75 76 77 78 79 80 81 81 81 82 84 85 page 4 4.5 4.6 4.7 4.8 4.9 5. 85 87 88 88 89 89 89 89 91 102 103 103 104 105 107 DATABASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 5.1 5.2 5.3 5.4 6. 4.4.1 HTML 4.4.2 URLs 4.4.3 Encryption 4.4.4 Clients and Servers 4.4.5 Java 4.4.6 Javascript 4.4.7 CGI NETWORKING IN LINUX 4.5.1 Network Programming in Linux DESIGN CASES SUMMARY PRACTICE PROBLEMS LABORATORY - NETWORKING 4.9.1 Prelab 4.9.2 Laboratory SQL AND RELATIONAL DATABASES DATABASE ISSUES LABORATORY - SQL FOR DATABASE INTEGRATION LABORATORY - USING C FOR DATABASE CALLS 109 114 114 116 COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 6.1 6.2 6.3 6.4 SERIAL COMMUNICATIONS 119 6.1.1 RS-232 122 SERIAL COMMUNICATIONS UNDER LINUX 125 PARALLEL COMMUNICATIONS 129 LABORATORY - SERIAL INTERFACING AND PROGRAMMING 130 6.5 7. LABORATORY - STEPPER MOTOR CONTROLLER 130 PROGRAMMABLE LOGIC CONTROLLERS (PLCs) . . . . . . .134 7.1 7.2 7.3 7.4 7.5 BASIC LADDER LOGIC WHAT DOES LADDER LOGIC DO? 7.2.1 Connecting A PLC To A Process 7.2.2 PLC Operation LADDER LOGIC 7.3.1 Relay Terminology 7.3.2 Ladder Logic Inputs 7.3.3 Ladder Logic Outputs LADDER DIAGRAMS 7.4.1 Ladder Logic Design 7.4.2 A More Complicated Example of Design TIMERS/COUNTERS/LATCHES 136 138 139 139 141 144 146 147 147 148 150 151 page 5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.20 7.21 LATCHES TIMERS COUNTERS DESIGN AND SAFETY 7.9.1 FLOW CHARTS SAFETY 7.10.1 Grounding 7.10.2 Programming/Wiring 7.10.3 PLC Safety Rules 7.10.4 Troubleshooting DESIGN CASES 7.11.1 DEADMAN SWITCH 7.11.2 CONVEYOR 7.11.3 ACCEPT/REJECT SORTING 7.11.4 SHEAR PRESS ADDRESSING 7.12.1 Data Files Inputs and Outputs User Numerical Memory Timer Counter Memory PLC Status Bits (for PLC-5s) User Function Memory INSTRUCTION TYPES 7.13.1 Program Control Structures 7.13.2 Branching and Looping Immediate I/O Instructions Fault Detection and Interrupts 7.13.3 Basic Data Handling Move Functions MATH FUNCTIONS LOGICAL FUNCTIONS 7.15.1 Comparison of Values BINARY FUNCTIONS ADVANCED DATA HANDLING 7.17.1 Multiple Data Value Functions 7.17.2 Block Transfer Functions COMPLEX FUNCTIONS 7.18.1 Shift Registers 7.18.2 Stacks 7.18.3 Sequencers ASCII FUNCTIONS DESIGN TECHNIQUES 7.20.1 State Diagrams DESIGN CASES 7.21.1 If-Then 152 153 157 159 160 160 161 162 162 163 164 164 165 165 166 168 169 172 172 172 173 174 174 175 175 179 181 182 182 184 191 191 193 194 195 196 198 198 199 200 202 203 203 206 207 page 6 7.22 7.23 7.24 7.25 7.26 7.27 8. 207 208 209 209 210 211 212 213 216 216 219 221 223 224 227 237 238 PLCS AND NETWORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . .240 8.1 8.2 8.3 8.4 8.5 9. 7.21.2 For-Next 7.21.3 Conveyor IMPLEMENTATION PLC WIRING 7.23.1 SWITCHED INPUTS AND OUTPUTS Input Modules Actuators Output Modules THE PLC ENVIRONMENT 7.24.1 Electrical Wiring Diagrams 7.24.2 Wiring 7.24.3 Shielding and Grounding 7.24.4 PLC Environment 7.24.5 SPECIAL I/O MODULES PRACTICE PROBLEMS REFERENCES LABORATORY - SERIAL INTERFACING TO A PLC OPEN NETWORK TYPES 8.1.1 Devicenet 8.1.2 CANbus 8.1.3 Controlnet 8.1.4 Profibus PROPRIETARY NETWORKS Data Highway PRACTICE PROBLEMS LABORATORY - DEVICENET TUTORIAL - SOFTPLC AND DEVICENET 240 240 245 246 247 248 248 252 258 258 INDUSTRIAL ROBOTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262 9.1 9.2 9.3 9.4 INTRODUCTION 9.1.1 Basic Terms 9.1.2 Positioning Concepts Accuracy and Repeatability Control Resolution Payload ROBOT TYPES 9.2.1 Basic Robotic Systems 9.2.2 Types of Robots Robotic Arms Autonomous/Mobile Robots Automatic Guided Vehicles (AGVs) MECHANISMS ACTUATORS 262 262 266 266 270 271 276 276 277 277 280 280 281 282 page 7 9.5 9.6 9.7 9.8 10. 283 284 286 286 290 291 296 296 OTHER INDUSTRIAL ROBOTS . . . . . . . . . . . . . . . . . . . . . . . .299 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 11. A COMMERCIAL ROBOT 9.5.1 Mitsubishi RV-M1 Manipulator 9.5.2 Movemaster Programs Language Examples 9.5.3 Command Summary PRACTICE PROBLEMS LABORATORY - MITSUBISHI RV-M1 ROBOT TUTORIAL - MITSUBISHI RV-M1 SEIKO RT 3000 MANIPULATOR 10.1.1 DARL Programs Language Examples Commands Summary IBM 7535 MANIPULATOR 10.2.1 AML Programs ASEA IRB-1000 UNIMATION PUMA (360, 550, 560 SERIES) PRACTICE PROBLEMS LABORATORY - SEIKO RT-3000 ROBOT TUTORIAL - SEIKO RT-3000 ROBOT LABORATORY - ASEA IRB-1000 ROBOT TUTORIAL - ASEA IRB-1000 ROBOT 299 300 301 305 308 312 317 319 320 330 331 332 332 ROBOT APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333 11.1 11.2 11.3 11.4 11.5 11.6 11.0.1 Overview 11.0.2 Spray Painting and Finishing 11.0.3 Welding 11.0.4 Assembly 11.0.5 Belt Based Material Transfer END OF ARM TOOLING (EOAT) 11.1.1 EOAT Design 11.1.2 Gripper Mechanisms Vacuum grippers 11.1.3 Magnetic Grippers Adhesive Grippers 11.1.4 Expanding Grippers 11.1.5 Other Types Of Grippers ADVANCED TOPICS 11.2.1 Simulation/Off-line Programming INTERFACING PRACTICE PROBLEMS LABORATORY - ROBOT INTERFACING LABORATORY - ROBOT WORKCELL INTEGRATION 333 335 335 336 336 337 337 340 342 344 345 345 346 347 347 348 348 350 351 page 8 12. SPATIAL KINEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352 12.1 12.2 12.3 12.4 12.5 12.6 13. 352 353 354 359 361 363 364 366 366 369 370 370 371 372 372 375 375 376 MOTION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390 13.1 13.2 13.3 13.4 14. BASICS 12.1.1 Degrees of Freedom HOMOGENEOUS MATRICES 12.2.1 Denavit-Hartenberg Transformation (D-H) 12.2.2 Orientation 12.2.3 Inverse Kinematics 12.2.4 The Jacobian SPATIAL DYNAMICS 12.3.1 Moments of Inertia About Arbitrary Axes 12.3.2 Euler’s Equations of Motion 12.3.3 Impulses and Momentum Linear Momentum Angular Momentum DYNAMICS FOR KINEMATICS CHAINS 12.4.1 Euler-Lagrange 12.4.2 Newton-Euler REFERENCES PRACTICE PROBLEMS KINEMATICS 390 13.1.1 Basic Terms 390 13.1.2 Kinematics 391 Geometry Methods for Forward Kinematics 392 Geometry Methods for Inverse Kinematics 393 13.1.3 Modeling the Robot 394 PATH PLANNING 395 13.2.1 Slew Motion 395 Joint Interpolated Motion 397 Straight-line motion 397 13.2.2 Computer Control of Robot Paths (Incremental Interpolation)400 PRACTICE PROBLEMS 403 LABORATORY - AXIS AND MOTION CONTROL 408 CNC MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409 14.1 14.2 14.3 MACHINE AXES NUMERICAL CONTROL (NC) 14.2.1 NC Tapes 14.2.2 Computer Numerical Control (CNC) 14.2.3 Direct/Distributed Numerical Control (DNC) EXAMPLES OF EQUIPMENT 14.3.1 EMCO PC Turn 50 14.3.2 Light Machines Corp. proLIGHT Mill 409 409 410 411 412 414 414 415 page 9 DeBoer) 14.4 14.5 14.6 418 PRACTICE PROBLEMS 417 TUTORIAL - EMCO MAIER PCTURN 50 LATHE (OLD) 417 TUTORIAL - PC TURN 50 LATHE DOCUMENTATION: (By Jonathan 14.6.1 15. G-CODES APT PROPRIETARY NC CODES GRAPHICAL PART PROGRAMMING NC CUTTER PATHS NC CONTROLLERS PRACTICE PROBLEMS LABORATORY - CNC INTEGRATION 428 436 440 441 442 444 445 446 DATA AQUISITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .448 16.1 16.2 16.3 16.4 16.5 16.6 16.7 16.8 16.9 16.10 17. 424 CNC PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .426 15.1 15.2 15.3 15.4 15.5 15.6 15.7 15.8 16. LABORATORY - CNC MACHINING INTRODUCTION ANALOG INPUTS ANALOG OUTPUTS REAL-TIME PROCESSING DISCRETE IO COUNTERS AND TIMERS ACCESSING DAQ CARDS FROM LINUX SUMMARY PRACTICE PROBLEMS LABORATORY - INTERFACING TO A DAQ CARD 448 449 455 458 459 459 459 476 476 478 VISIONS SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .479 17.1 17.2 17.3 17.4 17.5 17.6 17.7 17.8 17.9 17.10 OVERVIEW APPLICATIONS LIGHTING AND SCENE CAMERAS FRAME GRABBER IMAGE PREPROCESSING FILTERING 17.7.1 Thresholding EDGE DETECTION SEGMENTATION 17.9.1 Segment Mass Properties RECOGNITION 17.10.1 Form Fitting 17.10.2 Decision Trees 479 480 481 482 486 486 487 487 487 488 490 491 491 492 page 10 17.11 17.12 17.13 18. 19.5 19.6 19.7 502 502 514 516 516 INTRODUCTION VIBRATORY FEEDERS PRACTICE QUESTIONS LABORATORY - MATERIAL HANDLING SYSTEM 19.4.1 System Assembly and Simple Controls AN EXAMPLE OF AN FMS CELL 19.5.1 Overview 19.5.2 Workcell Specifications 19.5.3 Operation of The Cell THE NEED FOR CONCURRENT PROCESSING PRACTICE PROBLEMS 518 520 521 521 521 523 523 525 526 534 536 PETRI NETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .537 20.1 20.2 20.3 20.4 20.5 20.6 20.7 20.8 21. CORPORATE STRUCTURES CORPORATE COMMUNICATIONS COMPUTER CONTROLLED BATCH PROCESSES PRACTICE PROBLEMS LABORATORY - WORKCELL INTEGRATION MATERIAL HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .518 19.1 19.2 19.3 19.4 20. 494 499 500 INTEGRATION ISSUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502 18.1 18.2 18.3 18.4 18.5 19. PRACTICE PROBLEMS TUTORIAL - LABVIEW BASED IMAQ VISION LABORATORY - VISION SYSTEMS FOR INSPECTION INTRODUCTION A BRIEF OUTLINE OF PETRI NET THEORY MORE REVIEW USING THE SUBROUTINES 20.4.1 Basic Petri Net Simulation 20.4.2 Transitions With Inhibiting Inputs 20.4.3 An Exclusive OR Transition: 20.4.4 Colored Tokens 20.4.5 RELATIONAL NETS C++ SOFTWARE IMPLEMENTATION FOR A PLC PRACTICE PROBLEMS REFERENCES 537 537 540 548 548 550 552 555 557 558 559 564 565 PRODUCTION PLANNING AND CONTROL . . . . . . . . . . . . .566 21.1 21.2 OVERVIEW SCHEDULING 21.2.1 Material Requirements Planning (MRP) 21.2.2 Capacity Planning 566 567 567 569