SYNCHRONIZING A MODULAR PRODUCTION SYSTEM INTEGRATED WITH MACHINE VISION
By Yogi Hamdani
1-1111-054
BACHELOR’S DEGREE in
MECHANICAL ENGINEERING – MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY EduTown BSD City
Tangerang 15339 Indonesia
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STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Yogi Hamdani
____________________________________________
Student Date
Approved by:
Dr. Rusman Rusyadi B.Sc., M.Sc.
____________________________________________
Thesis Advisor Date
Dr. Ir. Gembong Baskoro M.Sc.
____________________________________________
Dean Date
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ABSTRACT
SYNCHRONIZING A MODULAR PRODUCTION SYSTEM INTEGRATED WITH MACHINE VISION
By Yogi Hamdani
Dr. Rusman Rusyadi B.Sc., M.Sc., Advisor
SWISS GERMAN UNIVERISTY
The purpose of this thesis work is to synchronize processing station and handling station of FESTO Modular Production System integrated with machine vision for work pieces recognition and their respective color detection. The processing station processes work pieces with work pieces checking, drilling, and holes checking on the configured rotary table. The handling station handles work pieces transaction with pick and place by Mitsubishi Movemaster RV-M1 and sorts processed work pieces according to their color. Machine vision is integrated in handling station with a camera and additional lighting attached to the arm robot. Communication between stations is established through PLC digital input – output pins and serial
communication via RS-232 for Mitsubishi Movemaster RV-M1 with computer.
The thesis work has proved to deliver 100% of processed work pieces out of required order under manual operation. The integrated machine vision has been improved as well to accommodate work pieces detection with illumination changes. Several conditions have been implemented to test the synchronization of information and
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© Copyright 2015 By Yogi Hamdani All rights reserved
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DEDICATION
I dedicate this work to the Almighty God and my beloved family.
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ACKNOWLEDGEMENTS
I would like to express my deepest gratitude to Lord Jesus Christ for His grace, provision, and wisdom to finish the thesis work well.
I would like to send my gratefulness to my dearly loved family who always been there for me, supporting me in every moment of my life.
I would like to thank Dr. Rusman Rusyadi, as advisor, in giving countless and
valuable advices. I want to thank Leonard Rusli Ph.D. in giving early consultation and Cepi Hanafi, MT. and Erikson Sinaga M.Kom, for their assistances during the thesis work.
Lastly I would like to thank Aditya, Ardi Satyamulyana, Brilly Nurhalim, Daniel, Enzo Oestanto, Kevin Inar, Michael Wijanarko, Mochammad Rizky, Putra Utama Jaya, Rheza Andika, Vincent Tjandra and all of my friends for their help and support throughout the thesis work.
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TABLE OF CONTENTS
Page
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
TABLE OF CONTENTS ... 7
LIST OF FIGURES ... 10
LIST OF TABLES ... 12
LIST OF EQUATIONS ... 13
CHAPTER 1 – INTRODUCTION ... 14
1.1 Background ... 14
1.2 Thesis Objectives ... 15
1.3 Thesis Scope ... 15
1.4 Problem Identification... 15
1.5 Thesis Limitation ... 15
1.6 Thesis Structure ... 16
CHAPTER 2 – LITERATURE REVIEW ... 17
2.1 Control System ... 17
2.2 Machine Vision... 18
2.3 Qt SDK ... 20
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2.9 Programmable Logic Controller ... 23
2.10 Mitsubishi Movemaster RV-M1 ... 25
2.11 Serial Communication ... 26
2.12 Error Detection ... 27
CHAPTER 3 – METHODOLOGY ... 28
3.1 System Design Overview ... 28
3.2 Work Pieces Attributes ... 32
3.3 Processing Station ... 33
3.4 Handling Station ... 36
3.5 Integrating Machine Vision ... 39
3.5.1 Equipment and Device ... 39
3.5.2 Digital Image Processing ... 42
3.6 Communication Network Design ... 46
3.7 Process Synchronization ... 47
CHAPTER 4 – RESULTS AND DISCUSSIONS ... 49
4.1 Initialization Check ... 49
4.2 Digital Image Processing Result... 51
4.2.1 Object Detection ... 52
4.2.2 Color Detection ... 56
4.3 Communication Network Test ... 59
4.4 Process Synchronization Analysis ... 59
4.4.1 What If Condition 1: Work Piece Misses in Processing Station ... 60
4.4.2 What If Condition 2: Jammed Work Pieces Flow ... 61
4.4.3 What If Condition 3: Processing Unwanted Work Pieces... 61
4.4.4 What If Condition 4: Uncompleted Work Piece Order ... 62
4.5 Human Machine Interface with C++ ... 63
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4.6 Integrated Run Test ... 64
CHAPTER 5 – CONCLUSIONS AND RECOMMENDATIONS ... 66
5.1 Conclusions ... 66
5.2 Recommendations ... 67
GLOSSARY ... 68
REFERENCES ... 69
APPENDICES ... 71
APPENDIX A – Technical Drawing ... 71
APPENDIX B – Mitsubishi Movemaster RV-M1 ... 72
APPENDIX C – PLC Wiring Connection ... 75
C1. Processing Station ... 75
C2. Handling Station ... 77
APPENDIX D – Program Code C++ ... 79
D1. Main Window ... 79
D2. Digital Image Processing ... 89
D3. Mitsubishi Movemaster RV-M1 Serial Communication ... 93
D4. Mitsubishi Movemaster RV-M1 Arm Robot Position Definition ... 97
APPENDIX D – Bill of Material ... 99
CURRICULUM VITAE ... 100
