By
Darwin Agustino 11301013
BACHELOR’S DEGREE In
MECHANICAL ENGINEERING – MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY
The Prominence Tower – Jl. Jalur Sutera Barat No. 15, Alam Sutera Tangerang 15143, Banten
Indonesia
August 2017
Revision after Thesis Defense on July 27th 2017
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.
Darwin
____________________________________________
Student Date
Approved by:
Leonard Priyatna Rusli, B.S, M.S., Ph.D
____________________________________________
Thesis Advisor Date
Benny Widjaja, M.T
____________________________________________
Thesis Co-Advisor Date
ABSTRACT
DESIGNING COMPACT CONTACT LENS GRIPPER FOR ARM ROBOT IN FILLING CONTACT LENS PROCESS
By Darwin, Student
Leonard Priyatna Rusli, M.Sc, PH.D, Advisor Benny Widjaja, M.T, Co-Advisor
SWISS GERMAN UNIVERSITY
The main purpose of this thesis is to design and construct a fully operated contact lens gripper within specific and desired parameters. Contact lens mold will be transferred from the raw material tray into the filling machine station and from the station to the oven tray using this specific gripper. The main problem is there is a different orientation between the trays and station. The gripper will be attached to a robot arm as it travels from one position to another. Using pneumatic grippers and pneumatics cylinder as primary actuators, it will deliver efficiently and with high precision of accuracy displacement. The actuators are integrated with the robot arm controller, which is also with all the sensors, to achieve a prefect sequential process between the robot arm and the gripper.
Keywords: Automation, Robot arm, Gripper, Pneumatic.
© Copyright 2017 by Darwin Agustino
All rights reserved
DEDICATION
I dedicated this thesis to God, my family, and the future of Indonesia’s Automation
ACKNOWLEDGEMENTS
First of all, I would like to thank my family for their endless support throughout my education and the development of this thesis
I would like to thank Leonard Priyatna Rusli, M.Sc, PH.D for his advice and guidance during the designing process until the ending of this thesis and also Benny Widjaja, M.T for his insight and experience in handling contact lens machines which significantly helps me in finishing this thesis
Also, I would like to thank PT XYZ for giving me the opportunities to develop one of their projects as my thesis topic and fully accommodate this entire thesis project. I would also like to thank Yohanes Freddy for his guidance in delivering a correct technical machine drawing and details on assembly machine.
Special thank for all the students in batch 2013 specifically Mechatronics class B for giving their never ending support and motivation to finish this thesis.
STATEMENT BY THE AUTHOR ... 2
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
TABLE OF CONTENTS ... 7
LIST OF TABLES ... 13
CHAPTER 1 - INTRODUCTION ... 14
1.1 Thesis Background ... 14
1.2 Thesis Purpose ... 15
1.3 Thesis Problem ... 15
1.4 Thesis Scope ... 15
1.5 Thesis Limitation ... 16
1.6 Thesis Structures ... 16
CHAPTER 2 - LITERATURE REVIEW ... 18
2.1 Introduction ... 18
2.2 Contact Lens Process ... 18
2.2.1 Contact Lens ... 18
2.2.2 Overview Process ... 18
2.2.3 Contact Lens Mold ... 19
2.2.4 Contact Lens Flower Orientation ... 20
2.3 Handling Small Item Using Robot Arm ... 21
2.3.1 Precious Study ... 21
2.3.2 Industrial Robot Arm ... 23
2.3.2.1 Software ... 25
2.3.2.2 Robot ... 26
2.3.2.3 Basic Programming ... 27
2.4 Gripper Mechanism ... 34
2.4.1 Pneumatic System ... 34
2.4.1.1 Pneumatic Control Valve ... 34
2.4.1.2 Pneumatic Actuators ... 35
2.4.1.2.1 Pneumatic Gripper ... 35
2.4.1.2.2 Pneumatic Suction ... 36
2.4.1.2.4 Pneumatic Linear Slide ... 38
2.5 Special manufacturing Machine Used and Software ... 38
2.5.1 Computer Numerical Control Machine ... 38
2.5.2 SolidWork ... 39
CHAPTER 3 - RESEARCH METHODOLOGY ... 41
3.1 Introduction ... 41
3.2 Defining Transfer Process ... 41
3.3 Defining Objectives and Constrain ... 44
3.4 Generate 3D Model ... 46
3.4.1 Contact Lens Flower ... 46
3.4.2 Oven Tray ... 47
3.4.3 Raw Material Tray ... 47
3.4.4 Filling Station and Box Constrain ... 48
3.4.5 Standard Part ... 48
3.5 Preliminary Design Concept or Prototype ... 49
3.6 Detail Design Results ... 51
3.6.1 Pneumatic Gripper ... 51
3.6.2 Gripper Shoe ... 54
3.6.3 Gripper Plate ... 58
3.6.4 Cylinder Piston ... 64
3.6.5 Linear Guide ... 67
3.6.6 Connection Linear Guide to Cylinder ... 68
3.6.7 Connection Plate Gripper to Cylinder ... 70
3.6.8 Connection Plate Mechanism with Robot Arm ... 72
3.6.9 Sensors and Mechanical Stopper ... 74
3.6.10 Finish Treatment ... 76
3.6.11 Simulation Study ... 76
3.6.11.1 Stress Simulation ... 78
3.7 Testing Procedures ... 90
3.7.1 X and Y Coordinate Testing ... 92
3.7.2 Envelope of Gripper System ... 94
3.7.3 Full cycle test ... 95
CHAPTER 4 - RESULTS AND DISCUSSION ... 96
4.1 Introduction ... 96
4.2 Assembly Review ... 96
4.3 Initial Evaluation ... 99
4.3.1 Testing Gripper Envelope ... 99
4.3.2 Testing at Raw Material Tray ... 102
4.3.3 Testing at Oven Tray ... 105
4.3.4 Testing at Filling Station ... 106
4.4 Data Analysis ... 107
4.4.1 Testing Gripper Envelope Analysis ... 107
4.4.2 Testing at Raw Material Tray Analysis ... 109
4.4.3 Testing at Oven Tray Analysis ... 121
4.4.4 Testing at Filling Station Analysis ... 126
CHAPTER 5 - CONCLUSIONS AND RECCOMENDATIONS ... 128
5.1 Conclusions ... 128
5.1.1 Gripper System... 128
5.1.2 Robot Arm ... 128
5.1.3 Testing Gripper Coordinates ... 129
5.2 Recommendations ... 130
GLOSSARY ... 132
REFERENCES ... 133
APPENDIX ... 134
