development and test of an application module for

(1)

DEVELOPMENT AND TEST OF AN APPLICATION MODULE FOR TRACKING TASKS WIHTIN FESTO CONTROL PLATFORM

By

Fabrilian Handoko Asali 11301015

BACHELOR’S DEGREE in

MECHANICAL ENGINEERING – MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY

SWISS GERMAN UNIVERSITY The Prominence Tower

Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia

August 2017

Revision after the Thesis Defense on 25 July 2017

(2)

Fabrilian Handoko Asali 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.

Fabrilian Handoko Asali

____________________________________________

Student Date

Approved by:

Dipl.-Ing. Walter Kuhlbusch,

Head of Advanced System Dynamics

____________________________________________

Thesis Advisor

Dr. Rusman Rusyadi, M.Sc.

____________________________________________

Thesis Co-Advisor Date

Dr. Ir. Gembong Baskoro, M.Sc

____________________________________________

Dean of Faculty of Engineering and IT (FEIT) Date

(3)

Fabrilian Handoko Asali ABSTRACT

DEVELOPMENT AND TEST OF AN APPLICATION MODULE FOR TRACKING TASKS WITHIN FESTO CONTROL PLATFORM

By

Fabrilian Handoko Asali Dipl.-Ing. Walter Kuhlbusch, Advisor Dr. Rusman Rusyadi, M.Sc., Co-Advisor

SWISS GERMAN UNIVERSITY

This thesis is intended as a viability test of using Festo CECC-X-M1 controller with CODESYS motion + CNC development kit to implement a conveyor tracking application. Conveyor tracking is a type of robotic application. In conveyor tracking, work pieces are placed on a constantly moving conveyor. The robot will then carries out sequences on the moving part like pick and place sequence or gluing sequence.

With this conveyor tracking technology, it is not necessary stopping the conveyor belt to process a work piece on it. In this thesis, the work pieces on the conveyor are detected with a light barrier. This limits the work piece to only have one pre- determined orientation. It was found that some additional software components besides the ones that provided by the CODESYS motion + CNC is needed to achieve conveyor tracking with multiple objects. Those additional software components are the part list, part handling function block, and a path planner task. After the implementation of the CODESYS motion + CNC paired with the additional software components, a conveyor tracking is possible with Festo CECC-X-M1 controller.

Keywords: Conveyor tracking, CODESYS, Robotic application, function block, part list.

(4)

(5)

Fabrilian Handoko Asali DEDICATION

I dedicate this thesis to my father, Albert Asali, and my mother, Ernawati Soegitanto, who always support me,

to all of my friends who help me to finish this thesis and to my home country Indonesia.

(6)

Fabrilian Handoko Asali ACKNOWLEDGEMENTS

I would like to express my deepest gratitude to my advisor and co-advisor Dipl.-Ing.

Walter Kuhlbusch, and Dr. Rusman Rusyadi, M.Sc., for making this thesis possible and for their knowledge and support. I would also like to thank my supervisors, Stefan Wörl and Michael Früh for their guidance and helping me solving the thesis problems.

In addition, I would like to thank all of my friends from Mechatronics Batch 2013 for their helps and moral supports, my other colleagues from Festo software and control department for their help when I have a problem with my kinematic, my highschool friends who still shows their supports and help me pulled through this thesis despite the distance and time differences.

Also not forgetting the last, I would like to express my biggest gratitude for my parents, Albert Asali and Ernawati Soegitanto, for their endless support, love, and prayer that makes me have the power to even start the thesis.

I hope this thesis can contribute something to the world.

(7)

TABLE OF CONTENT

STATEMENT BY THE AUTHOR ... 2

ABSTRACT ... 3

DEDICATION ... 5

ACKNOWLEDGEMENTS ... 6

TABLE OF CONTENT ... 7

List of Figures ... 10

List of tables ... 14

List of equations ... 14

CHAPTER 1 – INTRODUCTION ... 15

1.1 Background ... 15

1.2 Objectives ... 16

1.3 Research problem ... 16

1.4 Research scope... 17

1.5 Research limitation ... 17

1.6 Significance of the study ... 18

1.7 Thesis organization ... 18

CHAPTER 2 – LITERATURE REVIEW ... 19

2.1 Company profile – Festo AG & Co. KG ... 19

2.2 Principles of Conveyor Tracking ... 20

2.3 Trajectory planning ... 23

2.3.1 Point to Point (PtP) motion ... 23

2.3.2 Interpolated motion ... 23

2.4 Programmable Logic Controller – PLC ... 24

2.4.1 Central Processing Unit – CPU ... 25

2.4.2 Memory ... 25

2.4.3 Communication unit ... 26

2.4.4 Input Output module (I/O module) ... 26

2.4.5 Standard operation ... 26

(8)

2.5 Program Organization Unit – POU ... 27

2.5.1 Function (FUNC) ... 28

2.5.2 Function Block (FB) ... 28

2.5.3 Program (PRG) ... 29

2.6 IEC 61131-3 Languages ... 29

2.7 Structured Text (ST) language ... 32

CHAPTER 3 – Research Methodology ... 34

3.1 Mechanical and actuator components ... 34

3.1.1 H-Gantry with a Z-Axis ... 35

3.1.2 Conveyor belt with integrated motor ... 36

3.1.3 Smart stepper motor ... 37

3.1.4 Gripping unit ... 37

3.2 Electronic components and sensors ... 38

3.2.1 Programmable Logic Controller – PLC ... 39

3.2.2 Remote analogue output module ... 40

3.2.3 Incremental encoder ... 41

3.2.4 Light barrier ... 41

3.3 PLC programming environment – CODESYS V3.5 ... 42

3.3.1 CODESYS SoftMotion ... 45

3.3.2 SoftMotion + CNC ... 49

3.3.3 SoftMotion Robotics ... 51

3.3.4 Coordinate System (CS) ... 55

3.3.5 Comparison between SoftMotion CNC and SoftMotion Robotics ... 56

3.4 System overview ... 59

3.4.1 Hardware overview ... 59

3.4.2 Tracking application overview ... 60

3.5 Encoder signal processing concepts ... 62

3.5.1 Concept 1 - Absolute position detection ... 62

3.5.2 Concept 2 - Relative position detection ... 64

3.5.3 Concept 3 - Virtual axes ... 65

3.5.4 Comparison ... 65

(9)

CHAPTER 4 – RESULT AND DISCUSSION... 67

4.1 Calculating the encoder feed forward constant ... 67

4.1.1 Procedure ... 67

4.1.2 Result ... 68

4.2 Conveyor orientation ... 68

4.3 Implementation of the Part List ... 70

4.4 Implementation of the tracking application ... 72

4.4.1 Part handler implementation ... 73

4.4.2 Part handler function block development ... 77

4.4.3 Motion Sequencer implementation ... 87

4.5 Performance test of the system ... 91

4.5.1 Synchronizing time ... 91

4.5.2 Performance test – pick and place... 93

4.5.3 Performance test – gluing ... 96

4.5.4 Performance test – Gluing with variable conveyor speed ... 98

CHAPTER 5 – CONCLUSION AND RECOMMENDATION ... 99

5.1 Conclusion ... 99

5.2 Recommendation ... 100

List of Reference ... 102

GLOSSARY 103 APPENDIX A – PSEUDOCODES ... 104

APPENDIX B – DATA SHEETS ... 113

B1 - CECC-X-M1 – Controller ... 113

B2 - CPX – Modular electrical terminal ... 118

B3 - EXCM – Planar surface H-Gantry ... 122

B4 - EGSK – Electric spindle axis ... 125

B5 - VADMI – Vacuum Generator ... 126

CURRICULUM VITAE ... 129