2017 International Conference on Applied Mechanics and Mechanical Automation (AMMA 2017) ISBN: 978-1-60595-471-4 Design of Electronic Control System for Robot Cleaning Machine Based on Profibus-DP Wei GUAN Dalian Vocational & Technical College of Mechanical Engineering, Dalian, Liaoning, China Keywords: Cleaning machine, Industrial robot, Control system, Profibus-DP. Abstract. Introduces the composition of industrial cleaning robot and the main control function based on the key signal between ABB robot and SIEMENS PLC S7-300, given the Profibus-DP communication programming of the robot and PLC, finally through the flow chart of industrial washing machine work cycle are described, the main program logic robot and motion control using ABB robot Rapid language. The research and development of the electronic control system can improve the degree of automation and production efficiency. Introduction Robot cleaning machine is a revolution in the field of cleaning, but also a milestone in flexible cleaning. For independent research and development of industrial robot crankcase cleaning machine mechanical structure and simple operation, it can not only reduce the amount of labor, but also can effectively ensure the cleanliness of the engine factory index, the overall layout of the entire robot cleaning machine, as shown in figure 1. 1 Station 4 Station 6 Station 3 Station 5 Station 2 Station Figure 1. Layout of the robot cleaning machine. 100
Cleaning Machine Work Flow and Control System Hardware Configuration Cleaning Machine Work Flow 1st station grab workpiece: The manipulator is extended to locate and clamp the workpiece, and the workpiece is taken into the cleaning chamber according to the preset decomposition action. 2nd station surge cleaning: in the process of surge cleaning, the rotation of the 6 axis is as follows: the rotation of the shaft is 270 degrees, after 20 seconds, the water is discharged, the surface spray is continued, and the surface is sprayed for about 20 seconds, and the workpiece is lifted, and the spray washing stops. 3th station clamping surface cleaning:the workpiece is moved to the surface of the clamping surface of the cleaning nozzle, and the holes of the suspension surface of the crankcase are scanned and cleaned. 4th position pipe cleaning and turning water cleaning:the gesture of workpiece into end down, tube cleaning. When the workpiece is down, the high pressure pump is opened to supply water, the main oil passage is inserted into the main pipe, and the inner surface of the main shaft hole is cleaned. At the same time, the installation surface of the cylinder head is scanned and cleaned, and the repeated action is 2 times. Finish cleaning, high pressure pump switch to the unloading state, butterfly valve surge of flume tank water supply valve closed, open (delay time for 30 seconds or longer, the surge tank is full.), tank full of water after cleaning, unloading valve open, water tank valve closed. 5th station clamping surface drying: clamping surface blowing air valve open, in this position for the upper and lower crankcase suspended noodles for scanning drying. Blow dry, the clamping surface blow off the valve, the robot drives the workpiece rotation to the 6 station. 6th stations combined with surface drying action: open the air valve, the workpiece cylinder head surface to the bottom of the attitude, the scanning drying. Control System Hardware Configuration The control system of the robot cleaning machine is controlled by PLC, which mainly completes the coordination and control of each part of the cleaning system and the cleaning of the crankcase assembly. The workpiece state signal control system is provided, including start, stop, pause and stop operation state, can be controlled by the operating panel, and the running state of the system and alarm system etc. by the operating table indicator light or display on man-machine interface. SEIMENS SIMATICS7-300 series programmable controller (PLC) as the DP master Profibus-DP bus, the CPU unit selects 315-2DP, the type CPU has a large capacity to program memory and Profibus-DP master/slave interface, can be used for large-scale I/O configuration and can be used to establish the distributed I/O system, a digital input module processing stations the button, switch signal, the digital output module, relay control solenoid wide actuator, namely cleaning machine robot action sequence, programmable controller. Cleaning Machine Key Signal Processing The robot in the washing machine, washing machine must communicate signals with the cleaning station, because the signal communication with the robot cleaner more, using PLC as the total control of cleaning machine, robot through Profibus-DP and PLC communication adapter. In the electric control system of the cleaning machine, the input and output signals of the ABB robot system, the input and output signal processing between the robot and the PLC is the key of the electrical control system. PLC Hardware Configuration The hardware and network configuration in the SIEMENS configuration software STEP7, you must first install the ABB robot GSD file, the installation path for the STEP7 hardware configuration screen menu option to install the GSD file to HMS_1811.GSD and install. 101
Install the GSD file after the completion of each communication set length for input and output communication area of 4 bytes, in the hardware configuration screen, Additional Field, Bus hardware directory Any bus-cc Profibus DP-V1, Universal module, double-click the X1 slot, and set the I/O type in the DP attribute for the output input, each 4 bytes, and address configuration the distribution of the robot is shown in Figure 2, 3. Figure 2. PLC hardware configuration of robot. I/O Unit and Signal Configuration of Robot Figure 3. I/O address allocation for robots. SIEMENS S7-300PLC is installed in the ABB robot control cabinet Profibus-DP adapter DSQC667 communications, DSQC667 configurable 64Byte input and 64Byte output. In the configuration parameters of the controller, the following parameters are required. Type of unit: DP_SLAVE_FA, modify the number of bytes into the input and output of 4 words. DeviceNet address: set the Profibus adapter to the station address of, the same as the PLC settings. The allocation of input and output signals of robot I/O unit: a set of 4 word input signal, the signal from SIEMENS 300PLC, as the washing machine running state, the robot moves signal; 4 words output signal as the signal transmission station to complete cleaning station, mainly choose the distribution of Unit and Signal in the address offset set in the address offset here to correspond with the SIEMENS S7-300PLC address. The I/O unit configuration table of the robot workstation is shown in Table 1. The I/O signal configuration is shown in Table 2. Table 1. I/0 unit configuration of robot workstation. I/O Unit Name Type of unit Connected To bus DeviceNet address pboard8 DP_SLAVE_FA Profibus_FA1 8 102
Name Type of Signal I/O Unit Table 2. Robot I/O address configuration table. Unit Mapping Adress Signal Comment Di00WMauto Digital Input pboard8 0 DB11.DBX21.0 Automatic state Di01Manual Digital Input pboard8 1 DB11.DBX21.1 Adjust state Di02Pickallow Digital Input pboard8 2 DB11.DBX21.2 Claw fetching allow Di03GripperOpen Digital Input pboard8 3 DB11.DBX21.3 Claw clamping Di04Gripperclose Digital Input pboard8 4 DB11.DBX21.4 Loosen the claw Di05SurgeWend Digital Input pboard8 5 DB11.DBX21.5 Di08E_Stop Digital Input pboard8 8 DB11.DBX22.0 Emergency stop Di09ResetE_Stop Digital Input pboard8 9 DB11.DBX22.1 Emergency stop reset Di10ResetError Digital Input pboard8 10 DB11.DBX22.2 Error reset Di11Start_Main Digital Input pboard8 11 DB11.DBX22.3 Start Prom from Main Di12MotorOn Digital Input pboard8 12 DB11.DBX22.4 Motor power on signal Di13Start Digital Input pboard8 13 DB11.DBX22.5 Start signal Di14Stop Digital Input pboard8 14 DB11.DBX22.6 Stop signal Do00RobInHome Digital Output pboard8 0 DB11.DBX0.0 Robot in home position Do01ReclaimPOS Digital Output pboard8 1 DB11.DBX0.1 Robot in the workpiece Do02DoorClose Digital Output pboard8 2 DB11.DBX0.2 Wait for door close signal Do03InPos2W Digital Output pboard8 3 DB11.DBX0.3 To 2 station cleaning Do04 Pos2Ret Digital Output pboard8 4 DB11.DBX0.4 2 station cleaning end Do05InPos3W Digital Output pboard8 5 DB11.DBX0.5 To 3 station cleaning Do06Pos3Ret Digital Output pboard8 6 DB11.DBX0.6 3 station cleaning end Do07InPos4W Digital Output pboard8 7 DB11.DBX0.7 To 4 station cleaning Do08Pos4Ret Digital Output pboard8 8 DB11.DBX1.0 4 station cleaning end Do09InPos5W Digital Output pboard8 9 DB11.DBX1.1 To 5 station cleaning Do10Pos5Ret Digital Output pboard8 10 DB11.DBX1.2 5 station cleaning end Do11InPos6W Digital Output pboard8 11 DB11.DBX1.3 To 6 station cleaning Do12Pos6Ret Digital Output pboard8 12 DB11.DBX1.4 6 station cleaning end Do13PosEnd Digital Output pboard8 13 DB11.DBX1.5 End of cleaning Do14PosToReclam Digital Output pboard8 14 DB11.DBX1.6 Robot workpiece in place Do15RobManual Digital Output pboard8 15 DB11.DBX1.7 Robot manual mode Do16E_Stop Digital Output pboard8 16 DB11.DBX2.0 Rob Emergency stop state Do17CycleOn Digital Output pboard8 17 DB11.DBX2.1 Robot cycle operation Do18Error Digital Output pboard8 18 DB11.DBX2.2 Robot fault signal Robot and PLC Communication Control Programming When the master PLC through the PLC program SFC15 (address 264) function, through the Profibus-DP network to the ABB robot issued a cleaning command. The robot receives cleaning command after processing by the internal procedures, on the one hand set cleaning flag, through the Profibus-DP network by PLC SFC14 (address 256) the function of reading, the robot is returned to the PLC cleaning operation information; on the other hand, call the subroutine cleaning station. Figure 4. PLC and robot communication program. 103
Robot Programming After the mechanical and electrical assembly cleaning machine, cleaning machine to realize manual adjustment, automatic cycle mode through the PLC program, ABB PLC robot trajectory signal the completion of cleaning, issued at the same time, each station status signals, assist PLC to complete the external control action. In the process of cleaning the workpiece, the whole cleaning process is: when the start of the cycle, when the external cleaning condition is ready, the robot will carry out the work of the first step. In accordance with the requirements of the workpiece cleaning robot, in order to complete the 2~6 station cleaning subroutine, i.e. surge type anthropomorphic gripping surface cleaning, washing, cleaning and clamping surface of intubation, combined with the positioning robot and then dried, finally the workpiece is placed and then return to the initial position of the robot subroutine. The workflow is shown in figure 5. PROC Main() Initialization Init_All; WHILE TRUE DO N External condition ready IF di02_pickallow= 1 THEN Y Reset do_workcomplete; DIWait Di04_Gripperclose,0,3, waiting, Execute fetch sub Di_Gripperopen is off ; DIWait Di03_Gripperopen,1,3, waiting, Execute 2~6 station sub Di_Gripperopen is on ; rpickpart; Wait for door open sub rinpos2; rinpos3; Execute put back workpiece sub rinpos4; rinpos5; Calculate cleaning time rinpos6; DIWait Di03_Gripperopen,1,3, waiting, Delay Di_Gripperopen is on ; rplacepart; Figure 5. Main program flow chart. PulseDo\PLength:=2, Do_workcomplete; DIWait di02_pickallow, 0, 3, waiting, di02_pickallow is off ;!ENDIF waittime 0.2; ENDWHILE ENDPROC Summary Washing machine adopts the robot has many advantages of simple structure, good flexibility, small footprint, energy saving and environmental protection, the development of the washing machine after a year of commissioning and trial operation, the product quality and production efficiency have been significantly improved, good to meet the production requirements of the site. Acknowledgement This paper is one of the results of the research on the topic of " Research on the key technologies of robot cleaning machine " in the Dalian Vocational and Technical College research project (subject to the approval number: DZ2016A01). 104
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