PLC Program for Pick and Place parts by XY Gantry

This project is designed for efficiently handling raw materials. In detail, the raw material is unboxed and placed in a stacking box by XY gantry to be stored in inventory. The entire program is written professionally (Clear, Command, and Complete method) by using Studio 5000 Logix designer. And it is tested in an Alan-Bradley Compact Guard Logix 5380 (5969-L306ERMS2). While factory IO software is used to design the factory layout, consisting of different input and output devices. The project task is to place 3 random colour raw materials into the stackable box without crashing the gantry and other components. As well as required programming for all home, dry cycle, part count, cycle time, auto mode, manual mode, and faults.

Working Methodology

When the part is available on a 4-meter-long belt conveyor and the start button is pressed, the auto mode starts immediately after the siren is complete. Then, that part arrives in zone 1 through the belt conveyor and stops at the end of the conveyor. At that time, a diffuse sensor checks the part availability and sends the appropriate signals to commence gantry 1. After receiving a signal, gantry 1 moves forward to pick raw material. Subsequently, that raw material part is dropped on a transfer table which location is the right side of gantry 1 and into zone 2. When the gantry 1 drops the part on the transfer table, the presence of the part is inspected by another diffuse sensor which is located on the transfer table in zone 2.

When the part is successfully dropped on a transfer table, gantry 1 repositions its original position. Afterward, gantry 1 position and diffuse sensor at transfer table provide clear to move forward command to gantry 2. In the next step, gantry 2 picks that raw material and put it into the stackable box that is located on the roller conveyor in zone 2. The next cycle of gantry 1 starts when the new part is available at the entry conveyor and the previously dropped part at the transfer table is no more present. A counting sensor is placed near the box to count how many parts are placed into the box. The 3 parts must be placed in the box to make it full. As soon as, the box is filled, the roller conveyor belt runs until the new empty box does not available near gantry 2. Then, the cycle starts again and follows these operation steps repeatedly.

Features 

Machine operating panel 

Auto Mode

Auto mode is a majorly used mode to complete the task without human interaction. It can be changed by using a mode selector switch. And the machine cannot operate by pushing buttons during this mode except the machine stopping button.

Manual Mode

Manual mode is operated by the operator. The manual operation has been performed by pressing push buttons on a panel board. This mode is required when an unexpected error appears and the machine stops. It can be changed by using a mode selector switch.

All Home

All home only can be utilized in manual mode. When all home is activated, it resets all machines to their original positions. For example, a machine is working on a heavy weight lifting in an auto mode, and an error occurs. Due to that machine stop. To prevent any other damage to the worker or machinery, a safe repositioning of the machine is required. So, all home is the solution to this kind of issue.

Dry Cycle

The dry cycle feature is mostly used when the program is in development or being modified. The dry cycle runs all machines without any parts. This program feature help technician or engineers identify bugs in the program without damaging real parts.

Cycle Time

Cycle time represents how much time is utilized by a machine to complete given tasks. Recording cycle time has been beneficial for tracking projects and helped to improve the speed of operations. In this project, two different cycle times (Gantry 1 cycle time and Gantry 2 cycle time) can be seen in the two displays that are placed on a panel board.

Part Count

This feature is only useful to track the record of how man parts are completed. In this project, the part count can be seen in a display that is placed on a panel board.

Faults

This feature can show the issues of a machine. So, it is a significant part of solving problems. There are 13 faults has been set up/programmed in this program to identify issues in the machines.

Safety

Safety is the main issue that can be considered while developing programs. Because the program must be undefeatable easily to prevent a hazardous situation. To achieve this, two zones have been developed in this project. An emergency stops button, safety door, and the light curtain are used and programmed in safety plc to avoid unnecessary modification in device wiring and programs.