INTEGRATION OF SENSORS WITH KUKA ROBOT
- 1. TITLE PROJECT PRESENTATION ON “INTEGRATION OF SAFETY LIGHT CURTAIN SENSORS WITH KR30”
- 2. CONTENTS TIMELINE PROJECT SUMMARY PROJECT PARTS BLOCK DIAGRAM COMMUNICATION PROTOCOL BECKOFF MODULE SPECIFICATION TIME AND COST ANALYSIS PROJECT APPLICATION FUTURE ENHANCEMENT CONCLUSION
- 3. TIMELINE PHASE 1 PHASE 2 PHASE 3 PHASE 4 RESEARCHED INDUSTRIAL ROBOTS AND SAFETY MEASURES USED BY INDUSTRIES. ANALYSIS AND COMPARISION OF DIFFERENT SAFETY SENSORS. HARDWARE ANALYSIS OF CURTAIN SENSORS AND BECKOFF MODULE WITH DIFFERENT TESTS. CONNECTION OF SENSORS WITH KR30 THROUGH HARD WIRES.
- 4. SUMMARY PROBLEM THAT WE ARE FACING: Industrial Robots produce powerful and very rapid movements in a large operational space and when accidently human comes in contact with the robot during its process, it can harm human. SOLUTION THAT CAN BE IMPLEMENTED • To ensure safety in industrial area, safety light curtain sensors can be used. For example:In welding robots, interfacing of safety sensor system can be used to resist the human intervention in operational workspace. • Safety light curtain sensor is an effective and optimized device that can reduce numerous accidents.
- 5. PROJECT PARTS 1) LIGHT CURTAIN SENSORS 2) CABLE SETS AND CONNECTORS 3) BECKHOFF I/O MODULE 4) KUKA CONTROL PANEL C4
- 6. BLOCK DIAGRAM Input sensing device IPC PROGRAMMING DEVICE OUTPUT LOAD DEVICE(KR30)
- 7. MODULE • Beckhoff module implements open automation system which covers Industrial PCs, I/O and fieldbus components, drive technology and automation software. • Products are integrated to control system using Beckhoff automation technology. • It supports interprocess communication(IPC) that allow a programmer to coordinate activities among different program that can run concurrently in a control system. • It provide wide choice of I/O components means that the bus system best suited to the particular application can be chosen.
- 8. COMMUNICATION PROTOCOL • EtherCAT is a highly flexible Ethernet network protocol that is developing at a rapid rate. • A fieldbus system called Fast Lightbus to correct the low bandwidth utilization problem present in other Ethernet protocols. This protocol led to EtherCAT which Beckhoff released in 2003. • EtherCAT uses the standard IEEE 802.3 physical layer. No special hardware is required to implement an EtherCAT network. • The data representation in ethercat protocol is done by address bits, message and error detection bit. • Main advantage of ethercat protocol is: 1. Speed 2. Flexible topology 3. Synchronization
- 9. FLOWCHART IS WORK DONE START HUMAN PRESENCE IF HUMAN GOES OUT RESUME THE PROCESS HALT THE PROCESS PROGRAM RUN STOP THE PROGRAM END NO YES NO YES NO YES
- 10. SPECIFICATIONS 1. LIGHT CURTAIN SENSORS Features data RESOLUTION 25mm SENSING HEIGHT 180mm OPERATING VOLTAGE 24+/-20%VDC CURRENT CONSUMPTION 60mA RESPONSE TIME 10ms INDICATOR YELLOW(POWER) GREEN(CLEAR CONDITION) RED(BLOCK CONDITION)
- 11. SPECIFICATIONS 2. BECKHOFF MODULE FEATURES DATA DATA TRANSFER MEDIUM EtherCAT/Ethernet NO. OF EtherCAT TERMINALS Up to 65,534 COMMUNICATION PROTOCOL EtherCAT DATA TRANSFER RATE 100 Mbit/sec POWER SUPPLY 24V DC CURRENT supply E-bus 2000 mA
- 12. TIMEAND COST TASK TIME ITEMS COST RESEARCH WORK 2 MONTHS MECHANICAL PARTS NULL REPORT WRITING/ PRESENTATION/ ACCESSING ORDERS 1 MONTH DOCUMENTATION AND OTHER EXPENSES ₹ 500/- SYSTEM DESIGNING 1 MONTH PROTOTYPE DEVELOPMENT NULL HARDWARE PROTOTYPE 2 MONTH HARDWARE CIRCUITY ₹ 1,27,270/- PROGRAM DEVELOPMENT 1 MONTH GENERATION OF CODES FOR COMMAND OPERATION NULL TOTAL TIME= 7 MONTHS TOTAL COST= ₹ 1,27,570/-
- 13. PROJECT APPLICATION For Detecting Intrusions into Wide Entrances to Work Areas Safety Light Curtains Enable Horizontal Presence Detection. Position- detection Muting is Achieved for Greater Work Efficiency Floating Blanking Fixed Blanking Safety Light Curtains with Water-resistant Cases
- 14. FUTURE ENHANCEMENT It supports high level of reliability and pervasive attempts to make risk free work environment . Reducing hazardous threats arising from unintended contact between robots and humans. Improving overall performance of industrial robots.
- 15. CONCLUSION The use of industrial robots in manufacturing is becoming increasingly prevalent worldwide. This is an emerging trend driven primarily by the push for greater efficiency and higher productivity as well as falling robot prices, shortage of manpower and increasing labour costs. Robots are essentially machines and the mechanical hazards typically experienced when working with a machine apply also to industrial operations involving robots. Common mechanical hazards when using machines include entanglement, cutting, crushing, impact, shearing and draw-in hazards.
- 16. REFERENCE KUKA Introduction to Robotics (Prof. Dr. -Ing. Eberhood Roos) KUKAAdvance Robot Programming for KUKA System Software Manual https://www.beckhoff.com/english.asp?ethercat/ek1100.htm https://www.sick.com/in/en/opto-electronic-protective-devices/safety-light- curtains/c/g185751 https://ab.rockwellautomation.com/Sensors-Switches/Operator-Safety/Light-Curtain