Budapest University of Technology and Economics, Faculty of Electrical Engineering and Informatics

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    Robotized Manufacuring Systems

    A tantárgy neve magyarul / Name of the subject in Hungarian: Robotizált gyártórendszerek

    Last updated: 2024. február 24.

    Budapest University of Technology and Economics
    Faculty of Electrical Engineering and Informatics
    Bachelor's degree (BSc), electrical engineering
    Embedded and control systems specialization
    Course ID Semester Assessment Credit Tantárgyfélév
    VIIIAC06 5 2/2/0/v 5  
    3. Course coordinator and department Gincsainé Dr. Szádeczky-Kardoss Emese,
    Web page of the course https://edu.vik.bme.hu
    4. Instructors
    Emese Gincsainé Dr. Szádeczky-Kardoss, Associate Professor, Department of Control Engineering and Information Technology.
    Dr. Bálint Kiss, Associate Professor, Department of Control Engineering and Information Technology.

    5. Required knowledge Digital design, Basics of programming 1-2, Linear algebra
    7. Objectives, learning outcomes and obtained knowledge
    The aim of the subject is to present the main characteristics of discrete control systems, especially the standard programmable devices and industrial robots, widely used in manufacturing systems and supply chains. The subject also presents the sensors and actuators involed in the control loops with special focus on their potential application fields and operation. The subject also describes the characteristics of field bus systems that ensure reliable communication between devices. Students who successfully fulfill the requirements of the subject can
    - present the elements and structure of automated and robotized manufacturing systems,
    - describe the standard operating and programming model of programmable logic controllers (PLCs) and its frequently used modules,
    - implement typical control tasks in automated manufacturing systems with the help of PLCs,
    - to present the operating principle and characteristics of some commonly used sensors and actuator devices in automated manufacturing systems,
    - present and apply field bus systems,
    - describe the structure and characteristics of industrial robot arms, present the geometric model of the robot, and the methods of solving direct and inverse geometric tasks (transformations between the joint space and the work space),
    - implement typical assembly and tool handling tasks with industrial robots, using second-generation robot programming languages.
    8. Synopsis
    Lectures
     
    1. Robotic production systems and PLCs (2 weeks): history of industrial autoation. Structure, hardware and software elements of modern automated manufacturing systems. The concept of PLC, classification of PLCs, compact and modular controllers. Features of the central unit, types of input and output modules. The general memory model of PLCs, the concept of cyclic mode of operation and its effect on the programming model.

    2. The software model of the IEC-61131-3 standard (1 week): Features of modern PLC operating systems, scheduling, program organization units, data types, standard functions and function blocks.
     
    3. Displacement and proximity detection (2 weeks): Measurement of linear and angular displacement using potentiometers, relative and absolute encoders. Ultrasonic and laser distance sensors. Proximity sensors common in industrial practice: operating principle and characteristics, application of limit switches, optical, magnetic, inductive and capacitive sensors. 
     
    4. Servos and drives (2 weeks): typical electrical actuators of automated manufacturing systems. Asynchronous variable frequency drives (VFD): structure and operating principle of VFDs, typical applications and parameters, case study. Synchronous servo drives: construction and principle of operation of a servo amplifier, typical applications, operating modes and parameters, linear drives, case study. 
     
    5. Basic concepts of robotics (1 week): features and components of industrial robot arms with open kinematic chain, segments, joints, robot workspace, characterization of the position and orientation of the tool or gripper. Construction of robot cells, robots as intelligent actuators of production systems.
     
    6. Geometric model of robot arms (2 weeks): homogeneous transformations between the frames fixed to the robot segments and the tool or gripper. Denavit-Hartenberg parameters. The direct and inverse geometry problem between the configuration space and the workspace. The possibility of splitting the task into position and orientation subtasks.
     
    7. Robot programming (1 week): Methods of training robots, design of the track that fits the trained configurations. Features of second-generation robotic programming languages, the most commonly supported family of move instructions.
     
    8. Field bus systems (3 weeks): Characteristics of field buses and bus systems, application technical considerations. Presentation of the most common fieldbus systems: AS-i, MODBUS, CANopen, PROFIBUS, PROFINET.
     
    Practice sessions about programming PLCs according to the IEC 61131-3 standard
     
    1. The basic features of the CODESYS development environment and the basics of the ladder diagram based programming language. Implementation of networks (ladders), contacts and coils, logical functions (1 week)
     
    2. Program organization units and their use, scheduling options. Characteristics of functions and their implementation, functions of the IEC 61131-3 standard. Characteristics of function blocks and their implementation, use of standard bistable, edge-sensitive, timer and counter function blocks. Validation of modular development principles using function blocks. Implementation of cyclical, periodic and event-driven operation using tasks. (3 weeks)
     
    3. State machine-based control with ladder diagrams. Realization of sequential control, implementation of state machines using ladder diagrams. (1 week)
     
    4. Function block diagram. Signal flow graph based implementation of algorithms, the function block diagram (FBD) programming language. Implementation of sampling control algorithms in function block diagram language. (1 week)
     
    5. Structured text (ST). Syntax and features of ST, case selection and iteration. Use of derived data types: arrays, structures, enumeration types. Realization of state machine-based controls in structured text language, development of complex applications. (2 weeks)
     
    6. Sequential flowchart (SFC). Basics, divergent and parallel branches, safe and accessible networks, use of step-flag and step-time. Actions and standard action ratings, action control logic. Use of SFC for simple sequence control and coordinated operation of modules of complex applications. (2 weeks)
     
    Practice sessions about modeling and programming of industrial robotic arms
     
    7. Geometric modeling of a robot arm, the direct and inverse geometric task. Definition of the frames and the Denavit-Hartenberg parameters for a specific industrial robot arm. Solving the direct and inverse kinematic problem, implementing the solution as a function. (1 week)
     
    8. Solving robot programming tasks in the MELFA RT Toolbox development environment. Basic services of the development environment, project creation. Movement of the simulated robot in joint space and workspace. The TOOL and XYZ frames. Using the description of the robot hand (HAND) in the simulation. Creating, editing, and running a robot program, teaching trajectory points in the joint space and workspace. Use of the MELFA Basic robot programming language's movement instructions (MOV, MVS, etc.), examination of interpolation techniques, use of palletizing instructions and program organizing instructions. (2 weeks)
    9. Method of instruction Two hours of lecture per week, and two hours of practice per week. Concepts and methods presented during the semester are incremental, so thorough and continuous preparation is recommended to understand the material of the lectures and exercises. The development environments used in the exercises (CODESYS for industrial control technology applications and MELFA RT Toolbox for robot programming) are available to students on virtual machines during and outside of the practice sessions. We adapt the material of the practice sessions to the newer versions of the development environments as needed.
    10. Assessment
    During the period of classes: obtain a signature by fulfilling the following two requirements

    1. Successful submission of the independent solution of the two homework assignments issued during the semester (evaluation: accepted/not accepted).

    2. Summative assessment: effective (at least sufficient) writing of a 90-minute midterm. At midterm, the material part required for us is 40% of the entire semester's curriculum. The result of the midterm counts for 40% of the exam mark.

    During the exam period: Obtaining the signature is a condition for admission to the exam. The exam consists of a written performance evaluation and the inclusion of the results achieved in the mid-year performance evaluation. There is no way to improve the results of mid-year performance evaluations during the exam period. 
    11. Recaps The midterm can be repeated (both if failed or for a better grade) once during the period of classes. The midterm cannot be repeated during the replacement week. One of the two homework assignments can also be submitted during the repeat week.
    12. Consultations During the period of classes, it is primarily during the reception hours of the subject's instructors, or at a pre-arranged time if needed. During the exam period, after electronic consultation, on the working day before the exam. Instructors reserve the right not to respond to student letters/messages where the required information is clear based on the subject's data sheet or website.
    13. References, textbooks and resources
    Frank D. Petruzella: Programmable Logic Controllers. McGraw-Hill, 2005, ISBN 0-07-829852-0
    W. Bolton: Programmable Logic Controllers, Elsevier, 2009, ISBN 978-1-85617-751-1
    Karl-Heinz John, Michael Tiegelkamp: IEC 61131-3: Programming Industrial Automation Systems, Springer, 2010, ISBN: 978-3-642-12015-2
    Kevin M. Lynch, Frank C. Park: Modern Robotics : Mechanics, Planning, and Control. Cambridge University Press, 2017, ISBN: 978-1-10715-630-2
    Lantos: Controlling robots. Academic Publishing House, 3rd edition, 2002, ISBN 963 05 7944 8
    Electronic aids on the website of the subject.
    14. Required learning hours and assignment
    Kontakt óra56
    Félévközi készülés órákra19
    Felkészülés zárthelyire15
    Házi feladat elkészítése20
    Kijelölt írásos tananyag elsajátítása
    Vizsgafelkészülés40
    Összesen150
    15. Syllabus prepared by
    Gábor Kovács, teaching assistant, Department of Control Technology and Information Technology.
    Emese Gincsainé Dr. Szádeczky-Kardoss, Associate Professor, Department of Control Technology and Information Technology.
    Dr. Bálint Kiss, Associate Professor, Department of Control Technology and Information Technology.