Structure of the design
![图片](/uploads/8/3/4/1/83414854/5.jpg?250)
The structure of the whole design can be separated into five parts, two functional
mechanisms, two non-functional component and one system controlling unit.
mechanisms, two non-functional component and one system controlling unit.
![图片](/uploads/8/3/4/1/83414854/4.jpg?333)
Functional mechanisms
To begin with, two functional mechanisms are main multi axis robotic arm ( Referred to CAD file “Station 1”) and secondary rotating system ( Referred to CAD file “Platform 1”). The main multi axis robotic arm is responsible for gripping the cable holding tool to perform the task in each station, it consist three axis movement, X, Y and Z, each axis contain pneumatic cylinder with different size and stroke.
For X axis, we choose MY1C25-500 cylinder as our X axis movement , we chose this cylinder is based on its on mechanical properties that it is mechanical jointed cylinder, it prevents the load blocking from bending. Additional stopper (RS2H50-30DC) is introduced to allow the X axis cylinder can be stopped in desirable position, allowing the robotic arm can reach the machine simulation plate.
For Y axis, we choose MGGB20-200 as our cylinder, it is a integrated guide cylinder, with two guide rod to achieve lateral resistance and non rotating accuracy, side mounting of this cylinder is chosen which strengthen its inertia and provide easier mounting for Z axis cylinder. Cable carrier is also mount on the Y axis cylinder supported by aluminium block, to keep the cables secured in the cable trunk, avoid disordered cable inhibit the motion of the cylinder.
For Z axis, due to short stroke required by customer, we chose a small cylinder, CQMB16-30, it is also double rod guiding cylinder, to achieve lateral resistance and non rotating accuracy. Moreover, gripper is mounted on Z axis for grip the cable holding tool, MHZ2-25D is chosen which is parallel style air gripper, its linear guiding improves rigidity and accuracy, provide a stable datum for holding the cable holding tool.
The secondary rotating system consists of a X axis movement, a pneumatic rotary actuator and a stopper cylinder, the X axis cylinder using MY3M16-300, receive the cable holding tool from main multi axis robotic arm and perform the simulation of rosin dipping and soldering. When the platform receive from the robotic arm, the X axis is in its initial position, the robotic arm retracted and stopper of the platform (CJ2L10-30S) extend to hold the tool in place, then, the rotate actuator rotates to dip the rosin, and then the X axis cylinder move to final position to perform welding by rotate 90 degrees. Finally the stopper extracted and tool is ready for another robotic arm to grip and perform another process.
To begin with, two functional mechanisms are main multi axis robotic arm ( Referred to CAD file “Station 1”) and secondary rotating system ( Referred to CAD file “Platform 1”). The main multi axis robotic arm is responsible for gripping the cable holding tool to perform the task in each station, it consist three axis movement, X, Y and Z, each axis contain pneumatic cylinder with different size and stroke.
For X axis, we choose MY1C25-500 cylinder as our X axis movement , we chose this cylinder is based on its on mechanical properties that it is mechanical jointed cylinder, it prevents the load blocking from bending. Additional stopper (RS2H50-30DC) is introduced to allow the X axis cylinder can be stopped in desirable position, allowing the robotic arm can reach the machine simulation plate.
For Y axis, we choose MGGB20-200 as our cylinder, it is a integrated guide cylinder, with two guide rod to achieve lateral resistance and non rotating accuracy, side mounting of this cylinder is chosen which strengthen its inertia and provide easier mounting for Z axis cylinder. Cable carrier is also mount on the Y axis cylinder supported by aluminium block, to keep the cables secured in the cable trunk, avoid disordered cable inhibit the motion of the cylinder.
For Z axis, due to short stroke required by customer, we chose a small cylinder, CQMB16-30, it is also double rod guiding cylinder, to achieve lateral resistance and non rotating accuracy. Moreover, gripper is mounted on Z axis for grip the cable holding tool, MHZ2-25D is chosen which is parallel style air gripper, its linear guiding improves rigidity and accuracy, provide a stable datum for holding the cable holding tool.
The secondary rotating system consists of a X axis movement, a pneumatic rotary actuator and a stopper cylinder, the X axis cylinder using MY3M16-300, receive the cable holding tool from main multi axis robotic arm and perform the simulation of rosin dipping and soldering. When the platform receive from the robotic arm, the X axis is in its initial position, the robotic arm retracted and stopper of the platform (CJ2L10-30S) extend to hold the tool in place, then, the rotate actuator rotates to dip the rosin, and then the X axis cylinder move to final position to perform welding by rotate 90 degrees. Finally the stopper extracted and tool is ready for another robotic arm to grip and perform another process.
Non functional component
There are two non functional component, “MANU_TESTING_H” and "MANU_TESTING_L”(Referring to the CAD drawing embedded in the Drawing folder). “MANU_TESTING_H” is the higher table which is responsible for carrying the multi axis robot and the main control board including PLC, power transformer etc. Meanwhile, “MANU_TESTING_L” is the lower table which is responsible for carring intermediate platform transferring the cable holder tool to another multi axis robot, it also provides room for preparation table simulation plate and machine simulation plate.
Two table are built and connected using aluminium profile 40mm x 40mm, material type is 6061. Using angle mounting with screw and nuts as assembly method, approxiamated totally length of the profile required is around 20 meters, profiles are cutted in desirable length for assembly, table shape are designed into rectangular shape in order to stablize the working table and achieve simple manufacturing and assembly.
There are two non functional component, “MANU_TESTING_H” and "MANU_TESTING_L”(Referring to the CAD drawing embedded in the Drawing folder). “MANU_TESTING_H” is the higher table which is responsible for carrying the multi axis robot and the main control board including PLC, power transformer etc. Meanwhile, “MANU_TESTING_L” is the lower table which is responsible for carring intermediate platform transferring the cable holder tool to another multi axis robot, it also provides room for preparation table simulation plate and machine simulation plate.
Two table are built and connected using aluminium profile 40mm x 40mm, material type is 6061. Using angle mounting with screw and nuts as assembly method, approxiamated totally length of the profile required is around 20 meters, profiles are cutted in desirable length for assembly, table shape are designed into rectangular shape in order to stablize the working table and achieve simple manufacturing and assembly.
System controlling unit
Components of the system controlling unit consists of PLC, 24V power supply, terminal, NCB, emergency stopper, touch panel, pneumatic regulator, valve. They are mounted on a thin aluminium plate, with adequate spacing, allowing the wire can be hidden in cable trunk, the PLC control the sequence of the movement of the cylinders, regulator regulate the pressurized air input, touch panel provide a user-friendly interface for human control and finally a circuit breaker to stop the whole process in case of any accident are going to happen.
The system is being assembled in the following way, main multi axis robotic arm is mounted on “MANU_TESTING_H” with aluminium block spacers which aiming at connecting the robotic arm and the high table, the reason of non direct mounting is due to poor hole alignment between the X axis cylinder and the aluminium profile and the lift required for the stopper to reach proper position, design a aluminium block spacer can secured the cylinder on the profile as well as lift the robotic arm into suitable height for stopper to reach. Meanwhile the secondary rotating system is mounted on the lower table by direct mounting using screws and nuts, the dimension is pre-mark on the aluminium profile in order to provide a guide position to allocate the rotating system. By using aluminium profile, it allows us to change position slightly to compensate the human error will be built in manufacturing stage.
Components of the system controlling unit consists of PLC, 24V power supply, terminal, NCB, emergency stopper, touch panel, pneumatic regulator, valve. They are mounted on a thin aluminium plate, with adequate spacing, allowing the wire can be hidden in cable trunk, the PLC control the sequence of the movement of the cylinders, regulator regulate the pressurized air input, touch panel provide a user-friendly interface for human control and finally a circuit breaker to stop the whole process in case of any accident are going to happen.
The system is being assembled in the following way, main multi axis robotic arm is mounted on “MANU_TESTING_H” with aluminium block spacers which aiming at connecting the robotic arm and the high table, the reason of non direct mounting is due to poor hole alignment between the X axis cylinder and the aluminium profile and the lift required for the stopper to reach proper position, design a aluminium block spacer can secured the cylinder on the profile as well as lift the robotic arm into suitable height for stopper to reach. Meanwhile the secondary rotating system is mounted on the lower table by direct mounting using screws and nuts, the dimension is pre-mark on the aluminium profile in order to provide a guide position to allocate the rotating system. By using aluminium profile, it allows us to change position slightly to compensate the human error will be built in manufacturing stage.
Top down design or Bottom up design
In design stage, we choose Top down design approach, we discussed the overall concept of design and the tasks we need to accomplish in order to satisfy customer requirement, we planned the system as a whole, and then split the main project goal into smaller problem that can be easily solved.
In design stage, we choose Top down design approach, we discussed the overall concept of design and the tasks we need to accomplish in order to satisfy customer requirement, we planned the system as a whole, and then split the main project goal into smaller problem that can be easily solved.