This document discusses robot and system integration in manufacturing. It describes the characteristics of future automated factories, including shorter product life cycles, increased customization, and greater use of computers. It also outlines the levels in a manufacturing system hierarchy from the corporation level down to individual machines and cells. The document examines work cell architecture and integration, including interfaces between different control levels. It provides examples of simple and complex sensor interfaces and data transfer protocols.

1. SKEM4153
ROBOT TECHNOLOGY FOR
AUTOMATION
CHAPTER 8
Robot and System Integration
Prof. Dr. Shamsudin H.M. Amin
Ir. Dr. Mohd Ridzuan Ahmad
(mdridzuan@utm.my)

2. Contents
• Characteristics of the Future Factory
• System Overview
• Work Cell Architecture
• Interfaces
• CIM of ID Card Assembly
2

3. Characteristics of the Future Factory 1/3
Trends in manufacturing
Shorter product life cycles
Increased emphasis on quality and reliability
More customised products
New materials
Growing use of electronics
Pressure to reduce inventories
Outsourcing
Just-in-time production
Point-of-use manufacture
Greater use of computers
3

4. Characteristics of the Future Factory 2/3
Human workers in the Future Automated Factory
Equipment maintenance
Programming
Engineering project work
Plant security
Factory interface
Plant supervisor
4

5. Characteristics of the Future Factory 3/3
The Social Impact
Impact on labour
Retraining and education
Social impact and economic forces
5

6. Characteristics of the Future Factory
6
Artist’s drawing of the future automated factory.

7. System Overview
7

8. System Overview
8
Scope of CAD/CAM
and CIM

9. System Overview
9

10. System Overview
10
Company level
Factory level
Line level
Cell level
Station level
Machine level

11. 11
Company level
Factory level
Line level
Cell level
Station level
Machine level
System Overview

12. 12
Company level
Factory level
Line level
Cell level
Station level
Machine level
System Overview

13. System Overview
13
FMS Line Control System Layout

14. 14
FMS System Layout – SYSNET Application
System Overview

15. Work Cell Architecture
CIM (Computer Integrated Manufacturing)
15
Level 4
Level 3
Level 2
Level 1
Level 0
Corporation
Factory Area
Materials &
Equipment
Machines
Stations
Cells
Host
Computer
Factory
Computer
Cell computer
Robot Controller
PLC
Position controller Dedicated
controller
Mechatronic
Modules
Mechatronic
Components Sensors Actuators
Control
components

16. Work Cell Architecture
- Level 4
16

17. Work Cell Architecture
- Memory Card File Transfers
17

18. Work Cell Architecture
- CIM (Computer Integrated Manufacturing
18
Level 4
Level 3
Level 2
Level 1
Level 0
Corporation
Factory Area
Materials &
Equipment
Machines
Stations
Cells
Host
Computer
Factory
Computer
Cell computer
Robot Controller
PLC
Position controller Dedicated
controller
Mechatronic
Modules
Mechatronic
Components Sensors Actuators
Control
components

19. Work Cell Architecture
– Level 3
19

20. Work Cell Architecture
20
SYSMAC Net Link Systems Network Configuration

21. Work Cell Architecture
21
SYSMAC Link Systems: Coxial Cable System

22. Work Cell Architecture
22
SYSMAC Link Systems
- provide automatic data exchange through data links
Specifications

23. Work Cell Architecture
- CIM (Computer Integrated Manufacturing
23
Level 4
Level 3
Level 2
Level 1
Level 0
Corporation
Factory Area
Materials &
Equipment
Machines
Stations
Cells
Host
Computer
Factory
Computer
Cell computer
Robot Controller
PLC
Position controller Dedicated
controller
Mechatronic
Modules
Mechatronic
Components Sensors Actuators
Control
components

24. Work Cell Architecture – Level 2
24

25. Work Cell Architecture
25
SYSMAC Way

26. Work Cell Architecture
26
MODBUS

27. Work Cell Architecture
- CIM (Computer Integrated Manufacturing
27
Level 4
Level 3
Level 2
Level 1
Level 0
Corporation
Factory Area
Materials &
Equipment
Machines
Stations
Cells
Host
Computer
Factory
Computer
Cell computer
Robot Controller
PLC
Position controller Dedicated
controller
Mechatronic
Modules
Mechatronic
Components Sensors Actuators
Control
components

28. Work Cell Architecture – Level 1
28

29. Work Cell Architecture
29
Profibus

30. Work Cell Architecture
30
SYSMAC Bus

31. Work Cell Architecture - Level 0
31

32. Work Cell Architecture
32
Differences Between TCP & UDP

33. Work Cell Architecture
33
File Transfer Protocol (FTP)

34. Work Cell Architecture
34
The Power of FINS Communications Factory Intelligent Network Service
(FINS)
Communication developed for efficient
Network communication.
Benefits
1 FINS communications allow PCs on
networks to be controlled by reading or
writing memory area data without the need
to program these operations into the PC
user program.
2 FINS has unique set of address different
from the address system of Ethernet
network. This is to provide consistent
communications method that can be used to
communicate between different networks
such as Ethernet, Sysmac Net & Sysmac Link.

35. Work Cell Architecture
Overview of FINS Procedure Across Network
35

36. Work Cell Architecture
- CIM (Computer Integrated Manufacturing
36
Level 4
Level 3
Level 2
Level 1
Level 0
Corporation
Factory Area
Materials &
Equipment
Machines
Stations
Cells
Host
Computer
Factory
Computer
Cell computer
Robot Controller
PLC
Position controller Dedicated
controller
Mechatronic
Modules
Mechatronic
Components Sensors Actuators
Control
components

37. Interfaces
• Simple Sensor Interface
• Complex Sensor Interface
• Enterprise Data Interface
37

38. Interfaces
- Simple Sensor Interface
38
Robot Solid state
switch
Opto-isolator
driver
Input-output terminals for
work cell equipment
Robot output
signal
Light
coupling
ac input
module
Mains
voltage
Lamp

39. Interfaces
- Simple Sensor Interface
39
Robot
Opto-isolator
driver
Solid state
Switch
Input-output terminals
+ Voltage
Light
coupling
dc input
module
24V dc
24V dc
common
Sensor contacts
Signal into
robot

40. Interfaces
- Complex Sensor Interface
40
Vision
Camera
Vision
Camera
Vision
Camera
Camera Interface
Microprocessor
Robot Interface
DAC
ADC
Robot
Controller
Heater
Pressure
sensor
Control signals
And Data
Control signals
Commands
Operating modes
Data

41. • Textbook:
1. James A. Rehg: Introduction to Robotics in CIM Systems.
Fifth Edition, Prentice-Hall. 2003.
•
• Reference book:
1. Mikell P. Groover: Automation, Production Systems, and
Computer Integrated Manufacturing, Second Edition.
2004.
2. Mikell P. Groover, Mitchell Weiss, Roger N. Nagel,
Nicholas G. Odrey: Industrial Robotics: Technology,
Programming, and Applications, McGraw-Hill. 1986.
3. Farid M. L. Amirouche: Computer-Aided Design and
Manufacturing. Prentice-Hall.
4. Richard K. Miller, Industrial Robot Handbook. Van
Nostrand Reinhold, N.Y. (1987).
41
TEXT AND REFERENCE BOOKS