This document provides details of a project to design an automated pick and place system for components of a CNC lathe machine. It includes sections on the objectives, literature review, methodology, modeling using Solidworks, fabrication, static and dynamic FE analysis, optimization, and conclusions. The objectives are to reduce lead time, optimize design for cost and productivity, and evaluate the new design using simulation. The literature review covers various papers on robotics, pick and place systems, dynamic analysis, and multi-robot coordination. The methodology describes the components to be used, cycle time calculations, and assembly. FE analysis and optimization are performed to validate the design meets requirements. The conclusions are that automation increased productivity and reduced cycle times.

1. Hardik .A. Modi (Engineer-Production)
+91 94295 42460. Kalol City – Gujarat – India (382721)
hardikmodi024@gmail.com
“Automated system design for Pick & Place
of m/c components of CNC-Lathe.”

2. •Introduction
•Literature Survey
•Objective of Project
•Design Methodology & Calculation
•Modeling of CNC pick & place using Solid works
•Fabrication of Pick & Place Unit
•Static FE Analysis
•Dynamic FE Analysis
•Optimization of Pick & Place frame
•Conclusion
•Work Plan & Project Roadmap
•References
Contents

3. INTRODUCTION

4. Automation:-
Automation is defined as a technology that is
concerned with the use of mechanical, electronic, and computer-
based systems in the operation and control of production.
There are types of Automation :
(1) Fixed (2) Flexible (3) Programmable
Out of these Robots are related to Programmable Automation.
Robots :-
An industrial robot is a “reprogrammable,
multifunctional manipulator designed to move materials, parts,
tools, or special devices through variable programmed motions
for performance of a variety of tasks”.
Introduction

5. Robot Anatomy
 Common Robot Configurations
• Polar configuration (RRL)
• Cylindrical configuration (LRL)
• Cartesian coordinate configuration (LLL)
• Jointed-arm configuration (RRR)
Introduction

6.  Robot Motions
Motions associated with the arm and body are
1. Vertical traverse
2. Radial traverse
3. Rotational traverse
Introduction

7. Motions associated with the wrist, to solve the orientation
problem,
1. Wrist roll
2. Wrist pitch
3. Wrist yaw
Introduction

8. End Effectors
In robotics, the term end effectors are used to describe the hand
or tool that is attached to the wrist.
The end effecter represents the special tooling that permits the
general-purpose robot to perform a particular application.
This special tooling must be designed specifically for the
application.
End effectors can be divided into two categories: grippers and
tools. Grippers could be utilized to grasp an object, usually a
work part, and hold it during the robot work cycle. There are a
variety of holding methods
Introduction

9. LITERATURE SURVEY

10. •M. Pellicciari et all[14] interest in novel methods and tools for
optimizing the energy consumption in robotic systems is
currently increasing.
•Differently from other optimization routines, the proposed
strategy does not rely on either equipment replacement, plant
modification or path re-planning. In fact, starting from given
manipulator electromechanical parameters and prescheduled
trajectories compatible with the actuation limits, an energy-
optimal trajectory is simply determined by means of time-scaling.
Literature Survey

11. •Tian Huang et all [11]presents an approach for the optimal
design of a 2-DOF translational pick-and-place parallel robot. By
taking account of the normalized inertial and centrifugal torques
of a single actuated joint, two global dynamic performance
indices are proposed for minimization
•H. Isıl Bozma et all[12] considers the problem of multirobot
coordination in pick-and-place tasks on a conveyor band. The
robot team is composed of identical robots with mutually
exclusive, but neighbouring workspaces.
Literature Survey

12. •The developed algorithm has been implemented and tested in a
simulated manufacturing environment . Results obtained from the
simulations are analyzed using a variety of statistical performance
measures.
•Yanjiang Huang et all [13] addresses the problem of realizing
multi-robot coordination that is robust against pattern variation in
a pick-and-place task. To improve productivity and reduce the
number of parts remaining on the conveyor, a robust and
appropriate part flow and multi-robot coordinate strategy are
needed.
•The task-completion success rate derived via the proposed
method reached 99.4% for 10,000 patterns.
Literature Survey

13. •M. Taylan Das et all[17] A complete mathematical model of
SCARA robot (Serpent 1) is developed including servo actuator
dynamics and presented together with dynamic simulation in this
paper.
•The difference between both results is simply caused by
assumptions made while developing the mathematical model, and
also numerical calculations carried out (integration scheme). Here
the coordinates of pick and place points are very important for
exact positioning. This is certainly performed within the
tolerances given for the operation.
Literature Survey

14. •Istv´an Harmatia et all [19]involves a collision free target
tracking problem of multi-agent robot system. Target tracking
requires team coordination to maintain a desired formation and to
keep team-mates and target together.
•To enhance the robustness, a controller tunes the cost function
weights directly for the game theoretic solution and helps to
achieve a prescribed value of cost function components.
Simulation result for target tracking by a three member robot
team is presented.
Literature Survey

15. Objective of Project

16. Objective of Project Work :-
• The Main aim of this project is to develop pick & place sys. For
CNC Machine(DX 200) with the accuracy of 0.5mm.
•For better fulfilment of requirement and reducing trial & error
we can use Solid works by doing Model as well as structural &
Dynamic Analysis in ANSYS 12.1 we can evaluate the better
performance based design.
•The aim is to illustrate what can be done and also to identify
trends and those areas where further work is needed.
Objective of Project

17. Objective of Project Work:-
The objectives of the study are as follows:-
•To reduce lead time and trial & error method for development.
•To optimize the pick and place system design for cost.
•Evaluate the new design result with simulated data.
•Increasing productivity.
•Reducing manpower requirement.
Objective of Project

18. Design Methodology &
Calculation

19. Methodology
• Select CNC m/c.
• Select the component for CNC Loading and Unloading.
•Manual Cycle time calculation of Component for CNC Loading
& Unloading.
• Use cylinders for automate the process.
• Calculate the cycle time after automating the process.
• Check all the assembly.
• Compare the cycle time and Other Parameter.
• Conclusion.
Design Methodology & Calculation

20. Door
Sketch of Set-up
CNC M/c
1M
3M
(2A) M
C3
Components
C1
(2B) M
C2
Design Methodology & Calculation
Chuck

21. CNC Pick and Place Unit Consist of Below Mentioned Part:-
• Pneumatic Cylinder(Loading New Component into Loading
Station) :- 40 MM (BORE) X 20 MM (STROKE)
• Pneumatic Cylinder(Loading Cylinder) :- 100 MM (BORE) X
600 MM (STROKE)
• Pusher Pneumatic Cylinder:- 32 MM(BORE) X 40 MM
(STROKE)
• Door Open and Close Pneumatic Cylinder:- 63 MM (BORE)
X 500 MM(STROKE)
Design Methodology & Calculation

22. • M.S Frame
• Two Jaw Mechanical Gripper
• Teflon Spacers
Design Methodology & Calculation

23. Modeling of CNC pick & place
using Solid works

24. Work piece
Modeling of CNC pick & place using Solid works
Fig. Work piece

25. Modeling of CNC pick & place using Solid works
Fixture for Holding Work piece
Fig. – Fixture for holding Workpiece

26. Modeling of CNC pick & place using Solid works
3D Model of fixture with Work piece
Fig. – fixture with workpiece

27. CNC Turning Center (DX 200) - Technical Specification
Slides : Cross (X-axis) Travel: - 360 mm
Longitudinal Travel: - 200 mm
Rapid Travel(X &Z axis) :- 24 m/min
Main Spindle : Spindle Bore: - 50 mm
Max Bar Capacity: - 38 mm
Spindle Speed Range: - 50-4500 rpm
Full Power Speed Range: - 1333-3666 rpm
Other : Weight(Approx.) :- 2500 Kgs.
Dim.(Approx.)(LxWxH):-1850x1350x1670 mm
Modeling of CNC pick & place using Solid works

28. Parameters of m/c Vertical distances
• Height of the m/c – 1450mm
• Height from base to bed – 550mm
• Height from bed to chuck – 542mm
Parameters of m/c Horizontal distances
• From chuck to door – 600mm
• From door to outside frame – 400mm (Approx.)
Total Horizontal distance (From chuck to frame) – 1000mm
Modeling of CNC pick & place using Solid works

29. 3D Model of CNC Turning Centre
Modeling of CNC pick & place using Solid works
Fig. – 3D Model of CNC Turning Centre

30. Modeling of CNC pick & place using Solid works
CNC Turning Center with holding fixture and work piece
Fig. – CNC Turning Centre with holding fixture & workpiece

31. Modeling of CNC pick & place using Solid works
CNC Pick and Place Unit (R.H.S View)
Fig. – CNC Pick & Place Unit(R.H.S View)

32. Modeling of CNC pick & place using Solid works
CNC Pick and Place Unit (L.H.S View)
Fig. – CNC Pick & Place Unit(L.H.S View)

33. Fabrication Of Pick & Place
Unit

34. Fabrication of Pick & Place Unit
Fixture Assembly
Fig. – Fixture Assembly

35. Fabrication of Pick & Place Unit
Assembly of Pick & Place Sys.
Fig. – Assembly of Pick & Place Sys.

36. Fabrication of Pick & Place Unit
Assembly of Pick & Place Sys.
Fig. – Two jaw finger Fig. – CNC Pick & Place Unit(R.H.S View)

37. Fabrication of Pick & Place Unit
General Assembly Drawing

38. Fabrication of Pick & Place Unit
Pneumatic Circuit Diagram
Fig. – Pneumatic Circuit Diagram

39. STATIC FE ANALYSIS

40. 1) After Creating Solid Model of CNC Pick and Place Unit Frame
in SOLIDWORKS. Save that model in IGES format.
2) Import above 3D Model in ANSYS.
3) Define material for the entire structural component.
4) Define Contact between each structural component.
5) Create meshing of CNC Pick and Place Unit Frame.
6) Applying Boundary Conditions by Defining fixed supports
7) Defining Remote forces
8) Run Analysis.
9) Get Results.
10) Results of Analysis.
STATIC FE ANALYSIS

41. STATIC FE ANALYSIS
Imported Static Structure
Fig. – Static Structure

42. STATIC FE ANALYSIS
Welded Contact between joint of structure & Meshing
Fig. – Welded Contacts between joint of structure Fig. – Meshing

43. STATIC FE ANALYSIS
Fixed Support & Remote Force
Fig. – Fixed Support Fig. – Remote Force

44. STATIC FE ANALYSIS
Von Misses Stresses & Maximum Shear Stress
Fig. – Von Misses Stresses Fig. – Maximum Shear Stress

45. STATIC FE ANALYSIS
Results of Analysis (Total Deformation)
Generated Total Deflection = 0.3378 mm
Sr No. Experimental Deflection FE Generated Deflection % Deviation
1 0.350 mm 0.33784 mm 3.5

46. DYNAMIC FE ANALYSIS
There are two analysis done in Dynamic Analysis :
(1) Modal Analysis
(2) Transient Analysis
Results of Modal Analysis
Sr No. Modal Frequency(Hz)
1 7.3969
2 18.599
3 22.647
4 28.729
5 36.047
6 40.028
Fig. – Result of Modal Analysis

47. DYNAMIC FE ANALYSIS
There are two analysis done in Dynamic Analysis :
(1) Modal Analysis
(2) Transient Analysis
Results of Transient Analysis – Total Deformation
Fig. – Result of Transient Analysis – Total Deformation

48. Optimization of CNC Pick & Place Frame
Objective function is defined as the parameters that are attempted to
be optimized. In this study the weight, manufacturing cost and fatigue
performance of the component were the main objectives.
Optimization attempt was to reduce the weight and manufacturing
cost, while ORIGINAL MODEL: - 35 X 35 X 5 mm
Modification 1 : 30 X 30 X 4 mm Structure

49. Optimization of CNC Pick & Place Frame
Modification 2 : 25 X 25 X 3.5 mm Structure
Fig. – Von Misses Stresses Fig. – Maximum Shear Stress

50. Optimization of CNC Pick & Place Frame
Modification 3 : 20 X 20 X 3 mm Structure
Fig. – Von Misses Stresses Fig. – Maximum Shear Stress

51. Optimization of CNC Pick & Place Frame
Modification 1 Modification 2 Modification 3
Frame
30 X 30 X 4 25 X 25 X 3.5 20 X 20 X 3
Von Misses Stress
(Mpa) 100.72 164.81 247.22
Maximum Shear
Stress (Mpa) 55.875 91.432 137.15
Weight (Kg.) 213.87 197.1 188.62
Table : Optimization Table for diff. frames
Above Table Shows that Generated Stresses in Modified 2 Frame is
below the material Allowable Limit (Von Misses Stresses = 200 Mpa).
So Modified 2 Frame is optimum configuration for CNC Pick and
Place Unit.

52. From the Experimental model of CNC Pick and Place we have found
out that the pneumatic gripper has many advantages and is one of the
modern techniques in the world of robotics which makes pick and place
work easier and much faster than the conventional techniques.
Some important conclusions come from this work are as under:-
• A FEM Deflection result fairly matches with experimental work. So
we can say that FE Analysis is a good tool to validate our costly
experimental set up which reduces time and cost for trial and error.
• Earlier prior to CNC Pick and Place Automation , the cycle of pick
and Place carried out manually at that time loading and unloading
time is 12 sec which is reduced by 7 sec by using CNC Pick and Place
Automation. So productivity is increased.
CONCLUSION

53. •When the machine operated manually it operate hardly 12 hours per
day due to labour availability. while with CNC Pick and Place unit it
operates 20 hours per day.
CONCLUSION

54. Work Plan:-
• Perform Dynamic Analysis of Pick and Place system frame.
•Develop Pneumatic circuit diagram.
•Fabrication and assembly of Pick and Place system
•Testing of Pick and Place System
•Validate FE Analysis Results with Testing Results.
•Weight and cost Optimization.
Work Plan

55. Future Work Plan:-
Work Plan

56. Project Roadmap:-
Project Roadmap

57. [1] Eberhard Bamberg, "Principles of Rapid Machine Design", Massachusetts Institute of
Technology , 2000.
[2] Frantisek Trebuna, Frantisek Simcak, Jozef Bocko, Peter Trebuna, Miroslav Pastor, Patrik
Sarga.,"Analysis of crack initiation in the press frame and innovation of the frame to ensure its
further operation", Engineering Failure Analysis, 2011.
[3] Gary Jubb, "Modelling of melt on spinning wheels and the impact of scale-up onthe various
parameters", Thermal ceramics.
[4] John G. Cherng, Mahmut Eksioglu, Kemal Kizilaslan, "Vibration reduction of pneumatic
percussive rivet tools: Mechanical and ergonomic re-design approaches", Applied Ergonomics,
2009
[5] Michelle sueway chang, "Design of an Automated Sorting and Orienting Machine for
Electronic Pins,Department of Mechanical Engineering",S. B. Massachusetts Institute of
Technology, 2011.
[6] Ramezanali Mahdavinejad, Finite elemt analysis of machine and workpiece instability
in turning", International Journal of Machine Tools and Manufacture,2005
References

58. [7] "SolidWorks A Brief Discussion", Mechanical Engineering, (2005).
[8] Festo software
[9] Atak engineering construction trade Inc. co. , "Fabrication Method Statement",W-17,
2011
[10] Ada Che a, HongjianHua, MichelleChabrol b, MichelGourgand b," A
polynomialalgorithmformulti-robot2-cyclicscheduling in ano-wait robotic cell" Computers &
Operations Research38 (2011) 1275–1285
[11] Tian Huang Songtao Liu, Jiangping Mei, Derek G. Chetwynd," Optimal design of a 2-
DOF pick-and-place parallel robot using dynamic performance indices and angular
constraints", Mechanism and Machine Theory 70 (2013) 246–253
[12] H. Is-ıl Bozma n, M.E.Kalalıo˘glu," Multirobot coordinationinpick-and-
placetasksonamovingconveyor" , Robotics andComputer-
IntegratedManufacturing28(2012)530–538
[13] Yanjiang Huanga,b,∗, Ryosuke Chiba c, Tamio Arai d, Tsuyoshi Ueyamae, Jun Ota
b," Robust multi-robot coordination in pick-and-place tasks based on part-dispatching
rules" Robotics and Autonomous Systems 64 (2015) 70–83
[14] M. Pellicciari,G.Berselli ⇑, F.Leali,A.Vergnano," A method for reducing the energy
consumption of pick-and-place industrial robots" Mechatronics 23 (2013) 326–334
[15] Appuu K.K. Kuttan, "Robotics", I K International Publishing House Pvt. Ltd (23 July
2007)
References

59. [16] Ashitava Ghosal," Robotics: Fundamental Concepts and Analysis" Oxford (17
February 2006)
[17] M. Taylan Das, L. Canan Dulger"Mathematical modelling, simulation and
experimental verification of a scara robot"Simulation Modelling Practice and Theory 13
(2005) 257–271
[18] H. Is-ıl Bozma n, M.E.Kalalıo˘glu," Multirobot coordination in pick-and-place tasks on
a moving conveyor"Robotics andComputer-IntegratedManufacturing28(2012)530–538
[19] Istvan Harmatia, Krzysztof Skrzypczyk," Robot team coordination for target tracking
using fuzzy logic controller in game theoretic framework" Robotics and Autonomous
Systems 57 (2009) 75–86
References

60. Thank You