EXPERIMENT #7

UNDESTANDING MANUAL AND AUTOMATIC

OPERATIONS OF INDUSTRIAL ROBOTS
OBJECTIVES

To be familiar with the robot component.

To manually operate DENSO Robot for certain task using teaching pendant.

To manually operate FANUC Robot for certain task using teaching pendant.

To manually operate YASKAWA MOTOMAN Robot for certain task teaching

pendant.

INTRODUCTION
Manual operation refers to direct operation of the robot from operating panel
or teaching pendent. In manual operation mode, there are three types of operation
modes available:
a) Joint Mode: used to specify movement of each individual joint of the robots
b) X-Y Mode: the joint of the robot moves simultaneously as to create a
motion along the reference X, Y and Z-axis.
c) Tool Mode: which specifying movement of the robots hand relative to a
frame attached to the hand
PROCEDURE
The "Manual Operation" and "Valve Operation" was used to transfer three
balls from left to right with DENSO Robot. The operation was done in different
modes which are, Joint Mode and X-Y Mode. Then, the differences in movement are
noted in the data sheet.

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In the robotics lab, there are nine robots equipped for this course. Students
have to practice the movement of various robot based on different modes. The modes
available are Joint mode and X-Y mode.

Figure 7.1: Components of robots

Upon switching ON the controller, the robot moves to all axes in small
amount to confirm their current positions. Then, the calibration is normally done
before using the robot just after the switch of the robot is turned on.
There are five different robot configurations in general. They are Cartesian,
Cylindrical, Spherical, Articulated and SCARA. In this experiment, we are focusing
on SCARA configuration. SCARA robot has two revolute joints that are parallel and
allows the robot to move in a horizontal plane, plus an additional prismatic joint that
moves vertically. SCARA robots are very common assembly operations. Their
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specific characteristic is that they are more compliant in the x-y-plane, but are very
stiff along the z-axis, and thus have selective compliance. Another configuration
available is the articulated configuration. Articulated robot's joints are all able to
revolute, similar to a human's arm. They are most common configuration used for
industrial robots.
Before proceeding with the lab task, we need to switch ON the machine. To
switch ON the machine, we have to follow steps as mentioned in figure 2 below.
After the motor was switched ON, press the CAL button and then START button
for calibration. Calibration is needed in order to reformat the position to default
positioning. This is to prevent inaccuracy in the input coordinate given before
operating the robot.

Figure 7.2: Sequence to operate machine

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Two modes are available for manual operation in the machine. While, the
differences are as stated in the table 1 below;
Joint Mode
The movement is constrained to each joint

X-Y Mode
The movement is simultaneously for all

in a single operation
The motion is not linear (circular or curve)
Interference between two axis will cause

joints in single operation

The motion is always on a straight line.
Interference are impossible

damage to the motor

Table 7.1: Differences between Joint mode and X-Y mode
OPERATION OF FANUC ROBOT
OBJECTIVES

To familiarize different kind of teaching pendant due to different robot given a

set manual for the students to read, in industry this is also called On Job
Training. (OJT).

To manually operate Fanuc robot for certain task in Joint or X-Y mode using
teaching pendant and to get familiarize with the robot components.

To move the robot end effectors/gripper from one end in manual mode. (The
main reasons here are to identify similarity/differences between DENSO and
Fanuc)

PROCEDURE

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1. The "Manual Operation" is used to move the robot gripper/welder and

effectors from right to left, and then left to right. First in Joint Axis, and then
in Rectangular.
2. We searched from the "Fanuc Manual" in appendix C on how to identify the
coordinate of the current position that we are in. The position is then written
down. The robot was moved again in about L and inverted L shape and the
coordinate of the new position is noted.
RESULTS
Coordinates Identified From Different Positions:Current Position

L Shape

Inverted L Shape

J1 = -57.322

J1 = -55.239

J1 = -55.239

J2 = -2.523

J2 = -3.161

J2 = -2.607

J3 = 93.791

J3 = 176.3

J3 = 0.202

J4 = 178.682

J4 = 178.682

J4 = 178.082

J5 = 1.360

J5 = 1.36

J5 = 1.36

J6 = -0.974

J6 = -0.973

J6 = -0.973

DISCUSSION & CONCLUSION

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Figure 7.3: Robot System

The handling robot (basic stand-alone system) usually consists of a robot
control unit, robot mechanical unit, and hand (tool).

Figure7.4: The Configuration of the Handling Robot System

Each part performs different functions as follows:Parts

Functions

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Controls the line. This unit starts the robot control unit by calling
Remote Control Unit
a program.
Executes the called program.
Robot Control Unit
Robot

This unit moves the robot arm according to a move statement.

This unit opens or closes the hand according to a hand statement.

Mechanical Moves the torch to a specified position according to a move

Unit

statement.

Hand

The hand picks up and places objects as commanded.

Fanuc robot also needs calibration every time it starts operating. As we know,
calibration is done by machine by moving its entire axis in small amount to confirm
their current positions. It is performed right after turning ON the controller before
using the robot. The Fanuc robot used is of Articulated type of configuration
coordinate frame because all the joints revolute without any prismatic motion.

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Figure 7.5: Robot Workspaces

Upon operating the Fanuc Robot, the sequences of key operations are as follows:Operation

Tasks
1. Turn on the circuit breaker of the control unit.

Power-on Procedure

2. Press the power-on button on the operator's panel. The lamp on

the power-on button goes on.
1. Create a program on the program directory screen. Select
"SELECT" from the screen menu, or press the select key to

Selecting a Program
display the program directory screen.
2. Select a target program, then press the ENTER key.
1. Select a jog mode (which is X-Y Mode). Press the COORD key
Setting the Jog Mode

to switch the jog mode.

and Robot Speed

2. Set the robot speed. Set an appropriate cursor speed override

Jogging

sing the override keys.

1. Hold the teach pendant, and press the deadman's switch. Set the
teach pendant enable switch ON.

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2. Start the robot by Jogging. Press a jog key while holding down
the SHIFT key. The robot stops jogging when either the SHIFT
key or jog key is released.
1. Teach a program on the program edit screen. Select EDIT from
the screen menu or press the EDIT key to display the program
edit screen.
Teaching
Statements

Move 2. Jog the robot to a position to be recorded.

3. Press F1 "POINT" to display the standard move statement list in
a submenu.
4. Select a move statement with the arrow keys, then press the
enter key.

In this experiment, we have also seen both Joint-axis and Rectangular mode
for Fanuc. The motions of both configurations are of similar to the Denso robot. The
joint axis mode directs the robot axes (joint axes) by manipulating corresponding keys
on the teach pendant. While the rectangular mode moves the robot rectilinearly along
the axes of a Cartesian coordinate system.

Figure 5.4: Different Jogging Modes for Fanuc Robot

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Safety configurations are installed for the Fanuc robot during the manual
mode session. This is in order to prevent unwanted cases such as injury, etc from
happening while operating the robot.
For installation and layout's safety precautions, signals such as warning lamps
are used to indicate that the robot is in operation. Safety fence installed with a safety
door which will stop the robot when it is opened by a worker coming in. Emergency
button is also installed in places that allow the operator to press it immediately.
While for the system design, a safety joint between the robot joints forming a
tool so that if an abnormal external force is applied to the robot, the safety joints
breaks and the robot stops. A lock is also installed so that only authorized workers can
turn on the power.
The most important safety precautions to be observed are during the operation.
All Fanuc robot system users should be trained to acquire sufficient knowledge
especially on the safety precautions and robot functions. Before operating, the robot
should be checked first whether or not it is working properly and no dangerous
conditions are present. One should also place a partner as a guard to observe the
situation and act quick in case on any accident occurs.

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EXPERIMENT 8:
OFF-LINE AND ON-LINE PROGRAMMING
OF INDUSTRIAL ROBOT

EXPERIMENT #8
OFF-LINE AND ON-LINE PROGRAMMING OF
INDUSTRIAL ROBOT.

OBJECTIVES

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To operate the DENSO robot for certain task with on-line programming using
teaching pendant.

To edit a pre-created program in DENSO

To change the end effectors movement coordinates and operations speeds

Edit the written program with off-line programming using computer.

INTRODUCTION
Programming aims to express the operation procedure with language
(command). A program is defined as a chain of flow between beginning of operation
and the end of operation. Its possible to create a maximum of 100 programs and
name them PROGRAM 1 to 100. Program is created through teaching pendent and it
is saved in robot controller. There are two types of programming to operate DENSO
robot:
a) Online programming: Using teach pendent
b) Offline programming: Using WINCAPS software

PROCEDURE
As shown in the figure, an online programming is used to program the robot
using the un-operational and operational command to move the ball from location A
to B:
FOR PICK AND PLACE ROBOT

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Figure 2.1: Location of the ball

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FOR DRILLING ROBOT

Figure 2.2: Location of the Drill

Manual Mode
1. The robot controller is turned ON. Manual mode is set. The teaching pendant
is then used to start the motors. The robot is calibrated. The speed is set to
30% and the working mode is chosen (either Joint mode or X-Y mode).

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2. Any subroutine in the controller memory location 1 and 2 is deleted if there is

any.
3. Subroutine 1 is created for chuck close, Subroutine 2 for chuck open (refer
to supplementary manual), or the available subroutine is used if any.
4. Any program in the controller memory location 1 is deleted if there is any.
5. The main Program 1 is then created.
6. The un-operational and operational command is used to drive the desired
motion (refer to supplementary manual)
7. The mode is changed to TEACH CHECK mode and the movement of
Program 1 is checked. The speed is set to 20% during this check. All three
types of check is then checked; those are FWD CHECK, BACK CHECK and
CYCLE CHECK.
Auto Mode
3. The Auto mode is set, the motor is started, the robot is calibrated and finally,
the desired speed is determined.
4. The program which has been created: Program 1 is Re-Called.
5. The program is run first in step mode, then in cycle mode. A note of the
differences between the two modes is made.
6. The robot's speed is increased to a safe speed and the pick is repeated and
placed for 20 times. The differences are noticed. The datum for the object to
be pick and place are made sure to be the same for this observation. The
observation is written down in the data sheet.

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SAMPLE PROGRAM
0010
0020
0030
0040
0050
0060
0070
0080
0090
0100
0110
0120
0130
0140
0150

ISP
MV
APR
MV
SUB 1
TIM
DEP
MV
APR
MV
SUB 2
TIM
DEP
MV
END

100
E
E 50
E

Set ISP to 100

Move to the above point
Move the chuck above the point A
Move to the point A

50
P 50
P
E 50
E

Wait for 0.5 seconds

50 mm up
Pass over the point B
Move the chuck above the point
Move to the point B

50
E 50
E

Wait for 0.5 seconds

50 mm up
Move to the point A
End the Program

The robot repeatability problem can be solved while programming by putting

small amount on the internal speed and make the time for the robot motion become
longer. The difference between the step and the cycle mode are explained in the
diagram below.

VS

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EDITING THE PROGRAM

INTRODUCTION
In a manufacturing environment, the manufacturing processing time or cycle time is
very important. As such, the robots sequences operating in the production line can be
easily modified to perform any new assigned process or optimization. This could be
done by editing the existing program instead of rewriting the whole program.
It is only possible to edit commands in a program, which has been already created. A
program cannot be edited while we are creating the program. After writing the END

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command and completing creating mode, we can edit any command such as inserting,
deleting, copying and changing commands.
Editing Operation:
1. Create a new program
2. Insert: Insert a command to create program [INSERT]
3. Deletion: Delete a command from created program [DEL]
4. Display: Display the command of created program [FWD, BACK]
Display the current coordinate of robot [DISP]
5. Copying: Copying the program to another program [COPY]
6. Changing: Changing the numerical value of a command [CHG]
Change the position of a motion command.

PROCEDURE

7. The created PROGRAM 1 (from Experiment 2) is selected by using manual

mode.

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8. The step is displayed so that the previous command can be edited using
forward or backward check. The given manual given manual is referred.
9. The point B is changed to point C. The subroutine will not be included
because it is a drilling robot. The needed position is set and the desired
location is edited for drilling.
10. The speed is set to 1000rpm before drilling, and then reset to 500rpm.
11. After the command is changed, the movement is checked by using teach mode
and auto mode.
12. The speed is set to 500rpm after moving to another location.
13. The entire program is copied into PROGRAM 2. The manual is referred on
how this step could be achieved.
14. The programs 1 and 2 are edited so that it could run in loops.
15. 20 loops of both program 1 and 2 are run. The difference in timing is noted.
All results are recorded in data sheet.

RESULTS, DISCUSSION & CONCLUSION

This experiment shows the significance of understanding on how to edit and change
the program sequence upon different cases according to variety of situations. This is
important because different type of product's design requires different type of motions
for the machine to perform their operation. At the same time, we do not want to waste
more money and time to change the machines when different parts are on the
production line after a period of time. Therefore, the program should always be
flexible and easily edited in order to suite the variety of products and increase the
efficiency of the process executed by the program.

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Below is the process flow of the edited program:-

ISP 100: Set ISP to 100

APR E 50: Move the chuck above the point A

MV E 50: Move to point A

SUB 1
Tim 50
DEP P 50: 50 mm up
The
Changed
location
MV P: Move from above point A to the
point
B

APR E 50: Move to the point B

MV E: Move to the point B

SUB 2
Tim 50
DEP E 50: 50 mm up
END: End the program

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Changing the speed in term of cycle time will allow the process to avoid
unnecessary time consumption and waste more money for the waste of time while we
know that the quality is not affected due to the increase of speed. But still, a few
things need to be considered under these circumstances. Because when the speed is
higher, it might lead to unwanted movement by the robots because of the extra
momentum which is the result for the increase of speed. The positions of parts might
not be precise at the point indicated inside the programming. Besides, it might lead to
hazardous situations if it get in contact with any human because of the extra speed
differing to low safety risk when the speed is slower.
This process of editing is very crucial in the industry. For example, in the
manufacturing industry, while performing assembly of parts. Those different parts
require different type of motions path for them to be fastened or inserted to the right
position. Therefore, at different times, the machine needs to be informed by editing
the program with a slight different path command in order to handle the process
effectively.
As a conclusion, the experiment went well and we have basically achieved the
main objectives. We have understood on how to do editing on the programming as
required and how does this application come in handy in the industry itself.

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EXPERIMENT 9:
DEVELOPING AN AUTOMATION SYSTEM
AND TESTING THE SYSTEM

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EXPERIMENT #9
DEVELOPING AN AUTOMATION SYSTEM AND
TESTING THE SYSTEM
OBJECTIVES

To branch the program run order to optional step depending on the interfaced
signal with the robot controller input slow using branch instruction JUMP.

PROCEDURE
16. The robot has been fixed with a sensor on its gripper. The gripper will be
detected by the sensor whether it is in closed condition or in open condition.
Each sensor is used to identify an individual condition of closed and open.
17. The ports being used by the sensor are input port number 1 and input port
number 2. Short program identifies is used in order to detect whether port 1 or
port 2 is for open or close condition. The codes are written in the data sheet.
18. Upon identification of the ports for open or close. A program is created to
move the parts as follows using online programming to program the robot so
that the ball is moved from location A to B as shown in the figure below:
19. Include a JI / JZ command in the program to make sure that when a gripper is
open, an open gripper sensor status is checked before it is moved to the next
sequence and when a gripper is closed, the close gripper sensor status is
checked before it is move to the next sequence.
20. Through the process that has been programmed earlier, typical cross check
mechanism is created. In next sequence, assuming that the gripper is closed,

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but the close gripper sensor did not detect. The program is inserted/edited to
include in such a way that the robot would in sequence:
a) Open the gripper
b) Check the open gripper status
c) Move up
d) Move down
e) Close the gripper
f) Check the close gripper status
g) Move the part to another position and so forth
21. The program should run in a loop when the sensor is not triggered. This could
be observed using a teach check mode and moving forward through the
programs. Checking the looping issues within the programs.
RESULTS
Program 1
0010
0020
0030
0040
0050
0060
0070
0080
0090
0100
0110
0120
0130
0140
0150

ISP 100
LABL 1
APR E 50
MV E
SUB 1
TIM 50
DEP P 50
MV P
APR E 50
MV E
SUB 2
TIM 50
DEP E 50
JMP 1
End

Program 2
0010
0020
0030
0040
0050

ISP 100
SET I01= 0
LABL 1
APR E 50
MV E

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0060
0070
0080
0090
0100
0110
0120
0130
0140
0150
0160

SUB 1
TIM 50
DEP P 50
MV P
APR E 50
MV E
SUB 2
TIM 50
DEP E 50
SET I01= I01+ 1
CMP I01=< 5 go to

0170

1
END

DISCUSSION & CONCLUSION

This experiment shows the significance of JUMP command instruction while
operating a robot. For the robot system, the inputs are from the switches, proximity,
pressure, photoelectric. While the output accessories are the solenoids, relays and
indicator lamps.
The proximity sensors are the input device used to ensure the availability of
the pen. They are able to detect the presence of nearby objects without any physical
contact. A proximity sensor often emits an electromagnetic or electrostatic field, or a
beam of electromagnetic radiation (infrared, for instance), and find for changes in the
field or the return signal. The sensor or input should be identified by the program
because the robot will only operates when there are interactions between hardware
and software, space complexity in terms of the memory limitations of the robot's

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controller, and time complexity in terms of the speed of the robot's action decisions.
Without all these systems, the robot cannot operate accurately.
It is observed that the robot in the lab has been equipped with optical
proximity sensor. It can detect the presence of nearby objects without any physical
contact. This robot can detect the existence of the part/product to-be-pick during pick
and place programming when its receiver receives the signal from the transmitter. The
receiver and transmitter are usually placed at the hand of the robot arm or at the end
effectors. Input Voltage: 20 to 132 Vac.
The two sensors -one for open and one for close- is rather important to the
system, because when the close sensor detects an object; it will close within the
certain time according to programming. Then, the close sensor will detect the thing
that it is holding until the thing being released. That means close sensor cannot be
used to detect other signal. Therefore, one more sensor should be put to detect the
place where to put the thing. When 2 sensors detect an object in the close range it will
send the signal to the close sensor to open the gripper. The process is vice-verse.
MANDATORY QUESTIONS
1. There are 3 sensor going to be use to construct the line:
a) Infrared Sensor this sensor react to the intensity of light projected on
them by changing their electrical resistance. The port for this sensor is
on the conveyor. When the infrared sensor detects the pear on the
conveyor, the robot will automatically activated and pick up the pear
which is place between the transmitter and receiver.
b) Tactile Sensor This is a touch sensor device that sends a signal when
physical contact has been made. The sensor will detect the hardness of
the pear. This sensor will be put at the gripper of the robot, the gripper

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will give a small pressure during picking process, if the pear does not
follow the specification hardness which has been set it will consider as
old or spoil. Then the pear will be put into the reject basket meanwhile
if the pear meets the hardness specification it will go to further
inspection.
c) Camera sensor This sensor will detect the color of the pear. If the
color is green it will be put into the GREEN basket and if the pear is
yellow in color, it will be put into the YELLOW basket. The sensor
also being put nearer to the gripper.

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2.

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Differentiate
Color sensor (Camera)
Y=0
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BLACK basket

End

4. The

Program 3
0010
0020
0030
0040
0050
0060

ISP 100
APR E 50
MV E
LABL 1
SUB 1
JZ ( M N ) */(M input port

0070
0080
0090
0100
0100
0110
0120
0130

condition/if off) (N label)

TIM 50
DEP P 50
MV P
APR E 50
MV E
LABL 2
SUB 2
JI (M N ) */[ if on]

0140
0150
0160

TIM 50
DEP E 50
End

important of input and output in the robotic system are:

a) Easy for human to communicate with the robot.
b) Input of the robot is sensor and switches. They will collect information
about the internal state of the robot or to communicate with outside
environment.
c) Output of the robot is solenoids, relays and indicator lamps. They will do
the process that has been process in the robot system and follow the command
from the input.

5. Types of signal from the PLC:

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Input signals are typically generated by binary sensors, such as limit switches
or photo sensors that are interfaced with the process.
Output signals are generated by the controller to operate the process in
response to the input signals.
These output signals turn on and off switches, motors, valves, and other binary
actuators related to the process.
A list of binary sensors and actuators, along with the interpretation of their 0
and 1 values are shown in Table 9.1.
The purpose of the controller is to coordinate the various actions of the
physical system, such as transferring parts into the work holder, feeding the
machining work head, and so on.
One/Zero

Process

Control One/Zero

Interpretation
Contact/no contact
On/off

Actuator
Motor
Control relay

Interpretation
On/off
Contact/no contact

Sensor
Limit switch
Photo-detector
Push-button

On/off

Light

On/off

switch
Timer
Control relay

On/off
Contact/no contact

Valve
Clutch

Closed/open
Engaged/not engaged
Energized/not

Circuit breaker

Contact/no contact

Solenoid
energized

Table 9.1: Binary Sensors and Actuators Used in Discrete Control

Discrete process control can be divided into two categories:

logic control, which is concerned with event-driven changes in the
system; and

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Sequencing, which is concerned with time-driven changes in the

system?
Both are referred to as switching systems.
6. The robot knows when a jig is at its place, completed its task such as drilling,
identifying bad units or welding by using the sensor which is located at certain
check point in the PLC line system. There are a lot of sensor being used in PLC
system such as light and infrared sensor, touch and tactile sensor, proximity
sensor, range finder, sniff sensor, vision system and many more.

Appendix A:

FINAL LABORATORY PROJECT REPORT

Reports Title Page

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ROBOTICS CONTROL USING

MC68230

GROUP NUMBER : 1A
GROUP MEMBERS:
NO:
1. RAHISHAM ABD RAHMAN,
2. MUHAMMAD FAHMI ISMAIL
3. WAN MUHAMMAD IMRAN
4. FAZRI IDRIS

MATRIC
4080484
4271276
4120678
4090974

DATE OF SUBMISSION
Tuesday, 7th May 2012

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Appendix B:

Data sheet report forms

DATA SHEET FOR EXPERIMENT#:

LIST THE CODES USED:
PART B

PART C

(Note Please add the 'PART' accordingly)

DEMO PART A COMPLETE

DEMO PART B COMPLETE
DEMO PART C COMPLETE

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Data approved and verified by :

Signature and date

Appendix C:

Certificate of Originality and Authenticity

This is to certify that we are responsible for the work submitted in this
report, that the original work is our own except as specified in the
references and acknowledgement, and that the original work contained
herein have not been untaken or done by unspecified sources or person.
We hereby certify that this report has not been done by only one
individual and all of us have contributed to the report. The length of
contribution to the reports by each individual is noted within this certificate.
We also hereby certify that we have read and understand the content of
the total report and no further improvement on the reports is needed from
any of the individuals contributor to the report.
We therefore, agreed unanimously that this report shall be submitted for
marking and this final printed report have been verified by us.
Signature:
Name:
Matric Number:
Contribution:
Signature:
Name:
Matric Number:
Contribution:
Signature:
Name:
Matric Number:
Contribution:

Read
Understand
Agree
Introduction and calculation
Read
Understand
Agree
Graphs and procedures
Read
Understand
Agree
Conclusion and discussion part A

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