Introduction
I finished this project in 2022. Due to COVID we were extremely shorthanded so I finished all the PLC development and a few robot development. Afterwards, I almost finished the line commissioning all by myself.
Hardware and software involved in this application are:
- Software:
- Studio 5000
- Factory Talk View
- Robot Guide
- Hardware:
- GuardLogix
- PanelView
- Kinetix
- PowerFlex
- FANUC Robot
- Keyence Touch Prob Measurement Sensor
- FESTO Pneumatics
- Bosch Hydraulic Power Pack
- Lincoln Mig Welder
- Obara Spot welder
Sample Video
Challenges
The biggest challenge in this project is the very demading production cycle time. I had to analyze each workcell and find out if there is any opportunity to speed the production up.
Another big challenge is the welding quality. Due to the metal part’s thermal reaction to mig weld, it was very challenging to finish the weld and meet the precision requirements. I had to work with the mechanical engineers to design welding patterns that can minimize the thermal distortion’s impart on the final product dimensions.
The last challenge is the inline quality check that needs to be accurate and fast.
Solutions
To tune the product line to meet the production cycle time and produce the products in spec, the following approaches were taken:
- Optimize the production sequence.
- Fine tune the robot fly path and the safety interlocks.
- Fine tune the spot welding sequence and balance it with the welding quality.
- Implementing engineering approximation of the 3D geometry in simplified 2D module to reduce quality check complexity.