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 LECTURER’S INFORMATION

Assoc. Prof. Dr. Mazlee Bin Mohd Noor

Faculty of Mechanical Engineering & Technology
Universiti Malaysia Perlis
Office: 1st Floor, MBM6, Taman Muhibah, Jejawi,
02600 Arau, Perlis
(O) : 04-9798619
Email: mazlee@unimap.edu.my
mazleemmt33403.2023@gmail.com

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 SUBJECT INFORMATION

Subject/Code: Cyber Physical System in Welding / MMT33403

No. of Unit: 3

Teaching Mode Date Time Venue

Lecture Sunday 10.30 – 12.30 pm Online

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 REFERENCES
i) Alur, R. (2015). Principles of cyber-physical systems. MIT Press.
ii) Jeschke, S., Brecher, C., Meisen, T., Özdemir, D., & Eschert, T.
(2017). Industrial internet of things and cyber manufacturing
systems. In Industrial Internet of Things (pp. 3-19). Springer,
Cham.
iii) Pires, J. N., Loureiro, A., & Bölmsjo, G. (2006). Welding robots:
technology, system issues and application. Springer Science
& Business Media.

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 Course Outcome (CO)
CO1:
Ability to justify the added value that can be achieved
through application of CPS in welding process.

CO2:
Ability to demonstrate effectively the appropriate CPS tools
in acquiring process variables in real time.

CO3:
Ability to criticise the logged data acquired from variable
welding techniques.

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 Course Evaluation
Assessment Quantity PIC Mark (%)
(Individual)

Assignment 5 2 (by Dr. Mazlee) 20

1 (by Dr. Fitri)
2 (by Dr. Ishak)
Project Report 3 1 each by Dr. Mazlee, 30
Dr. Fitri & Dr. Ishak
Project Presentation 3 1 each by Dr. Mazlee, 15
Dr. Fitri & Dr. Ishak
Progress Presentation 3 By PIC at industry 20

Logbook 3 By PIC at industry 15

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Teaching Plan Academic Calendar Sem 2, 2023/2024

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Teaching Plan

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SOFTWARE USED:

Weeks 1 – 6; RoboDK via https://robodk.com/index

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Introduction to Cyber Physical Systems

Cyber Physical Systems (CPS) refer to the

integration of physical processes with
computational and communication capabilities.
CPS typically involve interactions between
physical devices and cyber systems, with the goal
of improving the efficiency, safety, and reliability
of these physical systems.

A CPS can be thought of as a network of

connected devices that work together to achieve
a common goal. This can include anything from
industrial control systems and autonomous
vehicles, to smart homes and healthcare
systems. CPS are designed to sense and
respond to their environment, making real-time
decisions based on the data they receive. Fig. 1
CPS for the industrial welding robot
What Are Cyber Physical Systems? https://youtube.com/shorts/7-7Ji9j2eoE?feature=share
https://www.youtube.com/watch?v=C6q88zJwq2g
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Fig. 2
Industry 4.0.

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 Overview of cyber physical systems, their architecture, and applications in
welding industry in details
Cyber Physical Systems (CPS) are complex systems
that integrate physical devices and cyber systems to
control and monitor physical processes. In the
welding industry, CPS can be used to improve the
efficiency, quality, and safety of welding operations.
The architecture of CPS in the welding industry
typically includes physical components such as
welding robots and equipment, computational
components such as sensors and controllers, and
communication components such as networking
devices and protocols.
The physical components interact with the
physical environment and are responsible
for carrying out the welding process. The
computational components process
information from the physical components
and other sources, making real-time
decisions on welding parameters and
controlling the physical components. The
communication components enable the
exchange of information between the
physical and computational components,
allowing for real-time, closed-loop control.
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The applications of CPS in the welding industry
include:

Welding Automation: CPS can automate welding

operations, reducing the need for manual intervention
and improving efficiency.

Welding Process Control: CPS can improve the

monitoring and control of welding processes, leading to
improved quality, efficiency, and reliability.

Welding Quality Monitoring: CPS can provide real-time

monitoring of welding quality, enabling prompt
correction of defects and reducing the risk of scrap and
rework.
Fig. 3
Welding Safety: CPS can improve the safety of welding Intelligent welding system technologies.
operations by controlling the welding parameters and
monitoring the work environment for potential hazards.

Welding Data Management: CPS can collect and

manage welding data, providing valuable insights into
welding processes and enabling continuous
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improvement.
Welding parameters:

Welding is a fabrication process that involves joining two or more materials by heating the surface to
the point of melting and fusing the materials together. The process of welding requires a range of
parameters to be controlled in order to achieve a high-quality weld, including:

Welding Current: The welding current is the flow of electric current that passes through the welding
electrode and the workpiece. The welding current determines the heat input to the weld and has a
significant impact on the quality of the weld.

Welding Voltage: The welding voltage is the electrical potential difference between the welding
electrode and the workpiece. The welding voltage affects the arc length and the depth of penetration
of the weld.

Welding Speed: The welding speed is the rate at which the welding electrode moves along the joint
being welded. The welding speed affects the size of the weld bead and the cooling rate of the weld.

Welding Electrode: The welding electrode is the filler material that is used to join the two workpieces.
The choice of welding electrode affects the strength, ductility, and corrosion resistance of the weld.

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Shielding Gas: Shielding gas is used in many welding processes to protect the weld from the effects
of atmospheric contamination. The choice of shielding gas can affect the quality and integrity of the
weld.

Welding Techniques: Different welding techniques such as MIG welding, TIG welding, and Stick
welding, have different requirements and parameters that must be considered. The choice of welding
technique affects the speed, cost, and quality of the weld.

Welding Position: The welding position refers to the orientation of the workpiece during the welding
process. The welding position affects the accessibility of the joint and the ease of welding.

Weld Preparation: Weld preparation involves preparing the workpieces to be joined, including cleaning,
fit-up, and edge preparation. Proper weld preparation can improve the quality and strength of the
weld.

Welding Environment: The welding environment, including temperature, humidity, and wind speed, can
have a significant impact on the quality of the weld. Proper control of the welding environment can
improve the quality and consistency of the weld.

By controlling these welding parameters, it is possible to achieve a high-quality, consistent weld that
meets the desired strength and corrosion resistance requirements.
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RoboDK Software

Offline programming using RoboDK is a technique used

to create and simulate robot programs on a computer
without the need for physical access to the robot. This
technique has several advantages over traditional on-
site programming, including increased safety, decreased
downtime, and improved efficiency.

The RoboDK software allows you to program and

simulate robot movements in a virtual environment, with
support for a wide range of industrial robots from
various manufacturers. The software provides a user-
friendly interface to create robot programs, including a To activate the license:
drag-and-drop feature for adding movements, and
supports different programming languages such as
Python and C++.

RoboDK - Robot Simulation Software

https://www.youtube.com/watch?v=qRsKtvN2Ztw

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 To use RoboDK for offline programming, you first need to create a 3D
model of your work cell in the software. This can be done by importing CAD
models of the work cell and robot or by manually creating a 3D model within
RoboDK. Once the model is created, you can use the software to program
the robot movements and optimize the program before running it on the
physical robot.

The simulation feature of RoboDK enables you to verify the program's

accuracy and functionality before deployment, minimizing the chances of
errors or collisions during the robot's operation. You can also perform
collision detection, create custom post-processors, and generate robot-
specific code for a range of industrial robots.

RoboDK's offline programming approach has several benefits, including

reduced downtime, increased safety, and improved productivity. With
RoboDK, robot programming can be done offline, allowing you to optimize
your program before running it on the physical robot, which saves time and
reduces the likelihood of costly errors.

Offline Programming – RoboDK

https://www.youtube.com/watch?v=XQs8-QnLy6c&list=PLjiA6TvRACQc5E_3c5f3TFXEa56XNR1-m
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Robot Configuration

Cartesian Jog

Cartesian jogging is a feature in RoboDK that allows you to

move a robotic arm in a specific direction and distance within
its Cartesian coordinate system. This is useful when you want to
make precise movements of the robot to a specific point or
location.

To use Cartesian jogging in RoboDK, first select the robot you

want to jog from the RoboDK main window. Then, click on the
"Jog" button located on the toolbar. This will open the jogging
panel, which allows you to control the robot's movement.

Next, select the "Cartesian" option from the jogging panel. You
will then see a set of arrows representing the X, Y, and Z axes of
the robot's Cartesian coordinate system. To jog the robot, Fig. 4
simply click on the arrow corresponding to the direction you Cartesian coordinate system.
want to move and enter the distance you want to move in
millimeters.

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Cartesian Jog

Cartesian jogging is a feature in

RoboDK that allows you to move a
robotic arm in a specific direction
and distance within its Cartesian
coordinate system. This is useful
when you want to make precise
movements of the robot to a
specific point or location. Fig. 5
Cartesian jogging.

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For example, if you want to
move the robot 50mm in the X
direction, click on the X arrow
and enter "50" in the distance
field. The robot will move
50mm in the positive X
direction. You can also use
negative distances to move the
robot in the opposite direction.

Overall, Cartesian jogging is a

powerful feature in RoboDK
that allows you to make precise
movements of a robotic arm in
a specific direction and
distance within its Cartesian
Fig. 6
coordinate system. Robot and Cartesian jogging.

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What is degrees of freedom
(mechanics)?

In mechanics, degrees of freedom (DOF)

is the number of independent variables
that define the possible positions or
motions of a mechanical system in
space. DOF measurements assume that
the mechanism is both rigid and
unconstrained, whether it operates in
two-dimensional or three-dimensional
space. The number of degrees of
freedom is equal to the total number of
independent displacements or aspects of
motion.

Fig. 7
Diagram illustrating how a mechanism in
three-dimensional space can support up to
6 degrees of freedom.

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Import 3D objects

Getting Started: Import Objects and Tools - RoboDK Documentation

https://www.youtube.com/watch?v=gNgCwwpZrWE&t=6s

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