Professional Documents
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COLLEGE
FINAL SEMESTER PROJECT
REPORT
SIEMENS CENTRE OF
EXCELLENCE
JNTU ANANTHAPURAMU
[1]
A REPORT ON
INDUSTRIAL TRAINING
ON
“INDUSTRIAL ROBOTICS &
MODELLING”
AT
COE JNTU,ANANTAPUR
“ROBOTICS DOMAIN”
GUIDED BY VAMSHI KRISHNA
SIR
MKS.DATTA SIR
SUBMITTED BY
K.SUSHMA MURTHY(17020-M-088)
M.ALEKHYA(17020-M-099)
[2]
A.RAMYA(17020-M-061)
P.RAGHUNATH REDDY(17155-M-046)
COURSES LEARNT:
ESSENTIALS OF NX CAD
CNC TURNING
ROBOT STUDIO
RAPID PROTOTYPING
SOFT SKILLS
[3]
ACKNOWLEDGEMENT
[4]
encouragement in all my endeavours at every moment during my
internship
[5]
CAD is widely used from conceptual design and layout of products to
definition of manufacturing of components.
CAD reduces design time by allowing precise simulation rather than
build and test physical prototypes. Integrating CAD with CAM
(Computer Aided Manufacturing) streamlines the product
development even more.
CAD is currently widely used for industrial products, animated
movies and other applications. A special printer or plotter is usually
required for printing professional design renderings. CAD programs
use either vector-based graphics or raster graphics that show how an
object will look.
Daimler Mercedes
[6]
Nissan
Fiat
Chrystler
Mazda
Suzuki
General motors
SKETCHES WE MADE:
MODELLING:
Nx mechanical design software delivers comprehensive modelling
enabling you the most productive modelling approaches
interchangeably from explicit solid and surface modelling to
parametric modelling
[7]
NX enables engineers to lay out piping and instrumentation diagrams
(P&ID) in two dimensions, while maintaining the design tied to the
3D space model. Designer powers faster authoring, common libraries
between diagramming and 3D, connectivity validation, diagramming
to 3D, and equipment-level data management
ASSEMBLY
Assembly modelling is the process of creating designs that consists of
two or more components assembled together at their respective work
positions
The components are brought together and assembled by applying
suitable parametric assembly constraints
We create new components (Menu>Assembly>Component>create
new) in the assembly named
[8]
1.Cylinder
2.Piston
same process create new component named piston.
In assembly navigator
By double clicking on cylinder in assembly navigator you can make
cylinder as a work part.
By making Cylinder as a work part you can start modelling in the
cylinder.
First create a circle
then extrude it
[9]
CNC TURNING:
For the first week we went through the common course I.e. CNC
turning.
Software: Sinumerik 808D on PC 4.6
Introduction:
Manufacturing: It is the process of converting raw material into a
finished product.
Types of manufacturing process:
Casting
Machining
Welding and Assembly
Forming
RPT (Rapid Prototyping)
Machining:
It is the process of removal of wanted material by using a
cutting tool in order to get the desired shape and size.
Machining operations:
1. Turning
2. Milling
[10]
3. Drilling
4. Shaping and planning
5. Broaching
Lathe operations:
1. Turning
2. Facing
3. Knurling
4. Grooving
5. Forming
6. Taper turning
7. Chamfering
8. Thread cutting
9. Drilling
[11]
APT (programming language)
APT or Automatically Programmed Tool is a high-level
computer
programming language used to generate instructions for
numerically controlled
machine tools
Douglas T. Ross is considered by
many to be the father of APT.
Tool Path for program
PARTNO SAMPLE PART MILLING
OPERATION
MACHIN/MILLING,02
CLPRNT
UNITS/MM
CUTTER/20.0
POINT/0, 0, -25.0
P2 = POINT/160.0, 0, -25.0
P3 = POINT/160.0, 60.0, -25.0
P4 = POINT/35.0, 90.0, -25.0
P8 = POINT/130.0, 60.0, -25.0
L1 = LINE/P1, P2 L2 = LINE/P2, P3
C1 = CIRCLE/CENTER, P8, RADIUS, 30.0
L3 = LINE/P4, LEFT, TANTO, C1
L4 = LINE/P4, P1
PL1 = PLANE/P1, P2, P4
REMARK Milling cutter motion statements.
FROM/PTARG
SPINDL/1000, CLW
FEEDRAT/50, IPM
GO/TO, L1, TO, PL1, ON, L4
[12]
GORGT/L1, PAST, L2 GOLFT/L2, TANTO, C1 GOFWD/C1,
PAST, L3 GOFWD/L3, PAST,
L4
GOLFT/L4, PAST, L1
RAPID
GOTO/PTARG
SPINDL/OFF
FINI
Applications:
Aerospace
Machinery
Electrical
Fabrication
Automotive
Instrumentation
Mould making
Medical
[14]
Co-ordinate system:
POLAR COORDINATE
SYSTEM
The polar coordinate can be
used instead of Cartesian
Coordinate to describe
P1 RP=100 AP=30*
P2 RP=60 AP=75*
Here RP Polar Radius
AP Polar Angle
Dimensioning methods:
We having 2 types of ng methods to describe the Points in both above
are:
Absolute Dimensioning
Incremental Dimensioning
FOR LATHE ABSOLUTE
P1 X25 Z-7.5
P2 X40 Z-15
P3 X40 Z-25
P4 X60 Z-35
[15]
FOR LATHE WORKPIECE
INCREMENTAL DIMENSIONING (G91)
P1 X25 Z-7.5
From Work Part zero
P2 X15 Z-7.5
From position P1
P3 X00 Z-10
From position P2
P4 X20 Z-10
From position P3
[16]
G94 Feed in mm/min
G95 Feed in mm/Spindle revolution
G96 Constant Cutting Speed ON G96….S….LIMS=…..
G97 Constant Cutting Speed Off
Programming:
File format:
Main program file
Sub program file
Main program consists of:
1. Header
2. Part program
3. Footer
[17]
CNC programming on turning:
[18]
M09
M30
Not only this we had also written many programs for different
operations like
grooving, thread cutting, undercut and contouring by using canned
cycles.
[19]
And we also gave a presentation on different topics like AGV
INDUSTRIAL ROBOTS
It is a Robot System used for Manufacturing. Industrial Robots are
automated,
Programmable and capable of movement of three or more axes.
As in our Training session we work on the following industrial
Robots:
1.Material Handling Robot
2.Arc Welding Robot
3.Spot Welding Robot
[20]
system such as motion control, development and execution of
application
programs communication etc The IRB 140 can be mounted on floor
inverted
or wall in an angle. It has a large work envelope and all mechanical
arms are
completely IP67 protected.
Axis Movement:
. Main Applications:
1.Cleaning/Spraying
2.Machine Tending
3.Material Handling
4. Assembly
5.packing and Deburring
Activity:
In our Training Session we did many activities like creating a
[21]
programs
for symbols, pick and place operations, and also we created
programs to IRB140
to write on work table like GPT,. WELCOME TO JNTU COE etc….On
below we can
see the activities.
[23]
Performance industrial robot. This robot is equipped with the
IRC5 controller
and robot control software.
IRB 6700 is floor mounted and inverted floor mounted.
Specifications:
S.No Description Values
1. Reach 2.60m
2. Payload 200kg
3. Protection Ip67
4. Controller IRC5 controller
Performance:
[24]
S.No Description Values
1. Pose Repeatability 0.05mm
2. Pose accuracy 0.03mm
3. Path Repeatability 0.11mm
4. Path accuracy 1.7mm
[25]
Axis 5Bend +130° to -130° 100°/s
Axis6 Turn +300° to -300° 210°/s
DIGITAL MANUFACTURING
Digital manufacturing is the use of integrated, computer based
system Comprised of Simulation, three-dimensional (3D)
visualization to create product and manufacturing process definitions
simultaneously .
Digital manufacturing systems allow manufacturing
engineers to create the complete definition of a manufacturing
process in virtual environment including;-tooling, assembly lines,
work center, facility layout, resources
ROBCAD
Robcad is a workcell design and simulation tool, that allows you to
design, simulation, optimization, validation and off-line programming
of multi-device robotic and automated manufacturing process in the
context of product and production resource information.
[26]
Robotic simulation widely utilised in the automotive industry as
their BIW assembly line involves multiple robots, tooling
fixtures ,humans,
i
ROBCAD BENEFITS
1. Increases manufacturing quality, accuracy and profitability
2. Reduce labour hours and process engineering lead time
3. Enable better use of production equipment
4. Reduce production costs
5. Shorten production ramp up through validated process
ROBCAD FEATURES
[27]
i
.
ROBCAD APPLICATION
ROBOT STUDIO
INTRODUCTION:
The basic commands to start using ABB Robot studio ,All the
necessary procedures to create a given robot application are
described step -by -step several print screens from robot studio help
us to understand in a better way the process to operate robot studio
and create robot program offline
MODULE 1
This is how Robot studio looks like:
Here we can see the help tab with all necessary information about
robot studio ,RAPID language and the ABB teach pendant
ROBOT:
The manipulator acts as body of a robot ,the controller is a
combination of computer and drives ,end effector is basically a tool
Man- machine interface which includes laptop and teach pendant
CONTROLLER:
JOGGING:
Jogging means manually moving a robot using the joy stick on the flex
pendant
Jogging cannot be done in auto mode
Jogging is used while teaching a robot points in space
Jogging can be done while programming
INSTRUCTION SET:
The common instructions available can be classified as:
Motion instruction
Program flow instruction
Assignment
Communication instruction
RPT(Rapid prototyping):
We just had an introduction about RPT. We didn’t work on software.
Introduction:
Prototype: An original or the working model of a new product or new
version of an existing product.
1. Crude prototype- proper, perfect imagination
2. Working prototype- demonstration
3. Final prototype- final product
Need of prototype:
To confirm suitability
To conduct test and verify performance
Visualisation
For promotion purpose
To improve the quality of final product
Errors can be detected much earlier
Cheap to manufacture, test and can make changes in final product
Development of prototyping:
1. Manual prototyping
2. Virtual prototyping
3. Rapid prototyping
Advantages of RPT:
One shot operation
Reduced lead time
The closeness to serve the purpose of prototype
Flexible
Economical
Clean and safe operation
Tooling
User friendly
Limitations:
Less than 0.5mm wall thickness can not be manufactured
High precision process, more expensive
Physical properties may vary
It is not comparable with CNC
STL:(Stereo Lithography)
STL-Standard Triangle Language
STL-Standard Tessellation Language
It can not store curve geometry only surface geometry and 3d
geometry can be stored
It is encoded as planar triangles- Tessellation
Each triangle is facet
STL format
It can not store colour and texture. If we want those .obj format is
used
STL files use planar elements they can’t represent curved surface
exactly.
Before 3D model is sent into RPT machine, it must be converted to
STL format
STL is the current industry standard data for RPT and manufacturing
After converting it into STL file we cannot edit the model in CAD
software
Fundamentals:
1. Input: it can be either CAD model or Solis model or
physical model
2. Material: solid based, liquid based, powder based
3. Method: it will be based on the material used
4. Application
Classification:
For solid based material
1. FDM (Fused Deposition Method)
2. LOM (Laminated Object Manufacturing)
For liquid based material
1. SLA (Stereo Lithography Apparatus)
For powder-based material
1. SLS (Selective Laser Sintering)
2. 3D ink jet printing
SOFT SKILLS:
This is a special course in our internship in which we learned
communication skills. We gave JAM sessions. We also participated in
Group Discussions.
Introduction:
There are top 10 soft skills:
Communication skills
Self motivation
Leadership
Responsibility
Team work
Problem solving
Decisiveness
Ability to work under pressure and time management
Flexibility
Negotiation and conflict resolution
Communication skills:
It includes:
Listening
Language
1. Verbal communication
2. Nonverbal communication like gestures and postures
Self motivation:
It includes:
Positivity: we have positive thoughts and positive mentality
Ambition
Commitment
Initiation
Leadership:
A positive attitude and outlook
Ability to make quick and effective decisions
Problem solving or conflict management skills
Ability to communicate effectively
Aptitude for self motivation and motivating others
Responsibility:
Trust worthyness
Discipline
Motivation
Consciousness
Accountability
Decisiveness: It is characterized by the ability to make quick and
effective decisions it does not mean recklessness or impulsiveness
Ability to put things into perspective
Weigh of the options
Access all relevant information
Anticipate any consequences that may be good or bad
A decisive employee will take effective and considered actions
quickly, especially when under pressure
a
All the information is taken from our written book and google by referring
these links
https://www.slideshare.net/ShahidFaizee/abb-training-report
https://www.slideshare.net/teperini/robot-studio-abb
https://www.geoplm.com/knowledge-base-resources/GEOPLM-Siemens-
PLM-Tecnomatix-Robcad.pdf
https://en.wikipedia.org/wiki/Rapid_prototyping#:~:text=Rapid
%20prototyping%20is%20a%20group,%22additive%20layer
%20manufacturing%22%20technology.
https://new.abb.com/products/robotics/application-equipment-and-
accessories/material-handling-equipment
https://new.abb.com/products/robotics/application-equipment-and-
accessories/spot-welding-equipment
https://new.abb.com/products/robotics/applications-by-industry/robot-
welding