http://www.bham.ac.uk/imageslib/polyu logo.jpg

 

IC349 Integrated Manufacturing Project

Retrofitting Project of the

Automatic Storage and Retrieval System (ASRS) for the

Computer Integrated Manufacturing System (CIMS)

 

Final Report

 

Members

Student No.

Members

Student No.

Chan Wai Kit

11504594D

Keung Man Lok

10026416D

Chen Wing Shan

09123764D

Law Shing Tim

11507559D

Choi Hon Yin

10517008D

*Ng Ka Kui

10101462D

Hau Wing Yi Curie

10118934D

Wong Tsz Kin

11505740D

 


 

Contents

1. Introduction. 2

1.1 Background. 2

1.2 Objective. 4

1.3 Project Scope. 5

2. Design stage. 7

2.1 Concept Generation. 7

2.2 Design Prototypes. 15

2.3 Problems encountered (Design Stage) 22

3. Manufacturing stage. 25

3.1 Manufacturing workflow of Materials. 25

3.2 Manufacturing techniques. 28

3.3 Problem encountered (Manufacturing Stage) 39

4. Project management. 43

4.1 Bill of Materials. 43

4.2 Budgets. 46

4.3 Schedule (with Gantt charts) 49

4.4 Team work and communication (with work distribution) 52

5. Conclusion. 54

5.1 Project results. 54

5.2 Reflections and comments. 64

Appendix I (List of files in CD ROM) 67

 

 


 

1.   Introduction

1.1 Background

The aim of this project is to analyze the existing automated storage and retrieval system (ASRS) system for computer integrated manufacturing system (CIMS) and then find ways to improve it by adding new technologies and functions, as well as renew the component inside.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/403786_10151052295011077_128636428_n.jpg

Based on the basic purposes, we have divided the whole system into different parts for further investigation and improvement. The followings would present the functions proposed to achieve and the reasons behinds. The following is the original system Architecture:

CIMS.jpg


 

1.2 Objective

Accomplishing this project, several outcomes could be achieved through various training activities, extensive discussions and practical works. Hopefully, our group can apply what we have learnt from normal teaching activities to this project and to achieve goals that we have set. It is also a chance for us to extend our knowledge to real working setting and to learn by working. As a team, it is not enough for us to study individually, but learn to cooperate and communicate with each other. Analytical skills, communication skills, leading skills and problem solving skills are what we can learn from this project.

Our team has set several achievements as our final goal. In order to bring values to engineering related parties, we would like to demonstrate how control system facilitates an automation process. Our objective is to illustrate an ASRS system with high accuracy, high reliability and more importantly, with high efficiency. Moreover, this project also provides an opportunity to allow our idea coming true by applying new technology.

The customer requirements (which are also our objectives) :

1.      To make the System Operate properly

2.      To retrofit the motor parts and PLC system

3.      To apply new technologies

4.      Project duration : 6 months

There are three approaches to achieve the objectives:

5.      Analyze the old system, to find out which of them should be renewed.

6.      Do research from catalogues and the Internet, in order to do screening and choose the most suitable component to replace the old one, so that the performance can be enhanced.

7.      Add some new technologies to the old system, in order to have new functions under limited budgets.

1.3 Project Scope

Control panel Touch screen used, new technology applied

Rotating arm Budget/time restriction

In/Out Conveyor New function, complete cycle

AGV Time restriction

Servo motors used Increase in accuracy and efficiency, retrofit the old one

RFID/Security Door Budget restriction

Whole new PLC program System operate properly, Increase in efficiency

 

 

 

During the course of designing the new system, some new features have been added while some suggestions have been abrogated after our consideration with painstaking effort. Those ideas abolished could be used for further development. Those features retrofitted are as follows. In lieu of the bulky control panel, touch screen control panel has been used where newer technologies are applied. Instead of the messy circuit box of the original PLC system, new PLC system has been installed.


 

There a step motor used in the system and it is now replaced by a servo motor so that accuracy has been enhanced.

A new function has been added for the system and that is the In/Out conveyor system. With the integration of AGV, which is decided for further development thanks to time limitation and budget restriction, the system cycle can be completed as the finished product could be transferred to the exit of the system and then be transported by the conveyor installed. Moreover, such function will be much smoother if the arm in center could be rotated.

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/599927_10151115117830420_1988331220_n.jpg

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-prn1/523956_10151052297146077_984346106_n.jpg

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-prn1/531641_10151115118145420_800027406_n.jpghttp://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/599379_10150930095401456_1209115017_n.jpg


 

2. Design stage

2.1         Concept Generation

2.1.1. ASRS inventory

http://learn.polyu.edu.hk/courses/1/IC349_20112_B/blog/_6616_1/post/_5438_1/417360_10150745222550420_603815419_11908627_1265472640_n.jpgConcept 1 conveyor

http://learn.polyu.edu.hk/courses/1/IC349_20112_B/blog/_6616_1/post/_5511_1/IMG_1679%5B1%5D.JPGText Box: Fig. 1Connect the entance and exit with an aditional conveyor. The function of this conveyor is to transport the raw material to entance and move away finished product from exit automatically. There are some stations in the way of conveyor so that workers can move the finished product out and add in raw material. In between the conveyor, there may be some places as a buffer to store the parts temporarily when demand is high. (Refer to Fig.1)

Concept 2 - Automated guided vehicle (AGV)-1

By using the technology of AGV, a robot can transport input(raw material) and output (finished parts) automatically. Pneumatic cylinder may be used. (Refer to Fig.2a, Fig.2b, Fig.2c)

A conveyor can be used to transport the parts to the AGV robot from the inventory rack, and to transport the parts back to inventory rack from the AGV robot. The conveyor is placed between the inventory rack and AGV robot. (Refer to Fig.2d)

Text Box: Fig. 2c

http://learn.polyu.edu.hk/courses/1/IC349_20112_B/blog/_6616_1/post/_5511_1/IMG_1698%5B1%5D.JPGConcept 3: Automated guided vehicle (AGV)-2

Text Box: Fig. 3Pneumatic cylinder can be used to push the parts to the AGV robot from the inventory rack, and to push the parts back to inventory rack from the AGV robot. The inventory rack and AGV robot should be connected by a rack. (Refer to Fig.3)

http://learn.polyu.edu.hk/courses/1/IC349_20112_B/blog/_6616_1/post/_5511_1/IMG_1697%5B1%5D.JPG

Concept 4: Automated guided vehicle (AGV)-3

There is a conveyor to connect the inventory rack and the AGV robot. The parts are moved from inventory rack to AGV robot by gravitational force. (Refer to Fig.4)

 

Text Box: Fig. 4

http://learn.polyu.edu.hk/courses/1/IC349_20112_B/blog/_6616_1/post/_5505_1/IMG_1693%5B2%5D.JPGConept 5: Automated guided vehicle (AGV)-4

There is a sensor so that motor would be activated when the parts is pressing the sensor. When the parts are in the right position and the sensor detects it, the circuit will be broked. (Refer to Fig.5)

Text Box: Fig. 5


 

ASRS inventory Concept screening matrix

Selection Criteria

Concept 1

Concept 2

Concept 3

Concept 4

Concept 5

Ease of install

0

+

+

-

0

Ease of manufacture

0

+

0

-

0

Durability

0

0

0

-

+

Safety

0

+

-

0

0

Cost(M+M)

0

+

+

0

-

Reliability

0

+

+

0

0

Effective

0

+

0

0

0

Sum +s

0

6

3

0

1

Sum 0s

7

1

3

4

5

Sum s

0

0

1

3

1

Net Score

0

6

2

-3

0

Rank

3

1

2

5

3

 

 

Concept 2

Concept 3

 

Selection Criteria

Weight

Rating

Weighted Score

Rating

Weighted Score

 

Ease of manufacture

20%

3

0.6

3

0.6

 

Ease of install

15%

3

0.45

3

0.45

 

Durability

10%

2

0.2

2

0.2

 

Safety

15%

3

0.45

2

0.3

 

Cost(M+M)

20%

2

0.4

3

0.6

 

Reliability

5%

3

0.15

2

0.3

 

Effective

15%

4

0.6

2

0.3

 

Net Scoce

 

 

2.85

 

2.75

 

Rank

1

2

 

Continue?

1

No

 

 

2.1.2. Arm

Concept 1: Rack

There are racks and pneumatic cylinder to guide the parts to move from inventory rack to the conveyor or move from conveyor to inventory rack. The conveyor will transport the the parts to machince station and bring them out. (Refer to Fig.7a, Fig.7b, Fig.7c)

Text Box: Fig. 7bText Box: Fig. 7c

http://learn.polyu.edu.hk/courses/1/IC349_20112_B/blog/_6616_1/post/_5438_1/img003.jpgConcept 2

The design of motor is changed to rotate at 180o so that the parts can be transfered more efficiently. This can be achieved by using motor with 3-axis control. Originally, there are two plates for placing the motor. Now, the proposed motor only has one plate. (Refer to Fig.8)

Text Box: Fig. 8

Concept 3: Arm with belt

Text Box: Fig. 9http://learn.polyu.edu.hk/courses/1/IC349_20112_B/blog/_6616_1/post/_5503_1/IMAG0356.jpgThis concept combines arm and belt. When the arm approaching the inventory rack, the belt can transport the parts in a perpendicular direction. The rotation of arm can be eliminated. The belt is connected with a motor so that the belt can move in reversible direction. (Refer to Fig.9)

Arm Concept screening matrix

Selection Criteria

Concept 1

Concept 2

Concept 3

Ease of install

0

+

0

Ease of manufacture

0

+

-

Durability

0

+

0

Safety

0

0

+

Cost(M+M)

0

-

0

Reliability

0

0

+

Effective

0

+

0

Sum +s

0

4

2

Sum 0s

7

2

4

Sum s

0

1

1

Net Score

0

3

1

Rank

3

1

2

 

Concept 2

Concept 3

Selection Criteria

Weight

Rating

Weighted Score

Rating

Weighted Score

Ease of manufacture

15%

3

0.45

2

0.3

Ease of install

15%

3

0.45

2

0.3

Durability

10%

2

0.2

3

0.3

Safety

15%

2

0.3

3

0.45

Cost(M+M)

20%

2

0.4

3

0.6

Reliability

10%

3

0.3

2

0.2

Effective

15%

4

0.6

2

0.3

Net Scoce

 

 

2.7

 

2.45

Rank

1

2

Continue?

yes

No

 


 

2.1.3. Motor and Gear Box

Since it is needed to know which gear ratio is suitable for the case, it need to be calculated the force, torque and the velocity of the axis.

The followings are the calculation of the 3 axis and 1 turning axis:

 

img005X axis :

After the calculation, 1:25 gear ratio is suitable for the system.

img007img006

As the same method of X axis calculation, other axises can be calculated.

Y axis :

After the calculation, 1:50 gear ratio is suitable for the system.

Z axis :

After the calculation, 1:15 gear ratio is suitable for the system.

img005img006

img006

2.2           Design Prototypes

2.2.1. ASRS inventory (AGV)

By using the technology of AGV, a robot can transport input(raw material) and output (finished parts) automatically. Pneumatic cylinder may be used.

A conveyor can be used to transport the parts to the AGV robot from the inventory rack, and to transport the parts back to inventory rack from the AGV robot. The conveyor is placed between the inventory rack and AGV robot.

2.2.2.    Arm

There are two main parts that the design of arm depends on the design of the plate as it is used for handle the plates safely.

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-prn1/558601_10150757790151077_529831076_11699221_1630343818_n.jpghttp://a2.sphotos.ak.fbcdn.net/hphotos-ak-prn1/546587_10150757790406077_529831076_11699223_1053179688_n.jpg

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash3/575413_10150757790471077_529831076_11699224_812498116_n.jpg

First of all, the design of the plates will not have a great change so as to save the manufacturing cost. There are two bearings under the plate which used as guidance. For the original design of the arm, there is an L shape single track for guidance and transport of the plates as well as store the two bearings. The arm is two sides symmetrical.

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash3/561248_10150619446191456_634231455_9642589_1641725782_n.jpg

For the new design, the arm will be able to have 180 degree rotation by the actuation pneumatic system. With the rotational motion, there will also be centripetal force acting on the arm, if the friction is not enough between the plate and the arm, or the stability of rotation is not high enough, there will be chance of accident. For this safety concern, a perpendicular actuation pneumatic system will be installed in order to stick the plate safely with the arm.

Finally, a RFID reader will also be installed on the arm to identify the product on the plate.

 

2.2.3.    Motor and Gear Box

For the motor and gears part, there will be few changes taken. Changes on all the servo motor to achieve a more accurate positioning in X-axis, Y-axis and Z-axis in which in the old system, the external brake on z-axis and x-axis, are replaced by internal brake with the servo motor.

Besides, the gear ratio have been changed from 1:1 to 3:2 and 1:3 to 1:2 in x-axis and z-axis respectively in order to achieve a higher angular speed and improve the efficiency (i.e. ,where M is the number of teeth of gear, T is the torque, and w is the angular speed) is the of the whole system, but worm gear box need not to be changed, to save the cost.

(Refer to Fig.12a, Fig.12b)

design%20of%20gear%20box%20&%20mounting%20(X%20axis).jpg

Fig. 12a

design%20of%20gear%20box%20&%20mounting%20(Z%20axis).jpg

Fig. 12b

2.2.4.    Control

  PLC System Structure & I/O Table I/O table

For the input module QX40-1

X0

E. stop button

X1

Contact switch

X2

Contact switch

X3

Contact switch

X4

Contact switch

X5

Contact switch

X6

Contact switch

X7

Contact switch

X8

Contact switch

X9

Contact switch

XA

Contact switch

XB

Contact switch

XC

Contact switch

XD

Contact switch

XE

Contact switch

XF

Contact switch

In our system, it consist of 3 axles, there are 5 contact switches at each axle.

For the input module QX40-2

X0

Vision cam

X1

Vision cam

X2

Vision cam

X3

Vision cam

X4

Vision cam

X5

Contact switch

X6

Contact switch

X7

Contact switch

X8

Contact switch

The four contact switches are for the security door.

For the input module QX40-3

X0

Roller sensor

X1

Roller sensor

X2

Photo sensor

X3

Photo sensor

X4

Reflective photo sensor

X5

Reflective photo sensor

X6

Stopper

The above input is used at AGV system.

For the output module QY40P-1

Y0

Vision cam

Y1

Vision cam

Y2

Vision cam

Y3

Vision cam

Y4

Vision cam

Y5

Operation lamp

Y6

Operation lamp

Y7

Buzzer

Y8

Electrical lock

Y9

Electrical lock

 

For the output module QY40P-2

Y0

Relay

Y1

Relay

 

 

  Control Architecture

This is our control architecture, it shows a brief idea of which part is included that should be under PCL control.

The upper part is something that related to user-interface. Our idea is, user may communicate with the PLC by touch screen, computer or even a smart phone. The lower part has shown the parts in our system. Three motors responsible for moving the three axis of the arm. The two relays is used to move the DC motor of our In/Out conveyor, thats these belts shown in the middle.

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-prn1/523956_10151052297146077_984346106_n.jpg

 


 


  Circuit Diagram

This is our circuit diagram, it shows the connection of all of the electrical device. If you want to know more details about the diagram, please view the CD version.

 

 

 

 

 


 

2.3 Problems encountered (Design Stage)

1.          Due to budget limitation, use of materials is restricted
Solution:
Modify original parts and try to redesign to fit with the material properties.

2.          Accuracy alignment for installing the system

Solution:

Careful measurement taken with more accurate measuring tools, and makes good use of CAD software to minimize the tolerance, using of CNC machining and wire cut to reduce human errors.

 

3.          Not enough space for the belt adjustment device designed (In/Out conveyor)

Solution:
Redesign the system, make use of a T-shape hole on the conveyor.

3.         Manufacturing stage

3.1 Manufacturing workflow of Materials

To accomplish the tasks, various facilities in IC building have been used for manufacturing different essential parts in the project. Those facilities used are listed as follow:

CNC machine

Machining

Automation PLC programming

Electronic wiring

Sheet Metal

Plastics

Surface finish

Most manufacturing works contributes to manufacture the In/Out conveyor, including machining, milling, CNC and wire cut. Some examples are listed in the following table:

Manufacturing process

 

Machining and milling

 

Modifying motor gear (turning process)

Conveyor

T-shape opening on the conveyor

CNC

 

Mounting of gear

Mounting of gear

others

 

Mounting of roller sensor

Mounting of roller sensor

Cutting of raw material

 

 


 

3.2 Manufacturing techniques

The techniques required to manufacture different parts will be discussed as follow:

3.2.1.    Inventory Rack

There are numerous roller sensors installed in all 3 axes on the inventory rack to detect and control the location of robot arm moved. 2 sensors are placed in two ends of Y axis respectively to ensure the robot arm just reach to desirable distance from the edge of plate. Once the robot arm touches the roller sensor, this will give a signal so that PLC can stop motion in Y-axis. This also avoids robot arm from impacting 2 sides of inventory rack during operation.

 

Besides, 5 roller sensors are installed in X-axis to ensure robot arm has moved to the correct row of inventory rack. The middle one among the 5 sensors is used for setting reference point, which is connected to position module. Once the robot arm triggers the roller sensor, PLC will set zero for X-axis. The advantage of using this technology is eliminating accumulative error in counting distance moved by robot arm. Apart from that, there is one roller sensor located at the two ends of X-axis respectively. These 2 sensors are connected to amplifier serving as left limit and right limit respectively. The remaining 2 sensors are connected to position module serving the functions of left limit and right limit in PLC programme.

 

Similar to X-axis, in Z-axis also has 5 roller sensors installed to ensure certain height is reached to pick up plates.


 

 

Close up

Overall view

Y-axis

Right Limit switch

Z-axis

Home switch and

lower limit switch

Upper Limit switch

X-axis

Left limit switch

 


 

3.2.2       In/Out conveyor complete cycle

Firstly, due to the limitation of the original size of inventory rack, the 2 conveyor used have to be in different length. That is, the right one has to be longer than the left one.

Secondly, every conveyor is made to have a T-shape opening so that the position of roller can be adjusted. In terns, the belts could be tightened or loosened. This can be achieved by passing through 2 screws into the shaft of roller.

Thirdly, in order to set alignment, there are 2 mountings on the conveyor to support itself.

 

Overview

One side of the mounting

T-shape opening

 

 

L shape mounting

 

3.2.3.    Control panel

There are 2 control panels, which serve for convenience and extensive use respectively. They are small control box and big control panel.

First, the small control box is consists of plastic and steel which are bent as L shape and U shape respectively. To fit the button and touch screen panel into the upper part steel, the metal sheet is subjected to punching at first. Then, the metal sheet is bent by using folding machine to form U shape. Since the small control box will be used by human, we have to take the outlook and ease of handle as consideration. Therefore, this part should be no rusting and burr. To prevent rusting, it has to be subjected into surface finishing process. The job sequence of surface finishing can be summarised as follow:

 

Procedure

Area (dm2)

Current density (A/ dm2)

Applied current (A)

Time (Min)

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/311503_10151050257361077_1975364846_n.jpg

Ultrasonic Clean

/

/

/

3

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/315339_10151050256896077_201353403_n.jpg

Electrolytic Degreasing

85

3.5

30

1.5

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash3/580915_10151050256391077_1619963646_n.jpg

Non-cyanide Alkaline Copper Strike

8.5

3

25

6.5

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/582093_10151050256046077_1908150503_n.jpg

Nickel strike

8.5

3.5

30

1.5

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/389075_10151050253846077_1306147622_n.jpg

Semi-bright Nickel

8.5

4.5

38

15

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/376206_10151050253406077_594109724_n.jpg

Tin-cobalt Alloy

8.5

0.7

6

2

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http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash3/552663_10151052295901077_1199565070_n.jpg

 

For the lower part plastic, electrical jigsaw is used to cut the material into desired size. Then, it is bent to designated L shape by the means of heating machine, to heat up the plastic and soften it, so that it is much easier for blending.

The upper and lower parts are then combined together by four screws at corner.

Second, for extensive use and official operation, there is a big control panel. To manufacture this part, electrical jigsaw has used to cut the wood so that buttons and touch screen panel can fit into it. Also, plastic is made for the same reason by using laser cut method. Besides, some words are written on the plastic to indicate the function of those buttons by laser cut.

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/480774_10151052296056077_1029119185_n.jpg


 

3.2.4       HMI

The software we used is called GT Designer 3, which providing services in designing the user interface on the touch screen panels.

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/283597_10150945429366456_857513701_n.jpg


 

3.2.5       PLC

In this project, GX Works 2 is used instead of GX developer and configurator and it provides both functions of GX developer and configurator. Under the Intelligent Function Module, we can define different parameters based on corresponding module we used. Since the PLC is used to control the motion of motor of robot arm, position module is connected. Some parameters are set beforehand and positioning axis is defined as 1 to 4 before the program is functioning. The axis includes both motors of robot arm and motor in entrance rack. In addition, we are able to add data into a table so that the position module can operate according to the data in the table.

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/484573_10150945428221456_973967436_n.jpg

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/480076_10150945427916456_1860378654_n.jpgIn the programming part, GX Works 2 enables us to write many sub programs instead of one big program. This property allows us to classify different sub program with different kinds of usage. Thanks to the clear structure of program with smaller size, running sub program can speed up the process and it is easier in debugging.

3.3 Problem encountered (Manufacturing Stage)

Throughout the whole manufacturing process, we have faced different kinds of problem.

1.      Lack of PLC programming knowledge

Solution:

The first problem is that we lack control knowledge, as we are mechanical student. Therefore, self-learning from the Internet and books are the key to accomplish our project successfully.

In addition, we are glad to have some industrial engineers to share their experience and give us guidance

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/552504_10151050269496077_207351135_n.jpghttp://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/376264_10151050270076077_580575524_n.jpg

2.      Due to high cost of mountings, old mountings are used
Solution:
Modify the original mounting to fit with the new motors with CNC machining and milling.

3.      Control failure in one axis
Solution:
Solving by trouble shooting method and finally replace it by the forth axis.
When we test the moment of the system, we found that one axis is failed to move. So we solve it in a very systematical way, we first check the software, and then hardware. We found that it is related to the PLC, thus we tested every part and finally it comes up with the position module. This trouble shooting method really helps and we then solving the problem by replace it by the forth axis.

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/427392_10150929452106456_174471512_n.jpghttp://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/318820_10150931091521456_53650260_n.jpghttp://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/8099_10150929484421456_94641403_n.jpg

4.      Assembly of In/Out conveyor is difficult because of inaccuracy in dimension
Solution:
Manufacture of the In/Out conveyor is always a difficult task, as we need to achieve the balance and tight tolerance of the system which has been mentioned by my group mate before. So, we need to modulate the parts with different tools, some simply like different kind of files to make it balance and fit to each other.

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/428876_10151052296461077_1673655350_n.jpghttp://a2.sphotos.ak.fbcdn.net/hphotos-ak-prn1/523956_10151052297146077_984346106_n.jpg


 

5.      To minimize the cost and save resources, rusted raw material is being used
Solution:
Because the control panel will always be exposed in air and touched with hands, therefore we carried out the Tin-cobalt plating to prevent rusting, in addition, to improve the overall appearance of the control panel.

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-prn1/552273_10151050252986077_1562403981_n.jpghttp://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/376206_10151050253406077_594109724_n.jpghttp://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc7/483169_10151050257806077_1198646496_n.jpghttp://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/311503_10151050257361077_1975364846_n.jpg

 

 

 

 

4.          Project management

4.1 Bill of Materials

ASRS inventory

Item

Part no.

Part Description

Usage

Unit

Level

1

 

ASRS inventory assembly

1

 

1

2

 

Contact switch (U-shape)

5

 

2

3

 

Contact switch (simple)

12

 

2

4

 

Operation lamp

1

 

2

5

 

Buzzer

1

 

2

 

Control panel

Item

Part no.

Part description

Usage

Unit

Level

1

 

Control panel assembly

1

 

1

2

 

Touch panel

2

 

2

3

 

Rotational switch

1

 

2

4

 

Operation lamp

1

 

2

5

 

E. stop button

2

 

2

6

 

Start button

1

 

2

7

 

Stop button

1

 

2

 

Electric device

Item

Part no.

Part Description

Usage

Unit

Level

1

 

Electric device assembly

1

 

1

2

 

MCB

5

 

2

3

 

Contactor

3

 

2

4

 

Relay

9

 

2

5

 

Wiring ducts (WECL GW-4545S) (W 45mm x H 45 mm x L 1700mm)

3

 

2

6

 

Flexible wiring ducts (35mm x 55mm x 1000mm L)

3

 

2

7

 

Acrylic plastic plate

1

 

2

 


 

Motor

Item

Part no.

Part Description

Usage

Unit

Level

1

 

Motor assembly

1

 

1

2

 

Bevel gear 30 teeth (KHK SB2.5-3020)

1

 

2

3

 

Bevel gear 20 teeth (KHK SB2.5-2030)

1

 

2

4

 

Key (Mild steel ) 25 x 6 x 6.3 mm

1

 

2

5

 

Key (Mild steel ) 20 x 5 x 5.3 mm

1

 

2

6

 

Servo motor HF-KP73J-S100

1

 

2

7

 

Servo motor HF-KP73BJ-S100

1

 

2

8

 

Servo motor HF-SN102BJ-S100

1

 

2

9

 

Servo motor HF-KP43

1

 

2

10

 

6061 Aluminium plate 150mm x 150mm (3/8" T)

3

 

2

11

 

6061 Aluminium plate 200mm x 100mm (3/8" T)

2

 

2

12

 

Straight cut gear 30 teeth (KHK SS2-30J18)

1

 

2

13

 

Straight cut gear 15 teeth (KHK SS2-15J14)

1

 

2

 

Arm

Item

Part no

Part Description

Usage

Unit

Level

1

 

Arm assembly

1

 

1

2

 

Nylon Plastic Plate (10mm thickness) 500mmX150mm

1

 

2

3

 

6061 Aluminium sheet matel (1.5mm thickness) 200mmX60mm

2

 

2

 

In/Out Conveyor

Item

Part no

Part Description

Usage

Unit

Level

1

 

Conveyor assembly

1

 

1

2

 

shaft (10mm dia) (L 132mm)

1

 

2

3

 

Conveyor (360mm)

1

 

2

4

 

Conveyor (370mm)

1

 

2

5

 

DC Motor

1

 

2

6

 

Timing Belts(Motor) (5mm pitch, 1.5mm thickness) (W 15mm, L 500mm, 100 teeth)

1

 

2

7

 

Belts(360conveyor) (1.5mm thickness) (30mm width) (746mm in length)

1

 

2

8

 

Belts(370conveyor) (1.5mm thickness) (30mm width) (766mm in length)

1

 

2

9

 

Timing belt pulleys (5mm pitch, Bore 6mm, Max bore dia 15mm, 20.5mm thickness, 20 teeth)

2

 

2

 

Control

Item

Part no.

Part Description

Usage

Unit

Level

1

 

Control assembly

1

 

1

2

 

Q00UJCPU-S8-SET

1

 

2

3

 

ETHERNET UNIT FOR 10BASE-T/ 10BASE -TX

1

 

2

4

 

240VAC/ 4mA, POSITIVE COMMON INPUT, 16pt

1

 

2

5

 

4 AXIS, DIFFERENTIAL OUTPUT

1

 

2

6

 

SOLDERING 32 - pt CONNECTOR

5

 

2

7

 

MR - E - 100A - KH003

1

 

2

8

 

MR - ECN1

4

 

2

9

 

MR - ECNP1 - B

4

 

2

10

 

MR - ECNP2 - B

4

 

2

11

 

MR - BKCNS1

1

 

2

12

 

MR - PWCNS4

1

 

2

13

 

MR - J 3ENSCBL5M-L

1

 

2

14

 

MR - E - 70A - KH003

2

 

2

15

 

Brake cable for HF-KP, lead out in direction of shaft. Length 5M. Standard life part

1

 

2

16

 

Power supply cable for HF-KP. Lead out in direction of shaft, Length 5M, Standard life

3

 

2

17

 

Encoder cable for HF-KP, lead out in direction of motor shaft, Length 5M, Standard life

3

 

2

18

 

MR - E - 40A - KH003

1

 

2

 


 

4.2 Budgets

IC 349 Budgets (Items)

Qty.

Price HKD

Amount HKD

Remarks

Total Cost

126779.50

Sponsors from Hanovic Co., LTD / Mitsubishi Electric

120260.00

IA Unit / IC

3085.00

Actual Expenditure

3434.5

ASRS inventory

Contact switch (U-shape)

5

65.00

325.00

Contact switch (simple)

12

30.00

360.00

Original

Operation lamp

1

30.00

30.00

IC

Buzzer

1

30.00

30.00

IC

745.00

Electric device

MCB 20A

1

250.00

250.00

Sponsor

MCB 10A

1

150.00

150.00

Sponsor

MCB 5A

3

120.00

360.00

Sponsor

Contactor

3

50.00

150.00

IC

Relay

9

20.00

180.00

IC

Wiring ducts (WECL GW-4545S) (W 45mm x H 45 mm x L 1700mm)

3

53.00

159.00

Acrylic plastic plate

1

500.00

500.00

Flexible wiring ducts (35mm x 55mm x 1000mm L)

3

380.00

1140.00

2889.00

Motor

Bevel gear 30 teeth (KHK SB2.5-3020)

1

420.00

420.00

Bevel gear 20 teeth (KHK SB2.5-2030)

1

310.00

310.00

6061 Aluminium plate 150mm x 150mm (3/8" T)

3

75.00

225.00

Orginial

6061 Aluminium plate 200mm x 100mm (3/8" T)

2

68.00

136.00

Original

Straight cut gear 30 teeth (KHK SS2-30J18)

1

690.00

690.00

Original

Straight cut gear 15 teeth (KHK SS2-15J14)

1

500.00

500.00

Original

Key (Mild steel ) 25 x 6 x 6.3 mm

1

35.00

35.00

Key (Mild steel ) 20 x 5 x 5.3 mm

1

10.00

10.00

Servo motor HF-KP73J-S100

1

5130.00

5130.00

Sponsor

Servo motor HF-KP73BJ-S100

1

9660.00

9660.00

Sponsor

Servo motor HF-SN102BJ-S100

1

10890.00

10890.00

Sponsor

Servo motor HF-KP43

1

5010.00

5010.00

Sponsor

33016.00

Arm

Nylon Plastic Plate (10mm thickness) 500mmX150mm

1

140.00

140.00

Original

6061 Aluminium sheet matel (1.5mm thickness) 200mmX60mm

2

12.00

24.00

Original

164.00

In/Out Conveyor

shaft (10mm dia) (L 132mm)

1

30.00

30.00

Timing Belts(Motor) (5mm pitch, 1.5mm thickness) (W 15mm, L 500mm, 100 teeth)

1

77.70

77.70

Belts(360conveyor) (1.5mm thickness) (30mm width) (746mm in length)

1

95.00

95.00

Belts(370conveyor) (1.5mm thickness) (30mm width) (766mm in length)

1

110.00

110.00

DC Motor

1

500.00

500.00

IC

Timing belt pulleys (5mm pitch, Bore 6mm, Max bore dia 15mm, 20.5mm thickness, 20 teeth)

2

81.40

162.80

975.50

Control

Q00UJCPU-S8-SET

1

9800.00

9800.00

Sponsor

ETHERNET UNIT FOR 10BASE-T/ 10BASE -TX

1

13370.00

13370.00

Sponsor

240VAC/ 4mA, POSITIVE COMMON INPUT, 16pt

1

1600.00

1600.00

Sponsor

4 AXIS, DIFFERENTIAL OUTPUT

1

15160.00

15160.00

Sponsor

SOLDERING 32 - pt CONNECTOR

5

180.00

900.00

Sponsor

MR - E - 100A - KH003

1

7510.00

7510.00

Sponsor

MR - ECN1

4

145.00

580.00

Sponsor

MR - ECNP1 - B

4

50.00

200.00

Sponsor

MR - ECNP2 - B

4

35.00

140.00

Sponsor

MR - BKCNS1

1

450.00

450.00

Sponsor

MR - PWCNS4

1

660.00

660.00

Sponsor

MR - J 3ENSCBL5M-L

1

420.00

420.00

Sponsor

MR - E - 70A - KH003

2

7330.00

14660.00

Sponsor

Brake cable for HF-KP, lead out in direction of shaft. Length 5M. Standard life part

1

360.00

360.00

Sponsor

Power supply cable for HF-KP. Lead out in direction of shaft, Length 5M, Standard life

3

420.00

1260.00

Sponsor

Encoder cable for HF-KP, lead out in direction of motor shaft, Length 5M, Standard life

3

420.00

1260.00

Sponsor

MR - E - 40A - KH003

1

5480.00

5480.00

Sponsor

73810.00

Control panel

10.5' Touch panel

1

10000.00

10000.00

Sponsor

5' Touch panel

1

5000.00

5000.00

Sponsor

Rotational switch

1

50.00

50.00

IC

Operation lamp

1

30.00

30.00

IC

E.Stop button

2

30.00

60.00