INDU 411 CIM Lab: Bishop

Date: Thursday April 18, 2013

Team Members:

Fadi BartikWasan Dorias

Abdulaziz Mohammed

“We certify that this submission is the original work of members of the group and meets the Faculty's Expectations of Originality

Concordia University 2013

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Table of Content

1. Introduction 3

2. CAD Drawings 4

3. G-Code with comments 6

3.1 Milling 6

3.2 Lathe 10

4. Robotic Assembly/ACL Code with Comments 12

5. Mixed Model Production and System Optimization 24

6. Conclusion 31

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1. Introduction

Computer Integrated Manufacturing (CIM) is an approach that requires the use of computers for a

production process. Through this approach, the manufacturing business can enhance productivity with

less error. The advantage of CIM is that it allows a production to be automated.

The objective of this lab is to show the use of CIM when manufacturing a chess piece with its base. The

base of the bishop consists of having a rectangular block with the word “BISHOP” engraved on it. The

base also has a circular whole where the chess piece will be placed once it is assembled. Three machines

will be used in this lab with the help of a supervisor as follows:

1. The milling machine: used to manufacture the bishop base.

2. The lathe machine: used to manufacture the bishop piece.

3. The assembly robot: used to assemble the bishop piece with its base.

The CAD drawings were provided for both, the bishop base and piece. The software application

AutoCAD was used to dimension the drawing in order to facilitate the manufacturing process when

creating the G code. Once the G codes were ready, a program is needed for the robot to assemble the

bishop base and piece.

This report will outline the bishop base and piece being manufactured in order to achieve a fully

automated system.

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2. CAD Drawings

The CAD Drawings were used to determine the dimensions of the following:

1. The Bishop Base

2. The Bishop Piece

The purpose of these dimensions was to help build an accurate G code when manufacturing the bishop

base and piece. Refer to the figures below for the CAD Drawings with their respective dimensions:

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Figure 1: Bishop Base

Figure 2: Bishop Piece

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3. G Code with Comments

G code is a numerical control programming language mainly used in automation. It is a language that

allows the control of the machine tools. Other codes, such as the M code, allow the control of machine and

its operations. For example, the M code allows for a tool change or turning a spindle motor on or off. The

G code is used for manufacturing the bishop base and piece as follows:

3.1 Milling (Bishop Base)

N000 G90 G70 M03 S1500;N020 M06 T02N025 G00 Z0.5;N030 G00 X0.625 Y1; N035 G01 Z-0.375 F2.5;N040 G01 X0.427;N045 G02 X0.427 Y1 I0.625 J1 F8;N050 G00 Z0.5;N055 M06 T03;N060 G42 D3;N065 G00 Z0.5;N070 G00 X1.125 Y0.375 M03 S1500;N080 G01 Z-0.063;N085 G01 Y1.68;N090 G02 X1.25 Y1.813 R0.125;N095 G01 X3.18;N100 G02 X3.31 Y1.688 R0.125N105 G01 Y0.375;N110 G02 X3.188 Y0.25 R0.125;N115 G01 X1.25;N120 G02 X1.125 Y0.375R0.125;N125 G00 Z0.5;N130 G40; N135 G41 D3; N140 G00 X1.1875; N145 G00Z0.5 ;N124 G00 X1.35;N126 G00Y1.563;N127 G01 Z-0.063;N120 G01X1.375;

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N135 G02X1.375Y1.313 R0.1248;N140 G03 X1.375 Y1.187 R0.063;N145 G02 X1.375 Y0.938 R0.125;N150 G01 X1.25;N185 G00 Z0.5; N190 G00 X1.375 Y1.62; N195 G00 Z-0.063; N200 G01 X1.5; N205 G01 Y0.48; N210 G01 X1.35; N215 G01 Y0.8; N220 G01 X1.475; N225 G01 Y0.48; N230 G01 X1.5; N235 G01 Y0.85; N240 G01 X1.33; N245 G01 Y0.48; N250 G01 X2.9375 Y0.4; N255 G01 Y1.125; N260 G01 X3.0625; N265 G02 X3.0625 Y0.875 I3.0625 J1; N270 G03 X3 Y0.8125 I3.0625 J0.8125;N275 G01 Y0.48; N280 G01 X2.563; N290 G01 Y1.0625; N295 G02 X2.8125 Y1.0625 R0.125;N300 G01 Y0.6875; N305 G02 X2.5625 Y0.6875 R0.125; N310 G01 X2.40;N315 G01 Y0.687;N320 G01 X2.1875; N325 G01 Y1.3125; N330 G01 X2.4375; N335 G01 Y1.0625;N340 G00 Z0.5; N345 G40; N350 G00 X2.307;N355 G01 Z-0.063;N360 G01 Y1.438;N365 G00 Z0.5; N370 G00 Y0.875;N375 G01 Z-0.063;N380 G01 Y0.48;

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N385 G42 D4; N390 G01 X1.75;N395 G01 Y1.5; N405 G01 Y0.875; N410 G01 X1.55; N415 G40; N420 G00 Z0.5; N425 G00 X1.937 Y0.937;N430 G01 Z-0.063; N435 G01 Y1; N440 G00 Z0.5; N445 G00 Y1.218; N450 G01 Z-0.063; N455 G01 Y1.31; N460 G01 X2.125; N465 G01 Y1.5;N470 G01 X1.75; N475 G01 Y1;N480 G01 X1.943;N485 G01 Y0.938N490 G01 X1.75;N495 G01 Y0.75;N500 G01 X2.125;N505 G01 Y1.221;N510 G01 X1.938;N515 G00 Z0.5;N520 G00 X2.87 Y1.12;N525 G01 Z-0.063;N530 G01 Y0.5;N535 G01 X2.8;N540 G00 Z0.5;N545 M06 T02;N550 G01 Z0.5;N555 G00 X1.624 Y1.70;N560 G01 Z-0.063;N565 G01 X3.17;N570 G01 Y1.28;N575 G01 X2.405 Y1.604;N580 G01 X2.205 Y1.504;N585 G01 X2.937 Y1.7;N590 G01 Y1.405;N595 G00 Z0.5;N600 G00 X1.627 Y0.690

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N605 G00 Z-0.063;N610 G01 X2.059;N615 G01 Y0.405;N620 G01 X1.41;N625 G01 X3.154; N630 G01 Y0.705;N635 G00 Z0.5;N640 G00 X2.9375 Y1.3125;N645 G01 Z-0.063; N650 G00 X2.5625 Y1.3125;N655 G40;N660 G01 Y1.4375;N665 G01 X2.50;N670 G01 Y1.625;N675 G01 X1.65625;N680 G00 Z0.5;N685 G00 Y0.75;N690 G01 Z-0.063;N695 G01 Y0.5625;N700 G01 X2.3475;N705 G00 Z0.5;N710 X1.25Y1.6875;N715 G01 Z-0.063;N720 G00 Z0.05;N555 G29 M05 M30;

This milling code requires a total of 10 minutes and 21 seconds. The total expenditure per hour,

including overheard, operator cost, and equipment cost, is 100 $. This number is based off of industry

standards at Bombardier Aerospace. It was obtained from direct resources summer internships. Thus,

the total cost of this piece is 100/3600*(621) = 17.25 $. Assuming material cost of 10 $ for the initial

plastic pattern, the total cost is 27.25$.

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3.2 Lathe (Bishop Piece) G90 G70; G29; M06 T05; M03 S1000;G00 X0.380 Z2.375;G01 X0 F10;G00 X0.380;G00 Z1.820;G01 X0.313;G00 X0.380; M06 T01;G00 Z2.375;G01 X0.375;G01 Z1.926;G00 X0.380;G00 Z2.375;G01 X0.325;G01 Z1.988;G00 X0.380;G00 Z2.375;G01 X0.275;G01 Z2.050;G00 X0.380;G00 Z2.375;G01 X0.225;G01 Z2.112;G00 X0.380;G00 Z2.375;G01 X0.175;G01 Z2.174;G00 X0.380;G00 Z2.375;G01 X0.125;G01 Z2.236;G00 X0.380;G00 Z2.375;

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G01 X0.075;G01 Z2.298;G00 X0.380;G00 Z2.375;G01 X0.025;G01 Z2.360;G00 X0.380;G00 Z2.375;G01 X0;G01 X0.375 Z1.910;G00X0.39; M06T7;G00 Z1.352;G01 X0.325;G01 Z0.954;G00 X0.380;G00 Z1.352;G01 X0.275;G01 Z0.988;G00 X0.380;G00 Z1.352;G01 X0.225;G01 Z1.063;G00 X0.380;G00 Z1.352;G01 X0.188;G01 Z0.938;G00 X0.380;M06 T03;G00 Z1.5;G01 X0.188;G01 Z1.61825;G03 x0.375 z1.82 r0.1875G00 X0.380;

This turning code requires a total of 1 minutes and 40 seconds. Using the same cost per hour as above

of 100$, the total cost is 100/3600*100 = 2.78$. Including the plastic cost of 10$, the total cost is 12.78$.

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4. Robotic Assembly/ACL Code with Comment

Here is the code for the robotic assembly.

Set Subroutine GET_CYL_RACKGo to Position 2 FastGo to Position 18 Speed 50 (%)Open GripperGo Linear to Position 19 Speed 10 (%)Close GripperGo Linear to Position 18 Speed 50 (%)Go to Position 2 FastReturn from SubroutineSet Subroutine GET_BLOCK_TEMPLATEGo to Position 2 FastGo to Position 14 Speed 50 (%)Open GripperGo Linear to Position 15 Speed 10 (%)Close GripperGo Linear to Position 14 Speed 50 (%)Go to Position 2 FastReturn from SubroutineSet Subroutine GET_CYL_TEMPGo to Position 2 FastGo to Position 12 Speed 50 (%)Open GripperGo Linear to Position 13 Speed 10 (%)Close GripperGo Linear to Position 12 Speed 50 (%)Go to Position 2 Speed 50 (%)Return from SubroutineSet Subroutine PUT_CYL_RACKRing BellGo to Position 2 FastGo to Position 8 Speed 50 (%)Go Linear to Position 7 Speed 10 (%)Open GripperGo Linear to Position 8 Speed 50 (%)Go to Position 2 FastReturn from SubroutineSet Subroutine PUT_BLOCK_RACKRing BellGo to Position 2 FastGo to Position 4 Speed 50 (%)Go Linear to Position 3 Speed 10 (%)Open GripperGo to Position 4 Speed 50 (%)

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Go to Position 2 FastReturn from SubroutineSet Subroutine GET_BLOCK_RACKRing BellGo to Position 2 FastGo to Position 4 Speed 50 (%)Open GripperGo Linear to Position 3 Speed 10 (%)Close GripperGo to Position 4 Speed 50 (%)Go to Position 2 FastReturn from SubroutineSet Subroutine PUT_CYL_CUBEGo to Position 2 FastGo to Position 20 Speed 50 (%)Go Linear to Position 21 Speed 10 (%)Open GripperGo to Position 22 Speed 50 (%)Go to Position 2 FastReturn from SubroutineSet Subroutine PUT_BLOCK_CUBEGo to Position 2 FastGo to Position 17 Speed 50 (%)Go Linear to Position 16 Speed 10 (%)Open GripperGo to Position 17 Speed 50 (%)Go to Position 2 FastReturn from SubroutineSet Subroutine GET_BLOCK_CUBEGo to Position 2 FastGo to Position 23 Speed 50 (%)Go to Position 17 Speed 50 (%)Go Linear to Position 16 Speed 10 (%)Close GripperGo to Position 23 Speed 50 (%)Go to Position 2 FastReturn from SubroutineSet Subroutine PUT_BLOCK_TEMPLATERing BellGo to Position 2 FastGo to Position 14 Speed 50 (%)Go Linear to Position 28 Speed 10 (%)Open GripperGo to Position 14 FastClose GripperGo to Position 2 FastReturn from Subroutine

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Set Subroutine ASSEMBLYRun Subroutine GET_BLOCK_TEMPLATERun Subroutine PUT_BLOCK_RACKRun Subroutine GET_CYL_TEMPRun Subroutine PUT_CYL_RACKRun Subroutine GET_BLOCK_RACKRun Subroutine PUT_BLOCK_CUBERun Subroutine GET_CYL_RACKRun Subroutine PUT_CYL_CUBERun Subroutine GET_BLOCK_CUBERun Subroutine PUT_BLOCK_TEMPLATEReturn from Subroutine

The goal of the programming is to create the complete assembly of the bishop base with the bishop piece. To do so, it is required to program the robot to pick up both pieces from the template jig and place them on the rack. Afterwards, it is required that the robot first picks the bishop base to place it on the cube. Then, pick the bishop piece and place it inside the hole of the bishop base while the piece is maintained at an upright position. Thus, the three jigs are the template, the rack, and the cube.

The programming required the creation of proper positions. The positions 18 to 23 are all user created for the proper movement of the robot.

Here are pictures showcasing the movement of the robot.

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5. Mixed Model Production and System Optimization

Using the OpenCIM, the production system was simulated while producing the 4 chess assemblies

involved in this project. The assembly parts were identified in OpenCIM along with the required

production processes as shown in the Part Definition and Machine Definition windows in the software,

which are shown in figure 1 and figure 2, respectively.

Figure 3: Part Definition window from OpenCIM.

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Figure 4: Machine Definition window from OpenCIM.

The process plan for the system was to retrieve required parts from the racks using the ARAS

system. Then, the parts were passed through to the lathe machine for turning and subsequently to the

mill. After that, the parts were transferred on a conveyor to the a special station for assembly. Lastly,

complete assembly were transferred on the conveyor back to the racks using the ARAS system. This

process plan is summarized in the value-stream map shown in figure 3. The system was arranged

according to this setting and is displayed in figure 4.

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Figure 5: Value-stream map of the production system.

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Figure 6: Process plan and system setting.Moreover, machine algorithms were all set to 28% first-in first-out (FIFO) and 72% random

processing; the optimization rule was to dispatch the parts waiting in a machine's queue following a FIFO

rule 28% of the time and randomly 72% of the time, as shown in the Optimization Definition window

(figure 5). The key performance indicators (KPIs) of the system following this dispatching rule are

presented in figure 6.

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Figure 7: Optimization Definition window from OpenCIM

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Figure 8: KPI results from the Performance Analysis window in OpenCIM.

Although the KPI results are considered satisfactory, the effect of non-value activities (NVAs) on

the total production time was evident. In order to effectively optimize the system, NVAs need to be

eliminated. An observation of the production run revealed several instances where NVAs activities took

place. The following table summarizes the detected NVAs and demonstrates the potential savings that

could be achieved with the elimination of these activities.

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Table 1: System non-value activities and estimated savings

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6. Conclusion

It can be concluded that the results obtained in the manufactured bishop (base + piece) was a great

success. This lab provided students with a better idea on Computer Integrated Manufacturing (CIM)

concepts. This lab included drawing, manufacturing, programming and using different software which

allowed students to practice the knowledge obtained from other courses.

When writing the G-code, it played a major role in determining the cycle time of every piece. This

allows a programmer to optimize the path the machine takes throughout the process in order to

minimize the number of tool exchange which plays a huge role in reducing the production cycle time.

Overall, this lab was very informative and provided students the opportunity to learn more about the

importance of Computer Integrated Manufacturing.

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