UNIVERSITI TEKNIKAL MALAYSIA MELAKA

DESIGN OF AUTOMATIC LOADING AND UNLOADING OF

WORKPIECE SYSTEM FOR HAAS CNC MILLING MACHINE

This report submitted in accordance with requirement of the Universiti Teknikal

Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Robotics and Automation) with Honours

by

THILIBAN SIVAPRAGASAM

B051210258

910923-07-5987

FACULTY OF MANUFACTURING ENGINEERING

2016

DECLARATION

I hereby, declared this report entitled “Design of Automatic Loading and Unloading of

Work pieces System for HAAS CNC Milling Machine” is the result of my own project

except as cited in references.

Signature :

Author’s Name : Thiliban A/L Sivapragasam

Date :

APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a

partial fulfillment of the requirements for the degree of Bachelor of Manufacturing

Engineering (Robotics & Automation) (Hons.). The member of the supervisory

committee is a follow:

……………………………………

(Official Stamp of Supervisor)

i

ABSTRACT

This project report presents the work done on the design of automatic loading and

unloading of work pieces system for HAAS VF-1 CNC Milling Machine. This CNC

machine is currently being used at CNC Lab at Block B of Faculty of Manufacturing

Engineering, University Technical Malaysia Malacca (UTeM). However, this machine

still uses human operator to load and unload the work pieces for the machine which are

considered inefficient and also dangerous. The objective of this project is to select a

suitable automatic system for loading and unloading work piece for HAAS CNC Milling

Machine, to design a suitable gripper or tool for handling the work pieces for loading and

unloading the CNC Machine and also to develop a soft prototype of the designed gripper

or tool. In order to ensure the automatic loading and unloading process to occur without

any error, a proper analysis and also comparison must be done in order to determine type

of system to be used, types of tool to be used, type of power system to drive the system,

also type of software to simulate the process. Flow chart of the methodology used for

achieving all the project objectives are presented. Furthermore, a process simulation is

done to represent the real life process of the improvise system, giving it a better look on

how the system will look like. Besides that, an analysis on the selected tool given be

carried out in order to determine the effectiveness and also the scale of safety of the tool.

In order to do so, the force exerted by the work piece should be taken into consideration

and also the lifting force required by the tool itself to lift the work piece.

ii

ABSTRAK

Laporan projek membentangkan kerja yang dilakukan pada reka bentuk automatik

memuatkan dan memunggah sistem kerja keping untuk HAAS VF-1 CNC Milling

Machine. Mesin CNC sedang digunakan di CNC Lab di Blok B Fakulti Kejuruteraan

Pembuatan, Universiti Teknikal Malaysia Melaka (UTeM). Walau bagaimanapun, mesin

ini masih menggunakan pengendali manusia untuk memuatkan dan memunggah bahan

kerja untuk mesin yang dianggap tidak cekap dan juga berbahaya. Objektif projek ini

adalah untuk memilih sistem automatik yang sesuai untuk memuatkan dan memunggah

bahan kerja untuk HAAS CNC Milling Machine, untuk mereka bentuk penggenggam

yang sesuai atau alat untuk mengendalikan bahan kerja untuk memuatkan dan

memunggah mesin CNC dan juga untuk membangunkan prototaip yang lembut daripada

penggenggam direka alat. Dalam usaha untuk memastikan pemunggahan proses

automatik untuk berlaku tanpa apa-apa kesilapan, analisis yang betul dan juga

perbandingan perlu dilakukan untuk menentukan jenis sistem yang akan digunakan,

jenis-jenis alat yang digunakan, jenis sistem kuasa untuk memacu sistem, juga jenis

perisian untuk mensimulasikan proses. Carta aliran metodologi akan digunakan untuk

mencapai semua objektif projek yang dibentangkan. Tambahan pula, simulasi proses

dilakukan untuk mewakili proses sebenar sistem yang telah ditambah baik, untuk

memberikan pandangan yang lebih baik mengenai bagaimana sistem akan kelihatan

dalam situasi sebenar. Selain itu, analisis ke atas alat dipilih dijalankan untuk menentukan

keberkesanan dan juga skala keselamatan alat. Dalam usaha untuk berbuat demikian,

daya yang dikenakan oleh bahan kerja perlu diambil kira dan juga daya angkat yang

diperlukan oleh alat itu sendiri untuk mengangkat bahan kerja .

iii

DEDICATION

To my beloved family, lecturers, and friends whose have guided and inspired me to

complete this project successfully

iv

ACKNOWLEDGEMENT

In completing Project Sarjana Muda I (PSM I), many people have lend their shoulder in

order to help me to complete this project. First of all, I would like express my gratitude to

my supervisor, Prof. Dr. Bashir Mohammad Bin Bali Mohammad for his guidance

throughout this project. Besides that, his criticism also has been an encouragement me

not only to complete this project, but to complete with flying colors. My course mates,

Mohammad Alif, Mohammad Hannan, and also Mohammad Azuan who have also

helped me in numerous way that they can to make this project successful. I would also

like to express endless gratitude to my family who as been pillar to me not only in

completing this project, also in my life.

v

TABLE OF CONTENTS

Abstrak i

Abstract ii

Dedication iii

Acknowledgement iv

Table of content v - ix

List of Tables x

List of Figures xi - xiii

CHAPTER 1: INTRODUCTION 1

1.1 Background of the Project 1

1.2 Problem Statement 3

1.3 Objectives 3

1.4 Scopes 4

CHAPTER 2: LITERATURE REVIEW 5

2.1 Introduction about HAAS VF-1 CNC Milling Machine 5

2.2 Types of system used for loading and unloading process 6

2.2.1 Man power in loading and unloading process 6

2.2.2 Hydraulic jack system in loading and unloading process 8

2.2.3 Robot operation system in loading and unloading process 9

2.3 Type of loading and unloading robot system 10

2.3.1 Stationary Robot 10

vi

2.3.2 Wheeled robots 11

2.3.3 Legged robots 12

2.3.4 Flying robots 12

2.3.5 Mobile spherical robots 13

2.4 Types of robots geometry 14

2.4.1 Cartesian Geometry 15

2.4.2 Cylindrical Geometry 16

2.4.3 Spherical Geometry 17

2.4.4 Articulate Geometry 18

2.5 Types an end effector 20

2.5.1 Vacuum Grippers 20

2.5.2 Magnetic Grippers 21

2.5.3 Standard Grippers 22

2.6 Type of power source 23

2.6.1 Pneumatic Power Source 24

2.6.2 Hydraulic Power Source 25

2.6.3 Electric Power Source 26

2.7 Type of software 27

2.7.1 Types of Robotic Software 27

2.7.2 Types of CAD Software 28

2.7.2.1 CATIA 28

2.7.2.2SolidWorks 29

2.7.2.3 UGSNX 30

2.7 Conclusion 30

vii

CHAPTER 3: METHODOLOGY 31

3.1 Flow Chart of the Project 31

3.2 Gantt Chart of the Project 32

3.3 Selection of type system for loading and unloading process 32

3.4 Selection of type of loading and unloading robot system 36

3.5 Selection of Types of Geometry of the Robot 37

3.6 Selection of the Gripper 40

3.7 Selection of Power Source 41

3.8 Selection of the Robot Soft Prototype 42

3.9 Selection of CAD Soft Prototype 43

3.10 Design Ideas 44

3.10.1 Design 1 46

3.10.2 Design 2 47

3.10.3 Design 3 48

3.11 Selection of Gripper Design 49

3.12 Conclusion 50

CHAPTER 4: DESIGN AND ANALYSIS OF GRIPPER AND ROBOT

WORKSPACE 51

4.1 Process Simulation 51

4.1.1 Creating Mechanism 52

4.1.1.1 Gripper Mechanism 52

4.1.1.2 CNC Machine Mechanism 56

4.1.2 Creating Simulation Path 59

4.1.2.1 Work Object 59

viii

4.1.2.2 Target 61

4.1.2.3 Path 61

4.1.2.3 Smart Component 63

4.1.2.4 SC_Gripper 63

4.1.2.5 SC_CNC Machine 65

4.1.2.6 Station Logic 67

4.1.2.7 RAPID Coding 68

4.1.2.8 System Layout 71

4.2 Finite Element Analysis (FEA) 72

4.3 Analysis of Maximum Work Load 72

4.4 Gripping Force 73

4.5 Applied 143N Force 76

4.6 Factor of Safety 76

4.7 Modified Parallel Gripper 79

4.8 List of Standard Part 82

4.9 List of Fabricate Part 83

4.10 Sustainability 83

CHAPTER 5 : CONCLUSION AND RECOMMENDATION FOR FUTURE

WORK 84

5.1 Conclusion 84

5.2 Recommendation for Future Work 85

REFERENCES 86

ix

APPENDICES

A Gantt chart for PSM I

B Gantt chart for PSM II

C 2D Drawing for Design 1

D 2D Drawing for Design 2

E 2D Drawing for Design 3

F 2D Drawing for Finger Gripper

G 2D Drawing for Connector

H 2D Drawing for Base Gripper

x

LIST OF TABLES

Table 2.1 Robot Brand and their language 27

Table 3.1 Comparison between hydraulic jack system and robot operating

system 34

Table 3.2 Comparison between robot’s geometry 37

Table 3.3 Rating system for robot geometry 39

Table 3.4 Rating system for gripper selection 40

Table 3.5 Rating system of Power Source 42

Table 3.6 Rating system between gripper designs 49

Table 4.1 List of Smart Components in Gripper 63

Table 4.2 List of Smart Components in SC_CNC Machine 65

Table 4.3 List of Standard Parts 82

Table 4.4 List of Fabricate Parts 83

xi

LIST OF FIGURES

Figure 1.1 HAAS VF-1 Milling Machine at FKP Lab 2

Figure 1.2 Manual loading of work piece into CNC Machine 3

Figure 2.1 Process of Loading inside HAAS VF-1 CNC Milling Machine 7

Figure 2.2 Cartesian Geometry 15

Figure 2.3 Cylindrical Geometry 17

Figure 2.4 Spherical Geometry 18

Figure 2.5 Articulate Geometry 19

Figure 2.6 Vacuum Grippers 21

Figure 2.7 Magnetic Grippers 22

Figure 2.8 Standard Grippers 23

Figure 3.1 Flow chart of the project methodology 32

Figure 3.2 Working space of CNC Machine 35

Figure 3.3(a) Front View of Design 1 46

Figure 3.3(b) Side View of Design 1 46

Figure 3.3(c) Top View of Design 1 46

xii

Figure 3.3(d) Isometric View of Design 1 46

Figure 3.4(a) Front View of Design 2 47

Figure 3.4(b) Side View of Design 2 47

Figure 3.4(c) Top View of Design 2 47

Figure 3.4(d) Isometric View of Design 2 47

Figure 3.5(a) Front View of Design 3 48

Figure 3.5(b) Side View of Design 3 48

Figure 3.5(c) Top View of Design 3 48

Figure 3.5(d) Isometric View of Design 3 48

Figure 4.1 Importing gripper parts to RobotStudio 52

Figure 4.2 Assembly of gripper 53

Figure 4.3 Type of Mechanism 54

Figure 4.4 Type of Joint 55

Figure 4.5 Tool Data of Gripper 56

Figure 4.6 (a) Assembly of HAAS CNC Machine 57

Figure 4.6 (b) CNC Machine Mechanism Type. 57

Figure 4.6 (c) Link Setting for CNC Machine 58

Figure 4.6 (d) Joint Setting for CNC Machine 59

Figure 4.7 WorkObject 60

Figure 4.8 Creating Target 61

Figure 4.9 Creating Path 62

xiii

Figure 4.10 SC_Gripper Connection 64

Figure 4.11 Line Sensor 64

Figure 4.12 SC_CNC Machine 66

Figure 4.13 Station Logic 67

Figure 4.14 Zone Data 70

Figure 4.15 (a) Isometric View of System Layout 71

Figure 4. 15 (b) Top View of System Layout 71

Figure 4. 15 (c)Front View of System Layout 71

Figure 4.15 (d) Side View of System Layout 71

Figure 4.16 Gripping Force of a Parallel Gripper 74

Figure 4.17 Coefficient of friction 75

Figure 4.18 Modal of the Gripper 77

Figure 4.19 Characteristics of the Plain Carbon Steel 77

Figure 4.20 Result for von Mises Stress fot 143N force applied. 78

Figure 4.21 Result for Factor of Safety when 143N force applied 79

Figure 4.22(a) Initial Dimension of Gripper 80

Figure 4.22(b) Modified Dimension of Gripper 80

Figure 4.23 Shows the result for von Mises Stress for 143N force applied for

Modified Parallel Gripper 81

Figure 4.24 Result for Factor of Safety when 143N force applied for the

Modified Parallel Gripper. 81

xiv

1

CHAPTER 1

INTRODUCTION

1.1 Background of the Project

Automation has become an important aspect in manufacturing industry. At early stage,

human was responsible for executing all the process from forging, grinding, until

welding. Even though automation have been replaced the human labor, yet

manufacturing still relies on the manual labor due to the complexity of the process

requires the human dexterity. (Charalambons, Fletcher, and Webb. 2008)

Nowadays automation also involved together with Computer Numerical Control Machine

(CNC). CNC machine is a type of operating machine, whereby a computer monitors the

machine tools. CNC is actually a further innovation from NC Machine. Almost every

manufacturing industry uses CNC machine in their process. CNC machine can execute

same operation repeatedly for a long period of time as long the work piece is being feed

into in.

Loading and also unloading task could not be performed by CNC Machine as it could

only execute machining task only. Loading and unloading task can be either done by

human labor or can be automated using robots. Automation by robots are proven to be

2

more effective and efficient compare to human labor because human could not execute

any task for a long period of time as fatigue will takes toll on them. HAAS VF – 1 CNC

Milling Machine are designed to perform machining process only. Hence it need the

work piece to be feed into it in order for it to operates

Figure 1.1: HAAS VF-1 Milling Machine at FKP Lab

3

1.2 Problem Statement

The problem arises when the HAAS CNC Milling Machine in CNC Lab at Block B of

Faculty of Manufacturing Engineering, UTeM uses human operator to load and unload

the raw work piece or semi finish work piece into the machine. This action seems to be

less productive and also might cause injuries if the operator that is loading the work piece

accidentally drops it. To solve this problem, a suitable automatic system will be selected

and designed to load and unload the work piece.

Figure 1.2: Manual loading of work piece into CNC Machine

1.3 Objective

i. To select a suitable automatic system for loading and unloading work pieces

for HAAS CNC Milling Machine.

ii. To design a suitable gripper or tool for handling the work pieces for loading

and unloading the CNC Milling Machine

iii. To develop a soft prototype of the above designed gripper or tool.

4

1.4 Scopes

i. Study and select a suitable automatic system such as robot or other equipment

for loading and unloading work pieces for HAAS CNC Machine.

ii. To design a suitable tool or gripper for handling the work piece based on the

following dimension:

Length = 150mm (max)

Width = 150mm (max)

Height = 80mm (max)

Work piece material = Steel

Density of steel = 8050 kg/m³

Maximum weight of the work piece :

= Volume x Density

= Width x Height x Density

= 0.15m x 0.15m x 0.15m x 0.08m x 8050kg/m³

= 14.49kg

iii. Develop a soft prototype of the designed gripper or tool using a suitable 3D

CAD / CAM software.

5

CHAPTER 2

LITERATURE REVIEW

This chapter discusses the entire element that needed to automate the loading and

unloading of the work piece into HAAS VF – 1 CNC Milling Machine. This chapter uses

various resources from books, journals, and also internet to review the elements in the

automated process

2.1 Introduction about HAAS VF – 1 CNC Milling Machine

HAAS Automation in a USA based company to manufacture Computer Numerical

Control machine (CNC) such as vertical machining centers and horizontal machining

centers, lathes/turning centers, and rotary tables and indexers. By using CNC in

manufacturing industry, fewer supervisors is need as the tool and the machine itself are

pre – programmed to run a certain course of operation. HAAS VF – 1 CNC Milling

Machine was first introduced in 1988 and immediately achieves high industry benchmark

for high quality, and high – value CNC technology.

6

Besides that, high performance of vector drive spindles, high – torque brushless servos,

and rigid cast – iron construction are among of few features possess by the CNC Milling

Machine. Configurations range from 40 – 50 taper gear – driven models for high –

torque, heavy – duty cutting, to Super Speed models with the inline direct – drive

spindles to handle the most demanding high – speed machining operations. (Haas

Automation, 2013).

2.2 Types of system used for loading and unloading process

The process of loading and unloading the work piece falls on the Flexible Manufacturing

System (FMS). Simultaneously process medium – sized volumes of a variety of part

types is called FMS whereby it is an integrated, computer controlled complex of

automated material handling devices and numerically controlled (NC) machine tools. In

FMS, there are several methods used to execute loading and unloading task, namely

hydraulic jack system, and robot operation system. These systems will be compared and

analyzed with the current method of loading and unloading the work piece.

2.2.1 Man power in loading and unloading process

The currently used method which is manual loading and unloading the work piece are

considered less productive, inefficient, and also dangerous. Loading and unloading

manpower consume ample of time, especially when the multiple of work piece need to be

placed inside the HAAS VF -1 CNC Milling Machine to undergo the same process of all

7

work piece. This kind of ineffective requires a human labor besides the machine all the

time just to load the work piece and unload the finished product.

Figure 2.1: Process of Loading a work pieces for the HAAS VF-1 CNC Milling Machine

Furthermore, during the loading and unloading process, there are chances for any kind of

incident to occur which mostly due to either human recklessness or fatigue due to

working of long time of period. Studies were carried out in Holland and found out that

from a data obtained from more than 9000 accidents in six years of the period,

occupational risk rates per hour of exposure are quantified for 63 occupational hazards

for the Dutch working population. All this accidents can be classified into three

categories which are fatal injury, permanent injury, and recoverable injury requiring at

least one day hospitalization. (Bellamy, 2015). Besides human recklessness and fatigue,

machine failure also cooperates with the probabilities of the accident takes place. An

incident such as power failure or error in the programming might cause the machine to go

haywire and collide with the human labor. When an error in the programming line, the

machine will read inaccurately and might cause to move unexpectedly, which might

startled the user of the machine.