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Ecava IGX Talks to the Robot Hands
Ecava IGX與機器人手對話
How It Started
Robots have been penetrated the industries ever since industrial automation was brought in. Basically, with the rising of Artificial Intelligence (AI), industrial robots can be designed and programmed to do almost anything. There are varieties of different robots used for industrial automation. Among all, robotic arms are one of the most popular used in different industries, and even robotic arms itself consists of multiple types. Articulated robotic arm is a type of robotic arm with rotary joints, in which these joints may vary in different number of axis. KUKA is well known in the market to produce 6 axis articulated robotic arms, used mostly for industrial purpose.
自從工業自動化被引入以來，機器人就被滲透到各個行業。基本上，随着人工智能(AI)的興起，工業機器人的設計和程式設計幾乎可以做到任何事情。有各種不同的機器人用于工業自動化。其中，機械臂是在不同行業中應用最廣泛的一種，甚至機器人手臂本身也是由多種類型組成的。鉸接式機器人臂是一種具有旋轉關節的機器人手臂，其關節在不同的軸數下會發生變化。KUKA是衆所周知的市場上生産6軸鉸接式機械臂，主要用于工業用途。
In order to ensure integration with the latest and popular industrial needs, Malaysia government has funded several technical institutes to provide professional courses in robotics and automation. Other than theories, these courses shall provide the environment / laboratory which equipped with real KUKA robots as well as the complete imitation system of an industrial manufacturing production line.
為了確定與最新和流行的工業需求相結合，馬來西亞政府資助了幾個技術學院提供機器人和自動化方面的專業課程。除理論外，這些課程還應提供配備真正KUKA機器人的環境/實驗室以及一條工業制造生産線的完整仿真系統。
Three (3) institutes in Malaysia are chosen to introduce and implement this project by government, which are Pahang Skill Development Center (PSDC), Pusat Pembangunan Kemahiran Sarawak (PPKS), and German-Malaysian Institute (GMI). By providing these courses, the attendants are allowed to get a hands on experience with the full system, this shall assist them to familiarize with the industrial real world.
政府選擇了馬來西亞的三所(3所)機構介紹和實施這一項目，它們是：Pahang技能發展中心(PSDC)、Pusat Pembangunan Kemahiran Sarawak(PPKs)和德國馬來西亞研究所(GMI)。通過提供這些課程，學員可以掌握整個系統的經驗，這将有助于他們熟悉工業現實世界。
Get the Robots Moving
In order to integrate with the robotic arms, a Computer Integrated Manufacturing (CIM) system is designed and implemented. Once again, Ecava IGX SCADA is chosen as the automation solution as well as training toolkit for this project. The system is established along with PLCs (Programmable Logic Controllers) to talk to the robotic arms. Process conveyor belt is built to transport pallets of raw materials, where they will be sent to stations with robot arms to perform the assembly operation. Besides, there are also RFID scanners and vision checking system devices to register and inspect each pallet’s barcode ID and status. The basic system architecture of CIM system is shown as follow diagram.
為了與機器人手臂內建，設計并實作了計算機內建制造(CIM)系統。再次，Ecava IGX SCADA被選為該項目的自動化解決方案和教育訓練工具包。該系統是與PLC(可程式設計控制器)一起建立的，用于與機器人手臂對話。過程傳送帶是用來運輸托盤的原材料，在那裡，他們将被送往站與機器人手臂，以執行裝配操作。此外，還有RFID掃描器和視覺檢查系統裝置，以登記和檢查每個托盤的條形碼ID和狀态。CIM系統的基本體系結構如下所示。
（Basic system architecture of CIM system / CIM系統的基本體系結構）
The main concept may seem simple, but the truth is there are multiple times of efforts required to achieve the expected impression. Ecava IGX plays the role of simulator, in which the robots’ movement will be automated. User can also monitor and control the operation by interacting with the SCADA screens. The procedures to configure Ecava IGX certainly involves powerful automated scripts to control the robotic arms. PLCs in this project act as the logic commanders to the robots. However, they will require an handshake agent to communicate with each other, and that is how Ecava IGX step in again. Thus, different communication protocol are involved to establish the complete CIM operation, which includes Modbus TCP/IP, OPC and Profinet.
主要的概念可能看起來很簡單，但事實是，要達到預期的印象，需要多次努力。Ecava IGX扮演模拟器的角色，在模拟器中機器人的運動将是自動化的。使用者還可以通過與SCADA螢幕的互動來監視和控制操作。配置Ecava IGX的過程當然需要強大的自動化腳本來控制機器人手臂。在這個項目中，PLC充當機器人的邏輯指揮者。然而，它們需要一個握手代理來互相通信，這就是Ecava IGX再次介入的方式。是以，需要不同的通信協定來建立完整的CIM操作，包括Modbus TCP/IP、OPC和Profinet.。
The CIM system is designed to consists of five (5) operation modes, as listed below.
– Store Raw Material
– Machine Raw Material
– Assembly
– Barcode Printing
– Unloading
CIM系統由五種操作模式組成，如下所示。
-儲存原料
-機械原料
-集會
-條碼印刷
-卸貨
These modes are actually sections of a complete CIM operation. User can also select to execute full mode from Ecava IGX, and all PLC kits will be activated to operate based on system designed routine. The manufacturing process can be monitored real-time on the HMI mimic screens, for example as shown below.
這些模式實際上是完整CIM操作的一部分。使用者也可以選擇執行完全模式從Ecava IGX，所有的PLC工具包将被激活，根據系統設計的例程操作。制造過程可以在人機界面模拟螢幕上實時監控，如下圖所示。
（Full mode CIM operation HMI mimic screen on Ecava IGX / Ecava IGX上的全模式CIM操作人機界面模拟螢幕）
（HMI mimic screen for Machine Raw Material operation in CIM system / CIM系統中機器原料操作的人機界面模拟螢幕）
The Hardware / Software:
Server Machine: Dell Precision T3600 Workstation
OS: Microsoft Windows 7
PLC (Programmable Logic Controllers):
– Siemens S7-200
– Siemens S7-1200
Protocol: Modbus TCP/IP, Profinet
Robotic Arms:
– KUKA KR10
– KUKA KR16
– KUKA KR5_ARC
– KUKA KR5_SIXX
Protocol: OPC
Vision Checking System
Protocol: Modbus TCP/IP
SCADA: Ecava IGX
IO tags: 1500 tags
如各位對Web SCADA平台及技術感興趣，歡迎轉發或私信我，大家共同學習，互相交流、共同進步、共赢；