Dual Robot Log Handling

The goal of the project is to design end effectors and program the robots to pick up, rotate, and manipulate a log through a band saw following a prescribed path. The path will be communicated via a Programmable Logic Controller after each log is scanned to find the optimized cutting planes. In the first year of the project, we will be able to cut two faces of logs with varying geometry.

=Project Value= In modern sawmills, logs become lumber through a massive automated assembly line of hydraulic equipment which is expensive to maintain. This could be replaced by a two-robot system which takes up far less space and significantly reduces total computing power. This would improve sawmill throughput and significantly reduce maintenance, computing, and operational costs.

=Product Requirements=

The end effector must meet the following requirements: The Programmable Logic Controller should perform the following functions: The Robots should be programmed according to the following requirements: The human-machine interface should communicate with the PLC to perform the following functions: Software:
 * End Effector :
 * Grip the log on its ends, preventing any slip
 * Fit within a 2 by 4 board to avoid being cut by the saw
 * Prevent the robot from being cut by the saw
 * Resistant to wear at the points of contact
 * Have a high stiffness spring mechanism to prevent the robot from detecting a collision
 * Strong enough to avoid fracture due to bending
 * Economical to produce, install, and uninstall
 * Programming :
 * Accept data from optimizer as input variables
 * Convert input variables into a form the robots can understand
 * Output variables to robots to communicate offset values into a pre-programmed path
 * A baseline program to cut one face a perfect log with infinitesimal geometry
 * Have spaces in the program to call variables from the PLC to act ass offsets to set the path of each cut according to log geometry
 * Start and stop the robots
 * Display errors in the system
 * Troubleshooting feature to edit PLC program
 * Specifics :
 * The robots we are programming are Fanuc R2000iC 210L Robots via Fanuc's robot simulation software Roboguide.
 * The PLC is programmed via Studio 5000 software.
 * The HMI will be developed with Ignition software.
 * We are using SolidWorks to model the end effector

Log:
 * Log diameter ranges from 5 to 12 inches
 * Log lengths up to 8 feet
 * Log mass does not exceed 350 kg (larger logs would be at risk of exceeding the maximum robot load of roughly 2 kN).

End Effector:
 * Member should be at least 6 inches long
 * Member should be less than 3.25 inches wide and 1.5 inches tall
 * Spring should compress no more than 0.5 inches under expected maximum loading

System: Click this link for more details about Product Requirements.
 * The system should be able to rotate a log with an accuracy of no more than ±1°
 * The cycle time to cut 4 sides of a log should not exceed 2 minutes
 * The system should be operational from temperature ranges of -40°C to 110°F

=End Effector Design= To test the tolerances and reaction to loading, we created a wooden rapid prototype to mimic the behavior of our end effector design:
 * Rapid Prototyping :

=PLC Programming=

=Robot Simulation=

=Final Design=

=Team Members=

=Additional Documentation=


 * Schedule
 * Budget
 * Meeting Minutes
 * PLC Training
 * End Effector Alignment Rapid Prototype Drawing Package
 * Design Validation Plan
 * Team Contract