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=

End Effector
The end effector must meet the following requirements:
 * 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
The Programmable Logic Controller should perform the following functions:
 * 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

The Robots should be programmed according to the following requirements:
 * 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

The human-machine interface should communicate with the PLC to perform the following functions:
 * Start and stop the robots
 * Display errors in the system
 * Troubleshooting feature to edit PLC program

Specifics
Software:
 * 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 length ranges from 1 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:
 * 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

=Design Considerations=

=Project Learning=

=Final Design=

=Validation=

=Team Members=

=Additional Documentation=

Project Schedule



Meeting Minutes

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Client Interview