Alejandro RubioWorkcell

Projects

OP10 Cell: CODESYS PLC, Simumatik and RobotStudio

An automated cell for a fictional customer. Boxes on pallets pass through conveyors, an elevation platform and a robot. A CODESYS PLC runs it against a simulated plant over OPC UA.

Type

Simulation

Context

University of Skövde, Industrial Control Engineering

Period

2022

Stack

CODESYS · IEC 61131-3 · Simumatik 3D · OPC UA · ABB RobotStudio · RAPID

Area

[Industrial automation] [Robot programming]

Team project.

Media

Boxes on a pallet
Full run, with the operator screen
Elevation platform
Input conveyors to robot
Robot to end of line
Plan of the cell between the supplier and OP20: robot, conveyors, elevation platform, fence, light curtain and safety gate.
Final layout
Operator screen with a plan of the cell.
Overview screen
Operator screen with manual controls for each conveyor.
Manual screen
Manual buttons for conveyors and a cylinder, forward and reverse.
Manual buttons
Operator screen with cycle times and total cycles.
Production screen
Alarm list with motor protection, safety door and emergency stop messages.
Alarm log
Handshake signals between OP10 and the stations before and after it.
Signals to the stations before and after
Operator panel with buttons and an emergency stop.
Operator panel
Drawing of the elevation platform lifting pallets.
Elevation platform design
Drawing of a roller conveyor lowering so a drag chain carries the pallet.
Drag chain design
Drawing of the sensors and pneumatic stop on the pallet conveyor.
Pallet sensors and stop
Safety gate in a green fence, with a signal light and buttons.
Safety gate
Sequence diagram of the signals between the supplier and OP10.
Supplier handshake, normal
Sequence diagram of the same signals during a fault.
Supplier handshake, fault
Plan view of the cell: a robot between two conveyors on a grid
Another layout
Plan of the line stations SOP600 to SOP680 with the robot beside them
Station plan
Flow of the inspection station steps, from station empty to detail moving out
Inspection sequence
First demo, with a ball

What was built

  • The operator screen, with six pages, an alarm log and cycle times.
  • Safety handling: light curtain, safety gate, fence and emergency stops.
  • The handshake with the stations before and after, including what happens on a fault.
  • The CODESYS PLC project for the OP10 station (final version v20).
  • The Simumatik 3D station model, connected to the PLC.
  • A RobotStudio station with an IRB 6620 and a RAPID module: pick-up targets for three pieces, an output-conveyor drop and a halt trap.
  • The I/O list, with inputs mapped to the M area so they can be written through the CODESYS OPC UA server.
  • The OPC UA server configuration for the robot signals: job done, tool on and off, piece present, halt, auto on.

This was the final project of the Industrial Control Engineering course. We took the cell through the steps of a real job: quotation, functional description, design review, then factory and site acceptance tests.

The plant is simulated in Simumatik and the robot in RobotStudio, linked over OPC UA. The operator screen covers overview, process, manual mode, production, diagnostics and the signals to the stations before and after this one.

Facts

ItemValue
Operator screen pages6
RobotABB IRB 6620, 150 kg, 2.20 m
Pieces handled by the robot3
Final PLC projectversion 20
[CODE] ↗