Control of Robotic Welding Cell

Andraž Zabukovec (2013) Control of Robotic Welding Cell. EngD thesis.

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Abstract

Industrial robots are common place in most modern manufacturing plants because the people running these factories are interested in reducing the plants’ dependence on a human workforce and to simultaneously improve productivity and quality. The thesis presents the operation of a robot welding cell project, which was developed at YASKAWA Ristro d.o.o. for the customer Akrapovič. The sub systems of the robot welding cell will be detailed in the thesis including the following topics; safety control, robot operation, Siemens PLC and the communication between these systems. Development of the PLC program controlling the robot welding cells will also be covered in detail. The PLC program is written ladder diagrams in the Siemens Simatic S7 platform. The safety controller and associated systems are also discussed, which are in place to ensure the safety of the human operator. The process of developing software for a robot welding cell begins with detailed analysis of the electrical drawings and customer requirements. Programming the safety controller can be separated into three steps. First, the inputs are defined, followed by developing the safety logic and finally output elements are connected to the logic. The safety logic is the key to programming the automatic operation of the robot welding cell as it ensures safe operation only after certain safety conditions are met. Programming the automation sequence in S7 begins with defining the symbol table before any actual programming takes place. Programming covers communication, messages, counters, alarms, work selection and the HMI.

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