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2006IEEEInternationalConferenceon Systems,Man,andCybernetics October8-11,2006,Taipei,Taiwan AnInternet-basedAutomaticRivetingSystemusingRemote MonitoringandControl H.C.Lin Abstract-Today,themechanicalarmusingpneumatic actuatorcontrolledbyProgrammableLogicControllers(PLC) forautomaticmaterialprocessiswidelyusedinthemodern manufacturing.Thepneumaticbasedmechanicalarmprovidesa relativelylowcostmeansofforce,torqueandmotion.However, thelimitationariseswhenthesystemrequiresanaccurate position.Withanincreasingdemandforanatural,intuitive man-machineinteractioninautomatedindustry,thegraphical operationistheotherimportantissuethatisgainingmuch attentionnowadays.Inacomprehensivecasestudy,aPC-based virtualinstrument(VI)foranautomaticrivetingsystem employingthepneumaticbasedmechanicalarmcombinedwith apreciseX/Yplatformisdeveloped.Theproposedschemecan carryoutbothfastandaccuraterivetingprocessusingaremote monitoringandcontrolfunctionviatheInternet.Thereal-time implementationshowsitsgoodperformanceandpresentsthe illustrativedemonstration. Keywords:TCP/IP,PLC,VI,Internet,HMI I.INTRODUCTION Intheindustrialarea,thereexistsalargenumberof mechanicalarmsusingpneumaticactuatorcontrolledby PLCsforfastsequentialindustrialprocesses.ThePLC particularlyprovidessuperiorityineasyprogrammingaswell asdigitalcommunicationsI/O.Italsopresentsascendant capacityincomplexsequencecontrolfunctions1-3. However,themechanicalarmmovementusingpneumatic actuatorcannotprovideanaccurateposition4-6.Moreover, PLCsingeneralhavecertainlimitationssuchasgraphical programmingandInternetconnection.Therefore,the developmentoffastandprecisepositionwith Human-MachineInterface(HMI)isnecessary. Nowadays,theInternethasbeenconstantlyvisibleand spreadthrougharoundtheworld.TheInternetwasfirstused forremoteterminallogin,filetransfer,e-mailandnewsgroups. Webpublishingwasthenavailable.NowtheWebcommerce becomesonemajorbusiness.Fromtheviewofengineering, whattheInternetcandomoreforusinindustry?Howcanthe Internettoolimprovethescientistsandresearchers experiences?ThecombinationofLabVIEWandPLCmay giveagoodsolutionfortheHMIsequentialcontrolin automatedindustry7-18. Becauseofthesignificantnetworkapplicationsinabroad offields,thedevelopmentofremotemonitoringandcontrol ManuscriptreceivedMarch1,2006.H.CLiniswiththeDepartmentof AutomationEngineering,ChienkuoTechnologyUniversity,Taiwan(e-mail: .tw) systemviatheInternethasledmodernindustrial equipment/facilities.Thus,thefunctionsoftheproposed systemincludeitsInternet-basedmanufacturingcontroltothe rivetingmachinewithpreciseX/Yplatformaswellas mechanicalarmsinsteadofhumanoperation.OnePC(the serverside)linkedbytheremotePC(theclientside)via WorldWideWebworkswiththePLCcoincidentally.The historyofworkpiecerivetingcanbealsorecordedandtracked fortheproductionmanagement.Thecapabilityofthe proposedmethodcanbeeasilyexpandedtoavarietyof applicationsaccordingtotherequirementsofusersand provideagoodguideforelectricalengineeringstudentsand automationengineerstoimprovetheirInternetprogramming efficiency. Thispaperisorganisedasfollows.SectionIIprovidesthe proposedsystemhardwarestructure.InSectionIII,thesystem softwarepackageforLabVIEWandthePLCareprovided. SectionIVpresentstheInternetconnectionbasedonWorld WideWeb.ThepracticalresultswithWebconnectionare giveninSectionV.Conclusionsandrecommendationsfor furtherinvestigationaregiveninSectionVI. II.STRUCTUREOFTHESYSTEMHARDWARE TheproposedsystemhardwareisshowninFig.1.Itcan performonlinereal-timemonitoringandcontrolfunctionvia WorldWideWeb. TCP/IP(LabVIEW) RemotePCt(Client)NearbyPC(Servern r-n RiingMathin I x*XMPlatonn RAitoingpr css iaeplatform _PLCI/O In.nMe Acnei._.nvnln.,pltfv Fig.1Structureoftheproposedsystemhardware TheremotePC(client)andnearbyPC(server) communicatewitheachotheraccordingtoTCP/IPusing LabVIEW.TheserverislinkedwiththePLC(Mitsubishi 1-4244-0100-3/06/$20.0002006IEEE4654 FX1N)throughtheIndustrialAutomationOPCServers.The X/YplatformassociatedwiththeRivetingMachineis operatedbythePLCsInput/Output(I/O)panel simultaneously.Therefore,theremotecontrolandmonitoring canbeimplementedusingthegraphicalprogramming environment.TheX/YplatformthatiscontrolledwithtwoAC servomotors(5x106cm/pulse)providesbothfastand highlyaccuratepositionsystemforautomaticmaterialfeeding processandworkpiecerivetingprocess. Theproposedsystemalsodevelopstheautomaticmaterial feedingplatformusingthreemechanicalarmsinsteadof humanoperation.InFig.2,thelarge-sizeonecanmove toward3dimensions,i.e.X,YandZaxles,usingpneumatic suckertodeliverthepatternplatetothepredefinedlocations. Thesecondone(smallsize)thathasonlyXandYaxlesisto cliptheconcavemetalcuboidusingaclampingapparatusto thepredefinedlocationatX/Yplatform.Thethirdone(small size)thathasX,YandZaxlescandrawintwokindsofmetal cylinders(mediumandsmallsizes)usingpneumaticsucker. NotethatthefirstandthirdmechanicalarmsuseACserver motorforZ-axlemovementandpneumaticsystemforX-axle andY-axlemovement,butthesecondoneuseonlythe pneumaticsystemforX-axleandY-axlemovement. (6)Oneaircompressor. (7)ThreevibratingtraystofeedwanteditemstoX/Y platform. (8)OneRivetingMachineforrivetingtheworkpiecesonthe X/Yplatformtable. (9)LabVIEWpackageincludingtheOPCserversforthe graphicalprogrammingandtheremote(Internet) connection. III.DESCRIPTIONOFTHESYSTEMSOFTWARE Besidesthehardwaresystem,therearetwokindsof softwaresystems,i.e.PLCprogrammingandoneLabVIEW programming,neededtoperformtheproposedapproach, describedasfollows. 111.1FlowchartofthePLCprogrammingforautomatic materialfeedingsystem Theautomaticmaterialfeedingprocessisoperatedbythree mechanicalarmsaswellasX/Yplatformconcordantly.The mechanicalarmscandeliverthedesignateditems,i.e.concave metalcuboid,metalcylinderandpatternplate,toX/Y platforminpredefinedlocationsbeforerivetingprocess.Its flowchartisshowninFig.3. PattesPlatre Metalcylndes(uo10i.-. ViblatiDgtlayVi6tatazy McItelalcyane(smassize) ik33) Lfvp-ff“7 Fig.7LabVIEWVIpanelforWebPublishingTool Fig.5FlowchartoftheLabVIEWprogramming IV.INTERNETCONNECTIONBASEDONWORLDWIDEWEB Whiletheproposedsystemisperformedbyboththe hardwareimplementationandsoftwareprogramming,the LabVIEWpanelisdesignedtomonitorandcontrolonline rivetingprocess,showninFig.6. 4dSWo heStoi.N-,0-4.4m;u.L;s Fig.8LabVIEWVIpanelforURLaccess 4657 ,.,.,!:,.F!f!f!ggr!Sfr!77_.r!g.!777rg_i!97h!Ch *Laj.*. -.1LYJ.n -i -WtAl Notethat“user2“intheURLpath,showninFig.8,should bereplacedbytheserversIPaddress,forexample 90,tobeviewedandcontrolledbytheclient (remotePC)viaWorldWideWeb.Forsecurity considerations,theFirewallhasbeensetuptoavoida stranger(orhacker)invasion,showninFig.9.Onlyacertified IPaddress,i.e.91and84,canbe permittedtoaccessthesystem,andallothersareprohibited. NotethatIP91canbeallowedtoviewandcontrol thesystem,butIP84canviewthesystemonly. .*r;.l.itlii.7)0;it.;0ttit.tt00i55.7fi100m -.u EOn.ZZflZZD .o.111. * *a INo rDeaY ,CeA/ WL; :“0 oUUtUUTh:eA;S *a0 turn becomeanimportantisunnowdyauomtd ecnloy particulalyremotemonitorinancontrluctonvah atutoairetifnd34gDsytebased33)LtoInegWapic knowledgegtoimroebiaeothetrdtinlisqencecnto mThod.eofnurtherlapptrlicatuions,thproposedappntroachscan bepasticualyrexotendeditoprformandistncontrolfucinvandh surveillanetcectivitiesoinautomated.inusrd.iscines. viewing ig IncnrlinWepbimageundethelirentlscuiy knoweidgestriacontrollerusingraditioalsequerfceshasro bethomes.imorfrtantapissueions nowday automated terochnology beparticualy remotendeditoprformandistncontrolfucinvandh lieurvilnacticavisutistsiiedautsmatedindustrmacdicpines.b 4658 WIMIMMIM AAMI 1,-. .,-. .A: -.;- Mt P.d.fmdW-41i-N-:C-1.1.dW.ftw,.N- VII.REFERENCES 1M.C.Zhou,andE.Twiss,“Designofindustrial automatedsystemsviarelayladderlogicprogramming andPetrinets“,IEEETransactionsonSystems,Man, andCybernetics,PartC,Vol.28,No.1,1998,pp. 137-150. 2D.Boothroyd,“Failsafesystemsgaintheflexibilityof thePLCapproach“,IEEEComputing&Control EngineeringJournal,Vol.6,No.1,1995,pp.43-44. 3R.RomanandR.Wilson,“Commercialdemandside managementusingaprogrammablelogiccontroller“, IEEETransactionsonPowerSystems,Vol.4,2000,pp. 2475-2480. 4B.Surgenor,“Continuoussliding-modecontrolofa pneumaticpositioningsystem“,Designand Performance,ResearchStudiesPress,from8thBathInt. 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