Návrh a realizace programu pro obslužný systém lisovacího stroje

Abstract

This thesis focuses on the design and implementation of an automated production process in the industry, incorporating robotic manipulation, a vibratory feeder, and other technologies. The main objectives are to increase production efficiency, quality, and safety, reduce error rates, and minimize human intervention. The process begins with manual loading of components by an operator at the handover station, from where the robot picks them up. Simultaneously, the manipulator ensures the transfer of additional parts from the vibratory feeder to the heating station. The robot then moves the components into the press, where joining or pressing operations take place. The finished parts are subsequently sorted either onto an output conveyor or into a NOK box for non-compliant parts. The thesis includes the design of the system's motion coordination, control of individual units using PLCs, and optimization of the entire process, along with the analysis of safety aspects. The solution involves the implementation of the PackML standard for station and operation mode management, deployment of an HMI panel with extended diagnostics and manual control features, and the integration of Profinet and IO-Link communication to ensure reliable data exchange between the PLC, the robot, and peripheral devices. The robotic arm functions are fully synchronized with the press production cycle using the Euromap 67 standard. Emphasis is also placed on robust fault diagnostics and alarm management to detect deviations early. Testing, stress trials, and validation in real production conditions ensure that the required level of stability, performance, and safety of the automated system is achieved.