Robotics Projects

This project involves the design, programming, and simulation of a robotic palletizing workcell using FANUC's ROBOGUIDE (HandlingPRO) software. The simulation features a 6-axis FANUC industrial robot tasked with performing a classic pick-and-place operation: retrieving boxes from an infeed conveyor and systematically stacking them onto a nearby pallet. The entire process, from workcell layout to program execution, is developed and validated within this virtual environment.

• 3D Workcell Design: The virtual environment was constructed in ROBOGUIDE, incorporating a FANUC robot, a conveyor for parts infeed, a pallet for stacking, and safety fencing to simulate a realistic industrial setup.
• Offline Robot Programming: The robot's operational sequence was programmed offline using a Teach Pendant (TP) program. This involved defining a series of target points (P[1], P[2], P[3], etc.) to create a precise and repeatable motion path for picking up each box and placing it in its designated spot on the pallet.
• Palletizing Application Logic: The program logic handles the complete cycle of moving to the conveyor, picking a part, moving to the pallet, and placing the part. The simulation demonstrates the robot's ability to follow a pattern to build a stable stack of boxes.
• Simulation and Validation: The entire pick-and-place cycle is simulated to verify the robot's path, check for potential collisions, and confirm the logic before deployment on a physical system. This demonstrates the core value of offline programming (OLP) in industrial automation.
• Virtual Teach Pendant Operation: The project utilizes the virtual Teach Pendant interface within ROBOGUIDE to create, edit, and run the robot's program, mirroring the process used on a real FANUC robot controller.

This project showcases a strong understanding of industrial robotics and automation principles. It highlights proficiency in using specialized simulation software (FANUC ROBOGUIDE) for workcell design, offline programming, and the implementation of a common and critical manufacturing task like automated palletizing.

This project showcases the design and simulation of an automated industrial sorting system using Factory I/O and Control I/O. The primary objective is to sort pallets carrying boxes of different sizes onto two separate conveyor lines based on their height. The control logic is developed in Control I/O using a Function Block Diagram (FBD) approach, demonstrating a practical application of PLC-style programming in a virtual commissioning environment.

• 3D Industrial Simulation: Utilization of Factory I/O to create a realistic digital twin of a conveyor system, complete with sensors, actuators, and physical constraints.
• Function Block Diagram (FBD) Programming: The system's control logic is designed in Control I/O, using standard automation blocks such as logic gates (AND, NOT), latches (SR Flip-Flops), and edge detection triggers (RTRIG, FTRIG) to manage the operational sequence.
• Automated Sorting by Height: The core of the system is a central station where pallets are sorted. An array of optical sensors determines the height of the box on each pallet.
  • Tall boxes (detected by a "High sensor") are transferred to the right conveyor.
  • Short boxes (which do not trigger the "High sensor") are transferred to the left conveyor.
• Sensor and Actuator Integration: The system uses multiple diffuse sensors (Pallet sensor, Low sensor, High sensor) to detect the presence and size of items. This input is processed by the controller to operate the actuators, which include roller conveyors and a bi-directional chain transfer mechanism.
• Sequential Control Logic: The simulation demonstrates robust sequential control: pallets are moved into position, stopped, measured, transferred left or right based on the measurement, and then moved along the destination conveyor line.

This project effectively demonstrates skills in industrial automation, PLC-style programming, and virtual commissioning. It shows a complete workflow from defining an automation task to implementing and validating the control logic in a safe, simulated environment, which is a key practice in modern manufacturing and system integration.

This project, developed entirely within the Siemens Totally Integrated Automation (TIA) Portal, demonstrates the automation of a bottle filling process. It integrates a SIMATIC S7-1200 PLC program with a SIMATIC HMI (Human-Machine Interface) to create a complete control and visualization solution. The system is designed to manage the level of a main supply tank and sequentially fill bottles as they pass along a conveyor.

• PLC Programming in Ladder Logic (LAD): The core control logic is implemented on a Siemens S7-1200 CPU. The program, written in Ladder Logic, manages the entire process sequence using standard instructions such as latches (SR blocks), timers (TON), counters (CTU/CTUD), and comparators. Key logic sections include system start/stop control, automatic filling and level maintenance of the main reservoir, conveyor belt movement, and the timed dispensing of liquid into bottles.
• HMI Design and Visualization: A graphical user interface was designed for a SIMATIC HMI panel. This screen provides operators with intuitive controls (Start/Stop buttons) and real-time process visualization, including the pump's operational status, the current level in the supply tank, and a counter for successfully filled bottles.
• Automated Filling Process: The system executes a fully automated sequence: upon starting, the conveyor transports a bottle to the filling position. The PLC logic ensures the main tank has sufficient liquid before opening a valve for a predefined time to fill the bottle. Once filled, the bottle is moved along the conveyor, and the system is ready for the next one.
• Integrated PLC-HMI Simulation: The project leverages TIA Portal's powerful simulation tools to test and validate the entire system without physical hardware. The PLC logic is run on PLCSIM, and the HMI screen is run in the RT Simulator, demonstrating a seamless interaction between the controller and the operator interface.

This project effectively showcases the end-to-end development of a small-scale industrial automation system. It demonstrates strong proficiency in PLC programming with the Siemens S7-1200 platform, HMI screen design for operator interaction, and the use of integrated simulation for virtual commissioning and troubleshooting within the TIA Portal environment.