XYZ Gantry: A PLC-Based Automated Pick and Place Robot for Precision Handling

XYZ Gantry: A PLC-Based Automated Pick and Place Robot for Precision Handling

Published by : http://www.ijert.org

International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181

Vol. 14 Issue 04, April-2025

Sreedeep Krishnan Dept of RA Adishankara institute of engineering and

technology,kalady,ernakulam

Adarsh M Murali Dept of RA Adishankara institute of engineering and

technology,kalady,ernakulam

Arjun Krishna VU Dept of RA Adishankara institute of engineering and

technology,kalady,ernakulam

Jyothish G Kumar Dept of RA Adishankara institute of engineering and

technology,kalady,ernakulam

Milan Joshy

Dept of RA Adishankara institute of engineering and

technology,kalady,ernakulam

AbstractAbstract-The XYZ gantry system is an automated solution designed for precise, coordinated movement along three orthogonal axes (X, Y, Z), commonly used in pick and place applications. Integrated with a PLC for seamless control, it enhances productivity, reduces costs, and improves accuracy in industrial tasks like material handling and assembly. Featuring a robust structure, high-precision motors, and advanced motion control, the system supports scalable, flexible automation. Its implementation drives technological innovation, creates skilled jobs, and promotes energy-efficient, sustainable manufacturing practices. This study focuses on the design, development, and industrial applications of the XYZ gantry system in modern automation

Keywords PLC, Gantry, Precision Robot, Automation

1. INTRODUCTION

   Fig.1. Figure of Gantry System

   A gantry system using XYZ coordinates is a versatile mechanical setup that delivers high precision along three

   linear axes: X, Y, and Z. This system is widely used in automation, robotics, CNC machining, 3D printing, and other industrial applications where accurate and coordinated movement is essential. Operating within a Cartesian coordinate system, the XYZ gantry provides the advantage of easy movement across a three-dimensional spatial plane. Its design, consisting of a rigid frame, stepper or servo motors, linear guides for smooth travel, and a control system to synchronize motor actions, makes it ideal for tasks requiring high accuracy, such as material handling, assembly, and machine manipulation

   When coupled with PLCs, the capabilities of XYZ gantry systems expand significantly. PLCs act as the brain of the system, coordinating and synchronizing the movements of the gantrys motors across all three axes. With a PLC controlling the system, real-time feedback mechanisms ensure that the gantry can adjust its movements on-the-fly based on various factors such as changes in load, variations in material properties, or external influences. This dynamic control ensures that even in high-speed, high-volume production environments, the system can maintain accuracy and prevent errors. The PLCs programming flexibility allows operators to easily modify movement paths, speeds, and sequences to optimize the gantry system for different tasks, whether its for picking and placing small parts in an assembly line or for machining large, heavy work pieces in a factory setting. Furthermore, PLCs enable sophisticated fault detection, which helps to identify potential issues before they cause disruptions, improving uptime and minimizing downtime. By integrating XYZ gantry systems with PLCs, manufacturers can significantly enhance their production efficiency, reduce material waste, improve quality control, and ultimately lower operational costs, making them a critical component in the automation of modern manufacturing processes.

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   International Journal of Engineering Research & Technology (IJERT)

   ISSN: 2278-0181

   Vol. 14 Issue 04, April-2025

   A key feature of XYZ gantry systems in automation is the integration of proximity sensors, which play a critical role in precise positioning and obstacle detection. These sensors allow the gantry to detect objects or surfaces within close range, ensuring that movements are executed with high accuracy. Proximity sensors can be used for positioning the gantry at specific locations, providing feedback to the PLC for fine adjustments and ensuring that the system aligns with the correct coordinates. Additionally, these sensors are essential for obstacle detection, preventing collisions with nearby objects or barriers during the systems operation. This enhances safety and reliability, particularly in environments where the gantry must navigate complex workspaces. The combination of precise positioning and real-time obstacle detection further optimizes the gantry systems performance, making it an indispensable tool in industries that require high efficiency, safety, and minimal error in their automated processes.

2. LITERATURE REVIEW

   XYZ gantry systems, known for their precision and adaptability, are critical components in various automation, robotics, and manufacturing processes. These systems, which operate along three orthogonal axes (X, Y, and Z), are widely used in applications like 3D printing, CNC machining, and automated material handling. The simplicity of their Cartesian coordinate system allows for highly accurate and reliable movement, which is essential in industries requiring precise operations, such as electronics assembly, automotive manufacturing, and packaging. Recent studies highlight the role of advanced control strategies in enhancing the performance of these gantry systems, particularly in complex environments where accuracy and efficiency are paramount Several studies have contributed to the development and enhancement of gantry systems, particularly in terms of precision, control, and efficiency in industrial automation. [1] focused on optimizing gantry scheduling in multi-gantry production systems, using an online task allocation method to improve throughput and reduce idle times in high-speed environments. [2] introduced back stepping boundary control for gantry crane systems, enhancing stability and robustness against disturbances and load variations. [3] proposed a composite approach for high-speed and high-precision positioning in dual-drive gantry systems, optimizing the positioning accuracy required for complex tasks. [4] applied global iterative sliding mode control to biaxial gantry systems, improving precision and reliability in contouring motion tasks. [5] focused on precision coordinated control of gantry multi-axis systems, addressing coupled dynamics and ensuring prescribed performance for complex industrial operations. [6] explored the modelling and synchronized control of dual-drive gantries, introducing composite adaptive feedforward and RISE feedback mechanisms to optimize performance under changing load conditions. [7] presented a customized gantry pick-and-place system for the forging industry, emphasizing the importance of tailored solutions for specialized tasks. [8] contributed to boundary output feedback control in gantry crane systems, utilizing a back stepping approach to ensure system stability and efficiency. These advancements reflect the ongoing integration of sophisticated control strategies and sensor technologies, enhancing the

   performance of gantry systems in diverse manufacturing and industrial applications. [9] Gantry scheduling research focuses on using smart techniques like online task allocation and reinfrcement learning to streamline operations and boost productivity. By analysing disruptions with mathematical models, it aims to improve efficiency, reduce delays, and enhance overall industrial performance.. [10] Research on PLC control systems for large gantry planers highlights the role of variable-frequency drives in boosting precision and efficiency. Douzhang Dings study emphasizes energy- saving, reliable automation and engineering techniques that enhance machining processes and overall performance effectively. [11Research on low-cost Cartesian robots focuses on making pick-and-place tasks efficient and affordable. Canales et al. showcase innovative, cost-effective designs that maintain functionality, enabling practical automation in limited-resource environments and expanding access to robotics for diverse applications. [12] Research on H-Gantry automation systems highlights the use of advanced electrical systems to improve manufacturing. H. N. Srinivasa Nayaka et al. focus on automating double-disc front brake production, emphasizing precision, adaptability, and efficiency in industrial processes.. [13] Research on adaptive boundary control for gantry crane systems explores ways to tackle uncertainties and disturbances. L. Ma and X. Lou focus on innovative control strategies to boost stability and efficiency, ensuring reliable operation in dynamic environments. [14] Research on dual-drive gantry systems focuses on advanced control designs to enhance precision and performance. W.-A. Chen et al. emphasize innovative strategies to overcome synchronization challenges, improving efficiency and reliability for industrial and automated applications.

3. DESIGN

   The design of an XYZ gantry pick-and-place system controlled by a Programmable Logic Controller (PLC) entails the precise coordination of movements across three axes (X, Y, and Z) to ensure accurate object manipulation. The X and Y axes control the horizontal and vertical movements, respectively, while the Z-axis manages up-and-down motions for optimal object handling. The PLC serves as the central controller, executing ladder logic to operate motors, actuators (such as grippers or suction cups), and sensors, including limit switches and proximity sensors. These components work in unison to guarantee precise positioning and to prevent collisions during operation.

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   Fig.2.CAD design model

   International Journal of Engineering Research & Technology (IJERT)

   ISSN: 2278-0181

   Vol. 14 Issue 04, April-2025 interface, which may include command-line instructions or a graphical user interface (GUI).The main component, a Programmable Logic Controller (PLC), processes these inputs and controls every aspect of the system, including communication with the gripper, motor drives, and sensors.

   Stepper or servo motors that enable rotational and linear motion along the X, Y, and Z axes are controlled by motor drives. The controller receives real-time output from position monitoring sensors like encoders or linear scales, and a pneumatic or servo-driven gripper performs accurate pick- and-place operations. Strong performance is guaranteed under a range of operational circumstances thanks to this tiered integration. In order to compute and reach the intended locations, the system is mathematically using both forward and inverse kinematics. Using the following formulas, forward kinematics determines the gripper’s location in

   The system’s functionality is initiated by a start button, which prompts the gantry to navigate to the target object. Once positioned, the gripper is lowered to pick up the object, after which the system transports it to a predefined location and releases it. The ladder diagram integrates motor control, axis synchronization, and sensor feedback, ensuring smooth and efficient operation. Safety features, such as emergency stop switches and overload protection mechanisms, are incorporated into the design to mitigate the risk of malfunctions and ensure safe operation. Overall, this automated pick-and-place system is designed for high precision and efficiency, making it well-suited for industrial applications that demand rapid and accurate handling of objects.

   Cartesian coordinates based on joint displacements using the equation

   X=L cos() + L cos(+) (1)

   Y= L cos() + L cos(+) (2) Z=d (3)

   Here, L1 and L2 represent link lengths,theta1 and theta2 are joint angles, and d3 is the linear displacement along the Z- axis. Conversely, inverse kinematics computes the required joint variables to reach a target position X, Y, Z using

   2 1 1 2

    

   2+222

   = ( ) (4)

   212

4. METHODOLOGY

   1

   1( 2 sin(2) ) (5)

   1 =

    

   The methodology for designing and implementing the XYZ

   ( )

   +

   cos( )

   gantry system is structured into several key stages. These include system architecture, kinematic modelling, control algorithm design, trajectory planning, and error correction. Each stage integrates hardware and software components to achieve precise and coordinated motion, ensuring efficiency and accuracy in industrial automation tasks. This comprehensive approach ensures the system can meet the high

   1 2 2

   3 =

   This mathematical framework enables accurate calculations for multi-axis coordination, which is critical for precise pick- and-place operations. The control algorithm employs a Proportional-Integral-Derivative (PID) controller to minimize positional errors. The control law is

   demands of modern manufacturing processes.

   u(t)=Ke(t) + K () + ()

   (6)

   where e(t) represents the positional error between the desired and actual positions, and Kp, Ki, Kd are the proportional, integral, and derivative gains, respectively. The algorithm continuously updates feedback and control signals to ensure accurate motion. This real-time feedback loop guarantees high responsiveness and minimizes deviations even under varying load conditions. Trajectory planning is implemented using a trapezoidal velocity profile to ensure smooth and efficient motion. During the acceleration phase, velocity and displacement are defined as:

   • Acceleration phase

   Fig.3.Block Diagram

   Fig. 3 shows the system architecture. The XYZ gantry system is made up of a number of interdependent parts. The target coordinates are specified by the user through an easy-to-use

   v(t)=a ,

   () =

   1

   2

   2 (7)

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   • Constant velocity phase

     v(t)= , x(t)= (8)

   • Deceleration phase

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   ISSN: 2278-0181

   Vol. 14 Issue 04, April-2025

   v(t)=

   max , ()=

   – 1 a2 (9)

   2

   This ensures a balance between speed and precision. The trajectory planning algorithm is optimized for efficiency, reducing energy consumption while maintaining smooth transitions between acceleration and deceleration phases. Real-time feedback and error correction are achieved using position monitoring sensors. The sensors provide continuous data to the controller, which compares the feedback with the desired positions to calculate positional errors. The controller adjusts the control signals to correct these errors, maintaining

   high precision and repeatability in operations. Additionally, adaptive control strategies can be employed to handle dynamic changes in system parameters or external disturbances, frther enhancing the reliability of the system. The energy consumption of the system is calculated to evaluate its efficiency. The total energy consumed is given by: E = P * t (10)

   where E is the energy in Joules, P is the power of the motors in Watts, and t is the duration of operation in seconds. Energy efficiency is a critical factor in modern industrial systems, and the XYZ gantry system is designed to minimize power usage without compromising performance. Additional measures, such as regenerative braking and optimized motor configurations, can further enhance energy efficiency.

   This methodology outlines the design, control, and operational principles of the XYZ gantry system, emphasizing its precision, efficiency, and scalability for modern industrial automation. By integrating advanced mathematical modelling, robust control algorithms, and energy-efficient designs, the system offers a reliable and cost-effective solution for various industrial applications.

5. GRIPPER MECHANISM

   The 2-fingered gear-type gripper utilizes an SG5010 servo motor, which is controlled by a separate Arduino microcontroller and powered by an independent 4V/6V power module. The servo motor drives the gear mechanism, providing precise control over the grippers finger movement and ensuring accurate opening and closing actions for secure object grasping. The Arduino microcontroller plays a pivotal role in adjusting the gripping force and position according to the specific task requirements, leveraging real-time feedback from sensors or pre-programmed logic. This configuration allows for highly flexible and independent control of the gripper, making it ideal for automated pick-and-place tasks where precision and reliability are crucial. Additionally, the separation of the grippers control system from the primary robotic or gantry system enhances its adaptability, enabling seamless integration into larger automated workflows without compromising performance.

   Fig .4. Gripper

6. VISUALIZATION AND HMI

   In this system, the Human-Machine Interface (HMI) serves as a vital connection between user inputs and the Programmable Logic Controller (PLC), facilitating real-time monitoring and control of the gantry system. The HMI interface provides operators with essential operational data, such as the current floor position, the status of buttons pressed, and the operational condition of the motor, allowing for efficient tracking of the systems performance. This display helps users quickly assess the state of the system and make informed decisions. Additionally, the HMI allows for interaction through the lift box’s internal switch panel, enabling operators to input commands such as calling the lift or resetting the system. An emergency stop button is incorporated into the interface, which can immediately halt the system in case of any malfunction or emergency situation, ensuring the safety of both the machine and its surroundings. The systems design ensures that the HMI provides an intuitive and user-friendly interface that enhances the control, safety, and efficiency of the gantry systems operation.

7. APPLICATIONS

   The XYZ gantry system, when integrated with a Programmable Logic Controller (PLC), plays a crucial role in enhancing automation across various industrial sectors. In manufacturing, it is employed for tasks such as material handling, assembly, and CNC machining, where precision and coordination across the three axes (X, Y, and Z) are vital. The PLC acts as the central controller, synchronizing motor and actuator movements based on real-time input from sensors like encoders and proximity detectors. This intelligent control enables tasks such as picking, placing, and manipulating objects with high accuracy, improving productivity, quality control, and reducing material costs. Additionally, the flexibility of real-time adjustments to movement paths and sequences through PLC programming allows the system to adapt to a wide range of tasks and industries.

   Furthermore, the integration of proximity sensors and advanced control strategies enhances the gantry systems performance, enabling it to navigate complex environments

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   International Journal of Engineering Research & Technology (IJERT)

   ISSN: 2278-0181

   Vol. 14 Issue 04, April-2025

   	Axis Systems With Coupled Dynamics and Prescribed Performance	g coupled dynamics and ensuring prescribed performan ce			ted control
   6	Modelling and Synchronized Control of a Dual-Drive Checkerboar d Gantry	Dual-drive gantry control using adaptive feedforwar d and RISE feedback techniques .	Synchron ized Control	±0.01 mm	Effective synchron ized control
   7	A Customised Gantry Pick and Place System for Forging Industries	Customize d design and implement ation of gantry systems for pick- and-place operations in forging.	Customis ed System	±0.1 mm	Custom solution for specific industry needs
   8	Boundary Output Feedback Control for A Class of Gantry Crane Systems via Back stepping Approach	Boundary output feedback control using a back stepping approach for gantry crane systems.	Output Feedback Control	Not Specifi ed	Enhance d boundar y control
   9	Gantry Scheduling for Multi- Gantry Production System by Online Task Allocation Method	Online task allocation for enhancing gantry production efficiency.	Online Task Allocatio n	Not Applic able	Effective scheduli ng for increase d producti vity
   10	PLC control system design of large gantry planer based on variable- frequency drives	Design of a PLC- based control system employing variable- frequency drives for large gantry planers.	PLC Control	±0.05 mm	Improve d control system design
   11	XYZ Gantry: A PLC-Based Automated Pick-and- Place Robot for Precision Ha ndling	The XYZ Gantry involves designing, program ming, and deploying a precision PLC system.	PLC Control	±0.1 mm	Improve d control system design and user friendly system

    

   while avoiding obstacles and ensuring safety. In high-speed applications, such as automated warehouses or assembly lines, the PLC-controlled XYZ gantry system maintains efficiency and precision even with varying load conditions. With built- in safety features, such as emergency stops and overload protection, the system can operate autonomously, reducing the need for human intervention. Overall, the application of the XYZ gantry system in automation not only boosts operational efficiency but also contributes to sustainability by optimizing energy use and minimizing waste, making it an essential tool in modern industrial and manufacturing processes.

   Table 1: Comparison of existing and proposed methodology

   Sl no	Title </td	Methodol ogy	Controll er	Precisi on	Result
   1	Gantry Scheduling for Multi- Gantry Production System by Online Task Allocation Method	Online task allocation for optimizing gantry scheduling in multi- gantry production systems	Online Task Allocatio n	Not Applic able	Effective scheduli ng for increase d producti vity
   2	Backstopping Boundary Control for a Class of Gantry Crane Systems	Back stepping control methodolo gy for boundary control of gantry crane systems	Back stepping Boundar y Control	Not Specifi ed	Improve d control accuracy and stability
   3	A Composite High-Speed and High- Precision Positioning Approach for Dual-Drive Gantry Stage	Composite control approach combining high- speed and high- precision positionin g for dual- drive gantry.	Composi te High- Speed Positioni ng	±0.01 mm	Enhance d positioni ng speed and precision
   4	Global Iterative Sliding Mode Control of an Industrial Biaxial Gantry System for Contouring Motion Tasks	Iterative sliding mode control for contouring motion in biaxial gantry systems	Sliding Mode Control	±0.02 mm	Improve d contouri ng performa nce
   5	Precision Coordinated Control of Gantry Multi-	Coordinat ed control strategy considerin	Coordina ted Control	±0.005 mm	High- precision coordina

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8. RESULT

   Fig.5.Gantry System

9. CONCLUSION

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   Vol. 14 Issue 04, April-2025

   1. Y. Wan, S. Chen, L. Yuan, C. Zhang, Y. Zhang and G. Yang, “Modeling and Synchronized Control of a Dual-Drive Checkerboard Gantry With Composite Adaptive Feedforward and RISE Feedback,” in IEEE/ASME Transactions on Mechatronics, vol. 27, no. 4, pp. 2044- 2052, Aug. 2022, doi: 10.1109/TMECH.2022.3171858
   2. S. Ranaganathan , M. Saravanabalaji and V. Athappan, “A Customised Gantry Pick and Place System for Forging Industries,” 2021 International Conference on Advancements in Electrical, Electronics, Communication, Computing and Automation (ICAECA), Coimbatore, India, 2021, pp. 1-4, Doi : 10.1109/ICAECA52838.2021.9675788
   3. Y. Wen, X. Lou and B. Cui, “Boundary Output Feedback Control for A Class of Gantry Crane Systems via Backstepping Approach,” 2021 China Automation Congress (CAC), Beijing, China, 2021, pp. 4030- 4035, Doi: 10.1109/CAC53003.2021.9728393.
   4. X. Ou, Q. Chang, N. Chakraborty and J. Wang, “Gantry Scheduling for Multi-Gantry Production System by Online Task Allocation Method,” in IEEE Robotics and Automation Letters, vol. 2, no. 4, pp. 1848-1855, Oct. 2017, doi: 10.1109/LRA.2017.2710259.
   5. Douzhang Ding, “PLC control system design of large gantry planer based on variable-frequency drives,” 2011 Second International Conference on Mechanic Automation and Control Engineering, Hohhot, 2011, pp. 4234-4237, doi: 10.1109/MACE.2011.5987938.
   6. L. F. A. Canales, D. M. Hernandez and F. Núñez, “A Model-Based

      Low-Cost Autonomous Pick-and-Place Cartesian Robot,” 2023 IEEE Central America and Panama Student Conference (CONESCAPAN),

      The XYZ gantry system is a critical innovation in industrial

      automation, offering key advantages in precision, efficiency, flexibility, and scalability. Its ability to automate tasks across three axes improves productivity, reduces costs, and enhances product quality in industries such as manufacturing, 3D printing, CNC machining, and material handling. By minimizing human intervention in repetitive tasks, the system ensures consistent output and accuracy, helping manufacturers meet stringent production standards Additionally, the XYZ gantry system fosters socio-economic growth by creating skilled job opportunities and enabling small and medium-sized enterprises to access advanced automation technology, thereby enhancing global competitiveness. It also contributes to sustainability by reducing material waste and optimizing energy usage. Ultimately, the XYZ gantry system is essential for advancing industrial automation, driving innovation, and supporting eco- friendly manufacturing practices, positioning it as a key factor in shaping the future of global manufacturing.

10. REFERENCES

1. X. Ou, Q. Chang, N. Chakraborty and J. Wang, “Gantry Scheduling for Multi-Gantry Production System by Online Task Allocation Method,” in IEEE Robotics and Automation Letters, vol. 2, no. 4, pp. 1848-1855, Oct. 2017, doi: 10.1109/LRA.2017.2710259B.
2. Y. Wen, X. Lou, W. Wu and B. Cui, “Backstepping Boundary Control for a Class of Gantry Crane Systems,” in IEEE Transactions on Cybernetics, vol. 53, no. 9, pp. 5802-5814, Sept. 2023, doi: 10.1109/TCYB.2022.3188494
3. W. Sun, J. Liu and H. Gao, “A Composite High-Speed and High- Precision Positioning Approach for Dual-Drive Gantry Stage,” in IEEE Transactions on Automation Science and Engineering, vol. 22, pp. 2514-2525, 2025, doi: 10.1109/TASE.2024.3380646
4. W. Wang, J. Ma, Z. Cheng, X. Li, C. W. d. Silva and T. H. Lee, “Global Iterative Sliding Mode Control of an Industrial Biaxial Gantry System for Contouring Motion Tasks,” in IEEE/ASME Transactions on Mechatronics, vol. 27, no. 3, pp. 1617-1628, June 2022, doi: 10.1109/TMECH.2021.3096601
5. P. Shi, X. Yu, J. Qin and W. Sun, “Precision Coordinated Control of Gantry Multi-Axis Systems With Coupled Dynamics and Prescribed Performance,” in IEEE Robotics and Automation Letters, vol. 10, no. 3, pp. 2638-2645, March 2025, doi: 10.1109/LRA.2025.3533456.

Guatemala, Guatemala, 2023, pp. 128-133, doi: 10.1109/CONESCAPAN60431.2023.10328435.

1. H. N. Srinivasa Nayaka, S. Nalinakshan, M. S. G. Prasad, V. Y and A. Venkatesh, “Design and Implementation of Electrical system in H- Gantry automation for Double Disc Front Brake,” 2023 International Conference on Recent Trends in Electronics and Communication (ICRTEC), Mysore, India, 2023, pp. 1-6, Doi : 10.1109/ICRTEC56977.2023.10111880
2. L. Ma and X. Lou, “Adaptive Boundary Control of a Gantry Crane System with Parametric Uncertainty,” 2021 China Automation Congress (CAC), Beijing, China, 2021, pp. 4391-4395,Doi

   :10.1109/CAC53003.2021.9728710

3. W. -A. Chen, C. -Y. Chung and M. -T. Ho, “Control Design and Implementation of the Dual-Drive Gantry System,” 2023 International Automatic Control Conference (CACS), Penghu, Taiwan, 2023, pp. 1- 6,Doi : 10.1109/CACS60074.2023.10326207

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