Robots on the Job Floor

Presented by: Daniel Galel, Matthew Hibbard, Brian Keating, and Elisabeth Kjellberg November 24th, 2009

Agenda
History of Robots on the Job floor General Advantages and Disadvantages of Robots Overview of Robotic Programming, Classification, and Terms Robotics in Electronics and on the Cutting Edge Robotics on the Food Production Job Floor

What is a Industrial Robot?

An automatically controlled, reprogrammable, multipurpose manipulator programmable in three or more axes, which may be either fixed in place or mobile for use in industrial automation applications. As Defined by ISO 8373

Agenda
History of Robots on the Job floor
History of the robotic Industry Overview of how robots work

General Advantages and Disadvantages of Robots Overview of Robotic Programming, Classification, and Terms Robotics in Electronics and on the Cutting Edge Robotics on the Food Production Job Floor

History
Multiple forms of automation
Fixed automation Flexible automation Programmable automation

History
First installation in 1961 Major uptake in 1980s Hydraulic-servo systems Slew of problems
Did not understand technology Reliability Accuracy Hazardous

History
Parabolic Growth in 1980s Advancements made in late 1980s
New control technology Smaller robots New drive systems

Growth in food processing, packaging

History
Drive Systems
Hydraulic Hydraulic-servo Pneumatic D/C Servo Brushless D/C Servo A/C Servo

History
Drive Systems
Stepper drive Linear Motor

Agenda
History of Robots on the Job floor General Advantages and Disadvantages of Robots
Advantages of implementing a robot Challenges facing incorporating robots into your plan

Overview of Robotic Programming, Classification, and Terms Robotics in Electronics and on the Cutting Edge Robotics on the Food Production Job Floor

Advantages
Accuracy Repeatability Flexibility
Basis for modern flexible manufacturing

Safety
Painting Welding Toxins

Advantages
Ergonomics
Repetitive motion injury Exhaustion

Cleanliness
Clean rooms Food and Drugs Electronics Human Genome

Disadvantages
Little R&D High Costs Hydraulics
Kinks, leaks

Union opposition

Agenda
History of Robots on the Job floor General Advantages and Disadvantages of Robots Overview of Robotic Programming, Classification, and Terms
Robotic Software Robotic Terms Cost

Robotics in Electronics and on the Cutting Edge Robotics on the Food Production Job Floor

Foundations of Robots
Robot software Instructions that control the robots actions Dataflow language most often used Software for industrial robots consists of program flow

Examples
Move to P1 (a general safe position) Move to P2 (an approach to P3) Move to P3 (a position to pick the object) Close gripper Move to P4 (an approach to P5) Move to P5 (a position to place the object) Open gripper Move to P1 and finish VAL PROGRAM PICKPLACE 1. MOVE P1 2. MOVE P2 3. MOVE P3 4. CLOSEI 0.00 5. MOVE P4 6. MOVE P5 7. OPENI 0.00 8. MOVE P1 .END

ROBOFORTH : PICKPLACE P1 P3 GRIP P5 UNGRIP P1 ;

Foundations Cont.
Parallelism and event-based programming Safety Considerations
whenever(face.visible) { headPan.val += camera.xfov * face.x & headTilt.val += camera.yfov * face.y }

Robotic Terminology
Robots Broken Down By Mechanical Structure

Cartesian (Gantry) Robot

SCARA Robot

Articulated Robot

Parallel Robot

Robots Broken Down By Control Types

Sequence Controlled Robot Trajectory Operated Robot Adaptive Robot Teleoperated Robot

Types of Robots in Industry

Welding - 1961 Spray Painting Assembly Operations - 1973 Palletizing and Material Handling - 1963

Cost
Typical stand-alone robot arms with welding packages cost between $28,000 and $40,000. A six-axis robot (below) costs about $60,000 Developing the robot costs another $200,000

Agenda
History of Robots on the Job floor General Advantages and Disadvantages of Robots Overview of Robotic Programming, Classification, and Terms Robotics in Electronics and on the Cutting Edge
Economic Effects Expanding and Existing Markets Expanding Technology

Robotics on the Food Production Job Floor

Economic Effects
Robotics development slows rapidly and starts slowly as economic conditions worsen
Recessions in 2001 and 2008

Drastic drop in price and cost of robots and robotic components in recent years Robots decreased in cost by 60% between 1993 and 2003

Existing Markets
Automotive markets in the U.S. are saturated
Expansion in Asian automotive markets

Small part assembly also saturated

Need for precision

Expanding Markets
More growth in hazardous work environments Starting to replace hard automation Design for Disassembly Laboratory Automation Medical Device Assembly Pharmaceutical Packaging Food Production

Expanding Technology
PC interface Vision option
Decreased cost Increased effectivness Point and click

Agenda
History of Robots on the Job floor General Advantages and Disadvantages of Robots Overview of Robotic Programming, Classification, and Terms Robotics in Electronics and on the Cutting Edge Robotics on the Food Production Job Floor
Background of Robots in Food Industry Applications in the Food Industry Advantages and Challenges of Robotics in the Food industry Things to consider in Designing a robot for food production

Background of Robots in the Food Industry

Earliest application of robotics in the 1980s
Equipment was expensive

Reasons it failed in the 80s and 90s

Return on Investment used to not be fast enough Lack of technical expertise Concerns about how to clean robots

In 2005 only 1% of the total number of robots in manufacturing facilities were in the food industry

Applications
Traditional Applications Water Jet Cutting Chicken and Fish fillets Placing different parts of the food together Packaging Material Handling More Recent Applications Color and Size inspections

Advantages
Early Typical Driver for Robotics is Labor Savings, but this is not the uniform case for Food Applications
Improved Quality and consistency Harsh Conditions they can work in Their Improved Sanitary Issues

Challenges
Robots are replacing low income workers Cant directly apply robots designed for automotive and electronics Industry due to requirements in the task itself
Tasks require dexterity and sensory feedback Robotic Components are restricted to certain materials

Cutting Edge Applications and Development

Infra Red Quality Control Mechanisms
Measuring the tenderness of meat and freshness of vegetables

Cross Applications
The da Vinci system allows doctors to perform heart surgery remotely, and has been approved by the FDA

Things To Consider While Designing a Robot for the Food Industry

Design for cleaning from the beginning Use FDA/USDA approved materials
General approved materials do not guarantee acceptance

ANSI/RIA standards

External Resources to Reference

International Federation of Robotics United Nations Economic Commission for Europe regularly surveys the robotics market

Questions?

Works Cited
http://www.sme.org/cgi-bin/findarticles.pl?&03mym006&ME&20030501&&S ME& http://www.ifr.org/industrial-robots/statistics/ http://www.dira.dk/Portals/0/Robotter/robot def.pdf Trends in Food Science & Technology UN World Robotics Report 2003