Industrial Robotics

Contents Introduction, Physical configuration, Basic robot motions, Technical features such as - work volume, precision and speed of movement, weight carrying, capacity, drive system, End effectors, robot sensors. Application Material transfer, machine loading, welding, spray coating, processing operation, assembly, inspection.

Definitions
The word Robot comes from the Czech word Robota, which means Work and Robotnik means Slave . Robot is an automatically controlled material handling unit that is widely used in the manufacturing industry It is an automatically controlled, reprogrammable, multipurpose, manipulative machine with several reprogrammable axes, which either fixed in the place or mobile for use in industrial automation application Robotic Industries Association states that a industrial robot is a re-programmable, multifunctional manipulator designed to move materials, parts, tools, or specialized devices through variable programmed motions to perform a variety of tasks.

Industrial Robot
A general-purpose, programmable machine possessing certain characteristics Hazardous work environments Repetitive work cycle Consistency and accuracy Difficult handling task for humans Multishift operations Reprogrammable, flexible Interfaced to other computer systems

ORIGINE OF ROBOT
In 1738 Jacques de Vaucanson builds a mechanism made of more that 4,000 parts. The duck could quack, bathe, drink water, eat grain, digest it an void it.

In 1805, Doll, made by Maillardet, that wrote in either French or English and could draw landscapes.

 From 1950 to 1960 : Computer technology advances and control machinery is developed. Questions Arise: Is the computer an immobile robot? -Robotic Industries Association states that a industrial robot is a re-programmable, multifunctional manipulator designed to move materials, parts, tools, or specialized devices through variable programmed motions to perform a variety of tasks.

 1956 - Researchers aim to combine perceptual and problem-solving capabilities, using computers cameras, and touch sensors. The idea is to study the types of intelligent actions. 1960- Shakey is made at Stanford Research Institute International. It contained a television camera, range finder, on-board logic, bump sensors, camera control unit, and an antenna for a radio link. Shakey was controlled by a computer in a different room.

The Categories Are..

Control Mechanisms Mechanics Sensors

Motion Planning
Perception Computer Science

Electrical Engineering
Mechanical Engineering

Combining these fields we can create a system that can

SENSE PLAN ACT

ADVANTAGES OF ROBOT
Robotics and automation can, in many situation, increase productivity, safety, efficiency, quality, and consistency of products Robots can work in hazardous environments Robots need no environmental comfort Robots work continuously without any humanity needs and illnesses Robots have repetable precision at all times Robots can be much more accurate than humans, they may have mili or micro inch accuracy. Robots and their sensors can have capabilities beyond that of humans

 Robots can process multiple stimuli or tasks simultaneously, humans can only one. Robots replace human workers who can create economic problems

DISADVANTAGES OF ROBOT
Robots lack capability to respond in emergencies, this can cause: Inappropriate and wrong responses A lack of decision-making power A loss of power Damage to the robot and other devices Human injuries Robots may have limited capabilities in Degrees of Freedom Sensors Vision systems Real-time Response

 Robots are costly, due to Initial cost of equipment Installation Costs Need for training Need for Programming

Robot Anatomy
Manipulator consists of joints and links Joint3 Joints provide relative motion Links are rigid members between joints Various joint types: linear and rotary Each joint provides a degree-offreedom Link1 Most robots possess five or six degrees-of-freedom Robot manipulator consists of two Joint1 sections: Body-and-arm for positioning of Link0 objects in the robot's work volume Wrist assembly for orientation of objects
Link3 End of Arm

Link2

Joint2

Base

Manipulator Joints
Translational motion Linear joint (type L) Orthogonal joint (type O)

Rotary motion Rotational joint (type R) Twisting joint (type T) Revolving joint (type V)

Joint Notation Scheme

Uses the joint symbols (L, O, R, T, V) to designate joint types used to construct robot manipulator Separates body-and-arm assembly from wrist assembly using a colon (:) Example: TLR : TR Common body-and-arm configurations

Polar Coordinate Body-and-Arm Assembly

Notation TRL:

Consists of a sliding arm (L joint) actuated relative to the body, which can rotate about both a vertical axis (T joint) and horizontal axis (R joint)

Cylindrical Body-and-Arm Assembly

Notation TLO:

Consists of a vertical column, relative to which an arm assembly is moved up or down The arm can be moved in or out relative to the column

Cartesian Coordinate Body-and-Arm Assembly

Notation LOO:
Consists of three sliding joints, two of which are orthogonal Other names include rectilinear robot and x-y-z robot

Jointed-Arm Robot
Notation TRR:

SCARA Robot
Notation VRO SCARA stands for Selectively Compliant Assembly Robot Arm Similar to jointed-arm robot except that vertical axes are used for shoulder and elbow joints to be compliant in horizontal direction for vertical insertion tasks

Types of motion control

Axis limit Point to Point Component insertion, hole drilling, spot welding. Contouring - Pray painting, finishing arc welding application Link Tracking

Basic Components of Robot

Manipulator - He movement of manipulator is controlled by actuators Controller - Communicate with computer and peripheral devices - To control manipulators movement Power Source - Supply power required for controller and actuators End Effectors

Sensors
Proximity sensors Range sensors Other sensors for specific applications Presence of part in specified region - For closing the gripper to pick up the job - Pressure or forcing sensors - Tactile sensors

Wrist Configurations
Wrist assembly is attached to end-of-arm End effector is attached to wrist assembly Function of wrist assembly is to orient end effector Body-and-arm determines global position of end effector Two or three degrees of freedom: Roll Pitch Yaw Notation :RRT

Example
Sketch following manipulator configurations (a) TRT:R, (b) TVR:TR, (c) RR:T. Solution:
R T R R R V T R R T

T (a) TRT:R

T (b) TVR:TR (c) RR:T

Joint Drive Systems

Electric Uses electric motors to actuate individual joints Preferred drive system in today's robots Hydraulic Uses hydraulic pistons and rotary vane actuators Noted for their high power and lift capacity Pneumatic Typically limited to smaller robots and simple material transfer applications

Robot Control Systems

Limited sequence control pick-and-place operations using mechanical stops to set positions Playback with point-to-point control records work cycle as a sequence of points, then plays back the sequence during program execution Playback with continuous path control greater memory capacity and/or interpolation capability to execute paths (in addition to points) Intelligent control exhibits behavior that makes it seem intelligent, e.g., responds to sensor inputs, makes decisions, communicates with humans

Robot Control System

Cell Supervisor

Level 2

Controller & Program

Level 1

Joint 1

Joint 2

Joint 3

Joint 4

Joint 5

Joint 6

Sensors

Level 0

End Effectors
The special tooling for a robot that enables it to perform a specific task Two types: Grippers to grasp and manipulate objects (e.g., parts) during work cycle Tools to perform a process, e.g., spot welding, spray painting

Gripper
It establish connection between the work piece and robot The tooling must be capable of gripping, lifting and realizing the part The tooling must sense the presence of part in gripper The clamping mechanism used in gripper are as foolows 1. Mechanical clamping 2. Magnetic clamping 3. Vacuum clamping

Type of drive system

Gripper drive Electric drive Stepper motor DC servo motor Pneumatic drive Pneumatic cylinder Compressed air motor Swivel cylinder (Low speed) Hydraulic drive Hydraulic cylinder Hydraulic motor Swivel cylinder (Limited rotation) Drive Movement Rotational Rotational

Linear Rotational Rotational

Linear Rotational Rotational

Grippers and Tools

Work space or work volume

It is a maximum volume that a robot can reach mechanically

Industrial Robot Applications

1. Material handling applications Material transfer pick-and-place, palletizing Machine loading and/or unloading 2. Processing operations Welding Spray coating Cutting and grinding 3. Assembly and inspection

Robot for spray painting

Robotic Arc-Welding Cell

Robot performs flux-cored arc welding (FCAW) operation at one workstation while fitter changes parts at the other workstation

Robot Programming
Leadthrough programming Work cycle is taught to robot by moving the manipulator through the required motion cycle and simultaneously entering the program into controller memory for later playback Robot programming languages Textual programming language to enter commands into robot controller Simulation and off-line programming Program is prepared at a remote computer terminal and downloaded to robot controller for execution without need for lead through methods

Leadthrough Programming
1. Powered leadthrough Common for point-topoint robots Uses teach pendant 2. Manual leadthrough Convenient for continuous path control robots Human programmer physical moves manipulator

Leadthrough Programming Advantages

Advantages: Easily learned by shop personnel Logical way to teach a robot No computer programming Disadvantages: Downtime during programming Limited programming logic capability Not compatible with supervisory control

Robot Programming
Textural programming languages Enhanced sensor capabilities Improved output capabilities to control external equipment Program logic Computations and data processing Communications with supervisory computers

Coordinate Systems

World coordinate system

Tool coordinate system

Motion Commands
MOVE P1 HERE P1 - used during lead through of manipulator MOVES P1 DMOVE(4, 125) APPROACH P1, 40 MM DEPART 40 MM DEFINE PATH123 = PATH(P1, P2, P3) MOVE PATH123 SPEED 75

Interlock and Sensor Commands

Interlock Commands WAIT 20, ON SIGNAL 10, ON SIGNAL 10, 6.0 REACT 25, SAFESTOP Gripper Commands OPEN CLOSE CLOSE 25 MM CLOSE 2.0 N

Simulation and Off-Line Programming

Example
A robot performs a loading and unloading operation for a machine tool as follows:
Robot pick up part from conveyor and loads into machine (Time=5.5 sec) Machining cycle (automatic). (Time=33.0 sec) Robot retrieves part from machine and deposits to outgoing conveyor. (Time=4.8 sec) Robot moves back to pickup position. (Time=1.7 sec)

Every 30 work parts, the cutting tools in the machine are changed which takes 3.0 minutes. The uptime efficiency of the robot is 97%; and the uptime efficiency of the machine tool is 98% which rarely overlap. Determine the hourly production rate.

Solution
Tc = 5.5 + 33.0 + 4.8 + 1.7 = 45 sec/cycle Tool change time Ttc = 180 sec/30 pc = 6 sec/pc Robot uptime ER = 0.97, lost time = 0.03. Machine tool uptime EM = 0.98, lost time = 0.02. Total time = Tc + Ttc/30 = 45 + 6 = 51 sec = 0.85 min/pc Rc = 60/0.85 = 70.59 pc/hr Accounting for uptime efficiencies, Rp = 70.59(1.0 - 0.03 - 0.02) = 67.06 pc/hr

Automation
Basic elements of automated system, Advanced automation functions, levels of automation. Flexible manufacturing system :-Introduction, FMS equipment, FMS application,

Introduction to CIM

INTRODUCTION
Industry
In a general sense the term Industry is defined as follows. Definition: Systematic Economic Activity that could be Manufacture/Service/ Trade.

Automation
The word Automation is derived from greek words Auto(self) and Matos (moving). Automation therefore is the mechanism for systems that move by itself.

Automated systems also achieve significantly superior performance than what is possible with manual systems, in terms of power, precision and speed of operation. Automation is the technology by which a process or procedure is accomplished without human assistance

Definition: Automation
Automation is a set of technologies that results in operation of machines and systems without significant human intervention and achieves performance superior to manual operation Automation can also defined as the technology by which a process or procedure is accomplished without human assistance.

Role of automation in industry

Manufacturing processes, basically, produce finished product from raw/unfinished material using energy, manpower and equipment and infrastructure. Since an industry is essentially a systematic economic activity, the fundamental objective of any industry is to make profit. Roughly speaking, Profit = (Price/unit Cost/unit) x Production Volume (1) So profit can be maximised by producing good quality products, which may sell at higher price, in larger volumes with less production cost and time. Fig shows the major parameters that affect the cost/unt of a massmanufactured industrial product.

Automation and control technologies in the production system

Manufacturing cost /unit

Basic elements of Automation

Power - to accomplish the process and operate the automated system Program of instructions to direct the process Control system to actuate the instructions

Basic Elements of Automation

Power to Accomplish the

Automated Process Power for the process To drive the process itself To load and unload the work unit Transport between operations Power for automation Controller unit Power to actuate the control signals Data acquisition and information processing

Electricity The electric power has many advantages Widely available at moderate cost Can be readily converted to alternative forms, e.g., mechanical, thermal, light, etc. Low level power can be used for signal transmission, data processing, and communication Can be stored in long-life batteries

Program of Instructions
Set of commands that specify the sequence of steps in the work cycle and the details of each step Example: CNC part program During each step, there are one or more activities involving changes in one or more process parameters Examples: - Temperature setting of a furnace - Axis position in a positioning system - Motor on or off

Decision-Making in a Programmed Work Cycle The following are examples of automated work cycles in which decision making is required: Operator interaction - Automated teller machine Different part or product styles processed by the system - Robot welding cycle for two-door vs. four door car models Variations in the starting work units - Additional machining pass for oversized sand Casting

Control System
Two Types 1. Closed-loop (feedback) control system a system in which the output variable is compared with an input parameter, and any difference between the two is used to drive the output into agreement with the input

2. Open-loop control system operates without the feedback loop Simpler and less expensive Risk that the actuator will not have the intended

Types of Automation Systems

Fixed Automation: It is used in high volume production with dedicated equipment, which has a fixed set of operation and designed to be efficient for this set. Continuous flow and Discrete Mass Production systems use this automation. e.g. Distillation Process, Conveyors, Paint Shops, Transfer lines etc.
Programmable Automation: It is used for a changeable sequence of operation and configuration of the machines using electronic controls. e.g. in Steel Rolling Mills, Paper Mills etc.

 Flexible Automation: It is used in Flexible Manufacturing Systems (FMS) which is invariably computer controlled. It is typically used in job shops and batch processes where product varieties are high and job volumes are medium to low.
Integrated Automation: It denotes complete automation of a manufacturing plant, with all processes functioning under computer control and under coordination through digital information processing.

Advanced Automation function

Safety monitoring: Use of sensors to track the system's operation and identify conditions that are unsafe or potentially unsafe Reasons for safety monitoring - To protect workers and equipment Possible responses to hazards: - Complete stoppage of the system - Sounding an alarm - Reducing operating speed of process - Taking corrective action to recover from the safety Violation

 Maintenance and Repair Diagnostics Status monitoring - Monitors and records status of key sensors and parameters during system operation Failure diagnostics - Invoked when a malfunction occurs - Purpose: analyze recorded values so the cause of the malfunction can be identified Recommendation of repair procedure - Provides recommended procedure for the repair crew to effect repairs

 Error Detection and Recovery Error detection functions: - Use the systems available sensors to determine when a deviation or malfunction has occurred - Correctly interpret the sensor signal - Classify the error Error recovery possible strategies: - Make adjustments at end of work cycle - Make adjustments during current work cycle - Stop the process to invoke corrective action - Stop the process and call for help

Levels of Automation
Device level actuators, sensors, and other hardware components to form individual control loops for the next level Machine level CNC machine tools and similar production equipment, industrial robots, material handling equipment Cell or system level manufacturing cell or system Plant level factory or production systems level Enterprise level corporate information system

Advantages of PLC
Flexibility:
One single Programmable Logic Controller can easily run many machines.

Correcting Errors:
In old days, with wired relay-type panels, any program alterations required time for rewiring of panels and devices. With PLC control any change in circuit design or sequence is as simple as retyping the logic. Correcting errors in PLC is extremely short and cost effective.

Space Efficient:
Today's Programmable Logic Control memory is getting bigger and bigger this means that we can generate more and more contacts, coils, timers, sequencers, counters and so on. We can have thousands of contact timers and counters in a single PLC. Imagine what it would be like to have so many things in one panel.

 Low Cost:
Prices of Programmable Logic Controlers vary from few hundreds to few thousands. This is nothing compared to the prices of the contact and coils and timers that you would pay to match the same things. Add to that the installation cost, the shipping cost and so on.

Testing:
A Programmable Logic Control program can be tested and evaluated in a lab. The program can be tested, validated and corrected saving very valuable time

Visual observation:
When running a PLC program a visual operation can be seen on the screen. Hence troubleshooting a circuit is really quick, easy and simple.

Advantages of Automation
Business process integration Repeatability Quality factor Improved productivity Optimization of manufacturing operations Reduction of waste Labor costs reduction