Advanced Manufacturing Industrial Robots

1. Advanced ManufacturingIndustrial Robots Dr. L. K. Gaafar This presentation uses information from: http://www.glue.umd.edu/~aksamuel/academic/Viewgraph_files/frame.htm

2. Industrial Robots Definition A robot is a programmable arm simulator “A robot is a programmable, multifunction manipulator designed to move material, parts, tools, or special devices through variable programmed motions for the performance of a variety of tasks” Robot Institute of America

3. The Advent of Industrial Robots Motivation for using robots to perform task which would otherwise be performed by humans. • Safety • Efficiency • Reliability • Worker Redeployment • Cost reduction

4. Main Components of Industrial Robots – Arm or Manipulator – End effectors – Drive Mechanism – Controller – Custom features: e.g. sensors and transducers

5. Arm or Manipulator • The main anthropomorphic element of a robot. • In most cases the degrees of freedom depends on the arm • The work volume or reach mostly depends on the functionality of the Arm

6. End Effectors Device attached to the robot’s wrist to perform a specific task Grippers – Mechanical Grippers– Suction cups or vacuum cups– Magnetized grippers– Hooks– Scoops (to carry fluids)

7. End Effectors Device attached to the robot’s wrist to perform a specific task Tools – Spot Welding gun– Arc Welding tools– Spray painting gun– Drilling Spindle– Grinders, Wire brushes– Heating torches

8. Sensors in robotics Types of sensors : – Tactile sensors (touch sensors, force sensors, tactile array sensors) – Proximity and range sensors (optical sensors, acoustical sensors, electromagnetic sensors) – Miscellaneous sensors (transducers and sensors which sense variables such temperature, pressure, fluid flow, thermocouples, voice sensors) – Machine vision systems

9. Sensors in robotics Uses of sensors: – Safety monitoring – Interlocks in work cell control – Part inspection for quality control – Determining positions and related information about objects

10. Sensors in robotics Desirable features of sensors: Accuracy Operation range Speed of response Calibration Reliability Cost and ease of operation

11. Physical Configuration Cylindrical Cartesian

12. Physical Configuration Polar(Spherical) Jointed Arm

13. Programming Robots •Manual Cams, stops etc •Walkthrough (Lead-through) Manually move the arm, record to memory • Manual teachingTeach pendant • Off-line programming Similar to NC part programming VAL, RAPT

14. Applications • Material Handling/Palletizing• Machine Loading/Unloading• Arc/Spot Welding• Water jet/Laser cutting• Spray Coating• Gluing/Sealing• Investment casting• Processing operations• Assembly• Inspection

15. Performance Specifications of Industrial Robots •Motion control– path control– velocity control •Types of drive motors– hydraulic– electric– pneumatic •Size of the working envelope • Precision of movement– Control resolution– Accuracy– Repeatability •Lifting capability •Number of robot axes •Speed of movement– maximum speed– acceleration/deceleration time

16. Work Volume Spatial region within which the end of the robot’s wrist can be manipulated Determined by – Physical configurations – Size – Number of axes – The robot mounted position (overhead gantry, wall- mounted, floor mounted, on tracks) – Limits of arm and joint configurations – The addition of an end-effector can move or offset the entire work volume

17. Spatial Resolution Smallest increment of motion at the wrist end that can be controlled by the robot Depends on the position control system, feedback measurement, and mechanical accuracy

18. Accuracy Capability to position the wrist at a target point in the work volume • One half of the distance between two adjacent resolution points • Affected by mechanical Inaccuracies • Manufacturers don’t provide the accuracy (hard to control)

19. Repeatability Ability to position back to a point that was previously taught • Repeatability errors form a random variable. • Mechanical inaccuracies in arm, wrist components • Larger robots have less precise repeatability values

20. Weight Carrying Capacity • The lifting capability provided by manufacturer doesn’t include the weight of the end effector • Usual Range 2.5lb-2000lb • Condition to be satisfied: Load Capability > Total Wt. of workpiece +Wt. of end effector + Safety range

21. Speed of Movement Speed with which the robot can manipulate the end effector •Acceleration/deceleration times are crucial for cycle time. •Determined by – Weight of the object – Distance moved – Precision with which object must be positioned

22. Motion Control • Path control - how accurately a robot traces a given path (critical for gluing, painting, welding applications); • Velocity control - how well the velocity is controlled (critical for gluing, painting applications) • Types of control path: - point to point control (used in assembly, palletizing, machine loading); - continuous path control/walkthrough (paint spraying, welding).- controlled path (paint spraying, welding).

23. Type of Drive System • Hydraulic– High strength and high speed– Large robots, Takes floor space– Mechanical Simplicity– Used usually for heavy payloads • Electric Motor (Servo/Stepper)– High accuracy and repeatability – Low cost – Less floor space – Easy maintenance • Pneumatic – Smaller units, quick assembly– High cycle rate – Easy maintenance

24. Robot Location and Workspace 2-link polar robot y Location: L2 q2 (x, y) Workspace: L1 q1 x Positioning:

25. Robot Applications (Configurations/Characteristics) SCARA Robot (Selective Compliance Assembly Robot Arm) Characteristics: •Repeatability: < 0.025mm (high) •No. of axes: min 4 axes • Vertical motions smoother, quicker, precise (due to dedicated vertical axis) • Good vertical rigidity, high compliance in the horizontal plane. •Working envelope: range < 1000mm •Payload:10-100 kg •Speed: fast 1000-5000mm/s Applications: •Precision, high-speed, light assembly

26. Robot Applications (Configurations/Characteristics) Cylindrical Coordinate Robot Characteristics: •Wide range of sizes •Repeatability: vary 0.1-0.5mm •No. of axes: min 3 arm axes (2 linear)•Working envelope: typically large (vertical stroke as long as radial stroke) • The structure is not compact. •Payload: 5 - 250kg •Speed: 1000mm/s, average •Cost: inexpensive for their size and payload Applications: •Small robots: precision small assembly tasks •Large robots: material handling, machine loading/unloading.

27. Robot Applications (Configurations/Characteristics) Vertical Articulated Arm Robot Characteristics: •Repeatability: 0.1-0.5mm (large sizes not adequate for precision assembly) •No. of axes: 3 rotary arm-axes, 2-3 additional wrist axis (excellent wrist articulation) •Working envelope: large relative to the size, Structure compact, but not so rigid •Payload: 5-130kg •Tool tip speed: fast 2000mm/s Applications: Welding, painting, sealing, deburring, and material handling

28. Robot Applications (Configurations/Characteristics) Spherical Coordinate Robot Characteristics: •Repeatability: poor 0.5-1mm •No. of axes: 3 arm-axes (1 linear radial), 1-2 additional wrist-axes. •Working envelope: large vertical envelope relative to the unit size •Payload: 5-100 kg •Speed: low (linear motions are not smooth and accurate- require coordination of multiple axes) Applications: Material handling, spot welding, machineloading

29. Robot Applications (Configurations/Characteristics) Cartesian Coordinate Robot Characteristics: •Repeatability: high (0.015-0.1) •No. of axes: 3 linear arm-axis, •Working envelope:relative large •Payload:5- 100kg •Speed: fast Applications: Precise assembly, arc welding, gluing, material handling

30. Robot Applications (Configurations/Characteristics) Gantry Robot Characteristics: •Repeatability: 0.1-1mm •No. of axes: 3 linear traverse-axes, 1-3 additional wrist axes •Working envelope: very large •Payload: vary function of size, support very heavy 10-1000kg •Speed: low for large masses Applications: Handling very large parts, moving material on long distances, welding, gluing.

31. What to Automate • Simple Repetitive operations. • Cycle times greater than 5s. • Parts can be delivered in proper locations/orientation. • Part weight is suitable.• One or two persons can be replaced in 24 hr period. • Setups and changeovers are not frequent.

32. Robot Implementation Planning Identify Objectives (Benefits) • Increase productivity • Reduce labor cost • Reduce cycle time • Eliminate undesired jobs• Safety reasons: protect from exposure to hazardous conditions • Increase product quality

33. Robot Implementation Planning •Consider Drawbacks • The impact upon the workers • The impact upon production schedule and maintenance • Questions of potential model changes or process changes

34. Robot Implementation Planning Fixed versus Flexible Automation Fixed automation: ExpensiveCan become obsolete early (dedicated for a single task)Large inventoriesDifficulties in commissioning and high maintenance costsFaster and more accurate Flexible (robot) automation:Reprogrammable for different tasksQuick to commissionEasy to maintainCheaper to design.