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Benefits of flexible automation Can respond quickly to changes in demand - the equipment can be reprogrammed to perform different functions depending on the current requirements eg: numerically controlled machine tools. May use 'off the shelf' equipment rather than design and build a specialised 'one off'. This usually leads to quicker implementation and is cheaper in the long run eg using a robot as a durability test rig to open and close car doors. Less de-bugging and more reliable than a one off piece of equipment. Any new piece of purpose built equipment is by definition a prototype and there will be some unknown quantities in the way it performs. A commercially available machine like a robot will already have been through various stages of development and should be reliable with good documentation on fault finding if this should be necessary. Disadvantages of flexible automation
Generally slower operating rate than purpose built (dedicated) automation. A dedicated piece of equipment can be designed so that it is optimised to perform the one task. There need not be any compromises in its design or its operation eg a light bulb testing machine. Robots Robots are just one example of flexible automation. Other examples in the industrial sector are NC machine tools, automated assembly machines (including automated component insertion machines), automated guided vehicles (AGV's) automated storage and retrieval systems (ASRS's), co-ordinate measuring machines (CMM's) laser / plasma / water jet cutting machines etc etc. There are many examples of flexible automation that pre-date the term 'robot'. These include Vaucanson's flute playing doll, c 1750; Jacquard's loom, 1801; Maillardet drawing doll, 1805; and there are many others. In all of these cases programs were stored on cams, drums or punched cards which controlled the sequence of movements and the type of movements made. The programs could be changed relatively quickly (a few minutes) but it could take a very long time (weeks / months) to make a new rotating drum for example. The word 'robot' first appeared in 1921 but was not a technical term. It was used by a Czech playwright called Karel Capek in a satirical play called 'Rossums Universal Robots' to describe slave labourers who had their souls removed to make them work harder. In, 1942 Isaac Asimov wrote a short science fiction story in which the word 'robotics' was first used and lit) presented 3 laws of robotics. 1. 2. 3. Robots must not injure humans Robots must obey orders Robots must protect their own existence
Asimov was exploring the possibilities and potential problems of artificial intelligence associated with human-like machine but at the same time engineers were developing mechanical arms which could be controlled remotely by a human operator to carry out hazardous operations at a safe distance. These mechanical arms were referred to as 'teleoperators' but the next major development was to eliminate the human operator and replace them with some form of controller with a memory to allow movements to be repeated without the operator present. This was first done successfully by George Devol who went on to form a company which became the Unimation Corporation whose most famous product was the Unimate robot. The terms 'robot' and robotics' both therefore originated in science fiction and the original perception was one of human-like machines or androids. In popular culture, and particularly in films, robots are often considered to have all the human attributes with some capabilities considerably enhanced over that normally found in humans, but in reality current technology is not yet able to match this vision. There are a variety of definitions of an industrial robot, two of which are as follows: 'A robot is a re-programmable multi-function manipulator designed to move material parts, tools or specialised devices, through variable programmed motions for the performance of a variety of tasks'. (Robotic Institute of America)
'An industrial robot is a re-programmable device designed to both manipulate and transport parts, tools or specialised manufacturing implements through variable programmed motions for the performance of specific manufacturing tasks' (British Robots Association) The vast majority of industrial robots are mechanical arms attached to a fixed base, with some form of programmable control for automatic execution of motion. This is simply because a market exists for such products and current technology is able to provide a product with acceptable performance at an affordable price. A feature which is currently possible but not yet widely used is mobility. Mobility can be provided by the use of wheels, tracks, or legs and a mobile robot may be concerned more with transportation than with manipulation and so may not carry an arm (or manipulator). Mobility requires an ability to navigate and to plan paths around obstacles in an environment where the position of obstacles is unknown. The level of performance of mobile robots is currently poor and the cost is prohibitive for all but highly specialised applications, eg decommissioning or maintaining nuclear power plant.
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ANATOMY OF A ROBOT
BASIC COMPONENTS OF INDUSTRIAL ROBOTS o An industrial robot has three types of components : 1. Physical parts or anatomy 2. Built-in instructions or instinct (placed there by the manufacturer) 3. Learned behaviour or task programs (on-the-job training).
WHAT IS A JOINT? o o
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A joint of an industrial robot is similar to a joint in the human body. Each joint gives the robot with a degree-of-freedom (d.o.f) of motion. In nearly all cases, only 1 d.o.f is allowed to a joint. However, future robots may be designed with joints having more than 1 d.o.f each. Robots are often identified according to the total number of d.o.f they possess, such as a 6 degree-of-freedom robot.
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WHAT IS A ROBOT LINK ? o o Links are rigid components that form a chain connected together by joints, Each joint has two links, known as an input link and an output link.
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The purpose of the joint is to provide controlled relative movement between the input link and the output link. Nearly all industrial robots have mechanical joints that can be classified into one of five types.
o They include two types that provide linear motion and three types that provide rotary motion. o Each of the joints have a range over which it can be moved. The five joint types illustrated in the figures below are:
1. Linear joint. The relative movement between the input link and the output link is a linear sliding motion, with the axes of the two links being parallel.
2. Orthogonal joint. This is also a linear sliding motion, but the input and output links are perpendicular to each other during the move.
3. Rotational joint. This type provides a rotational relative motion of the joints, with the
axis of rotation perpendicular to the axes of the input and output links.
4. Twisting joint. This joint also involves a rotary motion, but the axis of rotation is parallel
5. Revolving joint. In this type, the axis of the input link is parallel to the axis of rotation of
the joint, and the axis of the output link is perpendicular to the axis of rotation.
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Most robots are mounted on a stationary base on the floor. We will call it as robot base and its connection to the first joint as link 0. It is the input link to Joint 1, the first in the series of joints used in the construction of the robot. The output link of joint 1 is link 1. Link 1 is the input link to joint 2, whose output link is link 2, and so on. This joint-link numbering, scheme is shown below.
Stop at extreme o Medium technology Pick-and-place Material handling 4 to 6 axes o High technology Material handling Pick-and-place Loading and unloading Painting and welding 6 to 9 axes
Disadvantage: Can only reach in front of itself Requires large floor space for size of work envelop Axes hard to seal
Figure: (a) A Cartesian or rectangular coordinate arm. (b) The box shaped work envelope within which a Cartesian coordinate manipulator operates (c) An overhead crane. Its movement is similar to those of a Cartesian coordinate arm
Disadvantages: Cannot reach above itself Base rotation axis is less rigid than a linear axis Linear axes hard to seal Will not reach around obstacles Horizontal motion is circular
Figure: (a) A cylinder coordinate arm. It rotates about the base, moves in and out, and moves up and down. (b) The space between the two cylinders shown is the work envelop occupied by a cylindrical coordinates manipulator (c) A construction crane on top of a tall building. Its movement are similar to those of a cylindrical coordinates manipulator.
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Figure: (a) A polar or spherical coordinate manipulator. It rotates about the base and about the shoulder and moves linearly in and out (b) The work envelop for a polar-coordinates manipulator is the space between the two hemispheres (c) A ladder on a hook and ladder truck has movement similar to those of a polar coordinates manipulator
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Figure: (a) A SCARA manipulator. It rotates in two axes in the horizontal plane and moves linearly up and down (b) The work envelope for the SCARA manipulator is the space between the two cylinders. The SCARA manipulator can reach around obstacles. (c) A folding lamp has movements similar to those of a SCARA manipulator
Revolute manipulator is also called articulated or anthromorphic manipulator. These type of robot resembles human arm. Two common revolute designs are the elbow type manipulator such as the PUMA and the parallelogram linkage such as the Cincinnati Milacron T3 735. The elbow type configuration provides relatively large freedom of movement in a compact space. The parallelogram linkage configuration, although less dextrous typically than the elbow manipulator structure, nevertheless has several advantages that make it an attractive and popular design.
Advantages: 3 rotating, axes Can reach above or below obstacles Largest work area for least work space Two or four ways to reach a point Disadvantages: Difficult to program off-line The most complex manipulator
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Electric Drive Small and medium size robots are usually powered by electric drives via gear trains using servomotors and stepper motors. Most commonly used are dc motors, although for larger robots, ac motors may be utilised. Advantages Better accuracy & repeatability Require less floor space More towards precise work such as assembly applications Disadvantages Generally not as speedy and powerful as hydraulic robots Expensive for large and powerful robots, can become fire hazard There is now a trend towards designing, robot with all electric drives. A new design based on direct drives (without gear trains) is being developed.
o Hydraulic Drive
Larger robots make use of hydraulic drives. Hydraulic drive system can provide Advantages: more strength-to-weight ratio can also actuate at a higher speed rotational motion (rotary vane actuators) and linear motion (hydraulic pistons).
Disadvantages: Requires more floor space Tendency to oil leakage. There is now a trend towards designing robot with all electric drives. A new design based on direct drives (without gear trains) is being developed.
Pneumatic Drive For smaller robots that possess fewer degrees of freedom (two- to fourjoint motions). They are limited to pick-and-place tasks with fast cycles. Pneumatic drive system can be applied to the actuation of piston devices to provide linear motions. Rotational motions can be achieved by rotary actuators.
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Direct Drive Robots In 1981 a "direct- drive robot" was developed at Carnegle-Mellon University, USA. Is used electric motors located at the manipulator joints without the usual mechanical transmission linkages used on most robots. The drive motor is located contiguous to the joint. Benefits: Eliminate backlash and mechanical defiencies Eliminate the need of a power transmission (thus more efficient) Joint backdrivable (allowing for joint-space force sensing)
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Methods of Grisping
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There are many ways of grasping or other-wise handling a job, depending to a large extent on the nature of the material being processed. These includes 1. 2. 3. 4. 5. Mechanical grippers. Hooking on to a part. Lifting and transferring a part on a thin platform or spatula. Scooping or ladling Electromagnets.
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6. Vacuum cups. 7. Sticky fingers, using adhesives. 8. Quick disconnect bayonet sockets. o Some examples of appropriate handling methods 1. 2. 3. 4. Forgings - normally handled by massive steel hands. Thin metal sheets vacuum cups and magnets are preferable. Powders, Granular solid, liquids and molten metals-ladles or scoops. Fabrics and similar flimsy material - vacuum cups, adhesives, and electrostatic devices all offer possible solutions. 5. Spot welding - weld gun permanently bolted to the robot wrist or exchangeable by means of bayonet socket.
Mechanical Grippers
o o o o Mechanical grippers are the simplest and usually used end-effectors. How hard the robot must grasp 'the 'object depends on the weight of the object, the friction between the object and the fingers, how fast the robot is to move, and the relation between the direction of movement to the finger's Position on the object. Grippers are one area of robotization where specialized design of tooling is often necessary. However it is seldom expensive. There are a wide variety of mechanical grippers which have been designed to meet different robot applications in the market. Some of these grippers are shown in the following,
Cam-operated hand It can easily handle heavy weights or bulky objects. It is designed to hold the object so that its center of gravity (CG) is kept very closed to the wrist of hand. The short distance between the wrist and the CG minimizes the twisting tendency of a heavy or bulky object.
Wide-opening hand
It is recommended for picking up object which is not always in a constant orientation or at the same size. The hand develops low force when opening and maximum force when closed. It is for objects of moderate weight.
Cam-operated hand with inside and outside jaws Assume that a part is reoriented between the time when the part is placed in a machine and it is removed. This special hand is one of those which deal with this problem. When the part is orinted as shown, the hand can grasp it on the outside by employing the outer self-aligning pads. If '-he
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part is turned over, the inner pads will grasp the inside
Special hand with one movable jaw A hand with single-acting should be considered when there is any access underneath a part, as when it is on a rack. Where this hand can be applied, it will scoop up a part quite quickly. Simplicity of the design makes this one of the most econimical hands.
Special hind for cartons The dual-jaw hand will open wide to grasp inexactly located objects of light weight. Lifting and placement of cardboard cartoons is an application.
Special hand with modular gripper This special hand, with pair of pneumatic actuators, is one of the many special hand designs for industrial robots. It is suitable for parts of light weight.
Special hand for glass tubes This hand is specially designed for industrial robots to securely grasping of relatively short tubes. The fingers of the hand close in two stages -First, they travel through an arc until they are vertical; second, the actuator draws them together axially. Linear travel in this second stage of closure is selected to accommodate the range of tube lengths to be handled.
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Special hand chuck type This special end-effector is designed to pick up drums and similar type large cylindrical parts of various diameters. It is relatively a simple mechanism consisting of three fingers and a single actuator. The actuator drives all three fingers simultaneously by means of a chain or sprockets. The fingers expand against the inside diameter of the drum.
Vacuum Systems
o The vacuum systems uses the suction force to pick up on object. The system uses the vacuum cups which are normally made of an elastic material that conforms and forms a seal to the surface of the object to be handled. The holding, force of a vacuum cup is the effective are multiplied by the different of pressure between the outside and the inside of the cup. To get the best utilization of a cup, the largest possible vacuum or pressure differential should be used. The number of cups to be used in a design depends on such factors as weight of the load, size of cups available, location of the center of gravity, and support needed to handle large flimsy objects. To create vacuum, a choice exists between two devices : the vacuum pump or the venturi. The vacuum pump is either a piston or vane-type pump driven by electric motor. The venturi is a device where vacuum is created by having. a secondary high energy stream of flow impinge on the primary flow, it is actually converting pressure into vacuum. The venturi system differs from the pump system in that It is not controlled by a valve in the vacuum line, but rather by control of the high pressure air into the venturi. The advantages of the pump are : Able to create a high vacuum; Low cost of operation; and relatively silent. Its disadvantages are : High initial cost; Requires a more complex system ~ vacuum tank and blow off valve The advantages of a venturi are : Low initial cost; Does not normally need blow-off-valve or vacuum tank; and highly reliable.
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Its disadvantages are: Very noisy. and high cost of operation. Some typical vacuum pick-up systems are as shown in the following:
Vacuum cup hand The vacuum pick-up has the virtues of the magnetic pickup and is much less susceptible to workpiece side slip. For light to moderate weight glass, plastic, ferrous, and non-ferrous parts, the vacuum pick-up Is often an excellent choice.
Simple vacuum cup hand This simple vacuum cup hand is suitable for handling fragile parts such as cathode ray tube face plates (Illustrated). The vacuum pick-up has better reliability than the magnetic pick-up : there are welldesigned telescoping vacuum lines for long-reach arms.
Expansion bladder hand Large cylindrical vessels with flexible walls are difficult for mechanical hand and fingers to grasp, but an expendable bladder in the form of a cuff will do the job. A rigid back up ring supports the bladder.
Magnetic Pickups
o Magnetic handling is most suitable for parts of ferrous contents. Magnets can be scientifically designed and made in numerous shapes and sizes to perform various tasks.
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Magnets falls into two principle categories : Permanent and electro Electro magnets are well suited for remote control as well as for moderately high speed pick-up and release of parts. A source of DC power is required. Permanent magnets do not require a power source for operation which makes them well adapted for hazardous atmospheres that require explosion proof electrical equipment. They do, however, require a means of separating material from the magnet. To accomplish this, a slipper device may be employed, or if the part is positioned and clamped, welded or otherwise secured, the magnet can be pulled from the part. Regardless of either the permanent magnet or electro magnet is used, there several matters that must be considered before a proper selection can be made : Shape of part; Weight. Temperature. Surface condition; and position to be handled. An example of typical electro magnet pick-up
Tools
o There is a wide range of tools designed for robot applications available. These tools can be either permanently fastened to the robot hands, or if the robot has two or more tools to choose among, then quick disconnect selection of tool may be in order. Some of the tools are as illustrated below :
Stud-welding head Equipping an industrial robot with a stud-welding head is also practical. Studs are fed to the head from a tubular feeder suspended from overhead.
Heating torch The industrial robot can also manipulate a heating torch to bake out foundry molds by playing the torch over the surface, letting the flame linger where more. heat input is needed. Fuel is saved because heat is applied directly, and the bakeout is faster than it would be if the molds were conveyed through a gas-fired oven.
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Inert gas arc welding torch Arc welding with a robot held torch is another application in which an industrial robot is used. The welds can be single or multiple pass. The most effective use is for running simple-curved and compound-curved joints, as well as running multiple short welds at different angles and on various planes.
Spotwelding gun A general purpose industrial robot can maneuver and operate a spotwelding gun to place a series of spot welds on flat, simple-curved, or compound-curved surfaces.
Ladle Ladling hot materials such as molten metal is a hot and hazardous job for which industrial robots are well suited. In piston casting permanent mold die casting and related applications, the robot can be programmed to scoop up and transfer the molten metal from the pot to the mold, and then do the pouring.
Routers, grinders A routine, head, grinder, belt sander, or disc sander can be mounted readily on the wrist of an industrial robot. Thus equipped, the robot can rout workpiece edges, remove flash from plastic parts, and do rough snagging of casting
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Spray gun Ability of the industrial robot to do multipass spraying with controlled velocity fits it for automated application of primers, paints, and ceramic or glass frits, as well as application of masking agents used before plating. For short or medium-length production runs, the industrial robot would often be a better choice than a special purpose setup requiring a lengthy change-over procedure for each different part. Also the robot can spray parts with compound curvatures and multiple surfaces.
Tool changing A single industrial robot can also handle several tools sequentially, with an automatic tool-changing operation programmed into the robot's memory. The tools can be of different types or sizes, permitting multiple operations an the same workpiece
SAFETY CONSIDERATIONS
WHEN? o o Practise it as soon as starting robotics project Must be built into robotics system at the outset
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o Human safety first then Robot Safety then other equipment o then Robot Safety o then other equipment
WHAT DANGERS ? Starting with the most dangerous: o o Repairing a robot (has to be within work cell) - Faulty robots can suddenly move unexpectedly Training/programming a robot - For PTP (Point-to-Point) motion, human nearby to check - Robot programming results in physical motion o Normal operation -If other equipment fails, it is a source of danger e.g. case of Kawasaki robot engineer (10 years experience), died when struck by a robot while repairing a malfunctioning machine o Power supply -Apart from normal dangers of electrical supply, high pressure hydraulic leakage can punch a hole through a person's hand.
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Bodily impact Pinching - caught in grippers or joints Pinning human against a structure
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