Ch 8 Industrial Robotics Sections: 1. Robot Anatomy and Related Attributes 1. Robot Control Systems 2. End Effectors 3. Sensors in Robotics 4. Industrial Robot Applications 5. Robot Programming 6. Robot Accuracy and Repeatability ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Industrial Robot Defined A general-purpose, programmable machine capable of possessing certain anthropomorphic characteristics. The most obvious anthropomorphic characteristic of an industrial robot is its mechanical arm, which is used to perform various industrial tasks. Other human-like characteristics are: robot’s capabilities to respond to sensory inputs, communicate with other machines, and make decisions. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 1 Industrial Robot Defined These capabilities permit robots to perform a variety of useful task. The development of robot technology followed the development of numerical control, and the two technologies are quite similar. They both involve coordinated control of multiple axes (the axes are called joints in robotics), and they both use dedicated digital computers as controllers. Typical production applications of industrial robots include spot welding, material transfer, machine loading, spray painting, and assembly. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Industrial Robot Defined • Robots can be substituted for humans in hazardous or uncomfortable work environments. • A robot performs its work cycle with a consistency and repeatability that cannot be attained by humans. • Robots can be reprogrammed. When the production run of the current task is completed, a robot can be reprogrammed and equipped with the necessary tooling to perform an another different task. • Robots are controlled by computers and can therefore be connected to other computer systems to achieve computer integrated manufacturing. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 2 Robot Anatomy Robot manipulator - a series of joint-link combinations ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Robot Anatomy Manipulator consists of joints and links Joints provide relative motion Links are rigid members between joints Various joint types: linear and rotary Each joint provides a “degree-of-freedom” Most robots possess five or six degrees-of-freedom Robot manipulator consists of two sections: Body-and-arm – for positioning of objects in the robot's work volume Wrist assembly – for orientation of objects ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 3 Types of 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) ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Translational Motion Joints Linear joint (type L) Orthogonal joint (type O) ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 4 Rotary Motion Joints Rotational joint (type R) Twisting joint (type T) Revolving joint (type V) ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 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 ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 5 Robot Body-and-Arm Configurations Five common body-and-arm configurations for industrial robots: 1. Polar coordinate body-and-arm assembly 2. Cylindrical body-and-arm assembly 3. Cartesian coordinate body-and-arm assembly 4. Jointed-arm body-and-arm assembly 5. Selective Compliance Assembly Robot Arm (SCARA) Function of body-and-arm assembly is to position an end effector (e.g., gripper, tool) in space. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 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) ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 6 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 ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 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 ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 7 Jointed-Arm Robot Notation TRR: General configuration of a human arm ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 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. The arm is very rigid in the vertical direction, but compliant in the horizontal direction. This permits the robot to perform insertion tasks (for assembly) in a vertical direction, where some side-toside alignment may be needed to mate the two parts properly. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 8 Joint Notations ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 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 ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 9 Wrist Configuration Typical wrist assembly has two or three degrees-offreedom (shown is a three degree-of freedom wrist) Notation :RRT ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. SCARA Robot - No wrist The SCARA robot configuration is unique in that it typically does not have a separate wrist assembly. Since it is used for insertion type assembly operations in which the insertion is made from above, the orientation requirements are minimal, and the wrist is therefore not needed. Orientation of the object to be inserted is sometimes required, and an additional rotary joint can be provided for this purpose. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 10 Work Volume The work volume (the term work envelope is also used) of the manipulator is defined as the envelope or threedimensional space within which the robot can manipulate the end of its wrist. Work volume is determined by the number and types of joints in the manipulator (body-and-arm and wrist), the ranges of the various joints, and the physical sizes of the links. The shape of the work volume depends largely on the robot’s configuration. A polar configuration robot tends to have a partial sphere as its work volume, a cylindrical robot has a cylindrical work envelope, and a Cartesian coordinate robot has a rectangular work volume. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Work Volume ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 11 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 ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Speed The drive system, position sensors (and speed sensors if used), and feedback control systems for the joints determine the dynamic response characteristics of the manipulator. The speed with which the robot can achieve a programmed position and the stability of its motion are important characteristics of dynamic response in robotics. Speed refers to the absolute velocity of the manipulator at its end-of-arm. The maximum speed of a large robot is around 2 m/s (6 ft/s). ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 12 Speed Speed can be programmed into the work cycle so that different portions of the cycle are carried out at different velocities. What is sometimes more important than speed is the robot’s capability to accelerate and decelerate in a controlled manner. In many work cycles, much of the robot’s movement is performed in a confined region of the work volume, so the robot never achieves its top-rated velocity. In these cases, nearly all of the motion cycle is engaged in acceleration and deceleration rather than in constant speed. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Speed A term that takes all of these factors into consideration is speed of response, which refers to the time required for the manipulator to move from one point in space to the next. Speed of response is important because it influences the robot’s cycle time, which in turn affects the production rate in the application. Stability refers to the amount of overshoot and oscillation that occurs in the robot motion a the end-of-arm as it attempts to move to the next programmed location. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 13 Load Carrying Capacity Load carrying capacity depends on the robot’s physical size and construction as well as the force and power that can be transmitted to the end of the wrist The weight carrying capacity of commercial robots ranges from less than 1 kg up to approximately 900 kg (2000 Ib). Medium sized robots designed for typical industrial applications have capacities in the range of 10 to 45 kg (25 to 100 Ib). One factor that should be kept in mind when considering load carrying capacity is that a robot usually works with a tool or gripper attached to its wrist. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Robot Control Systems The actuations of the individual joints must be controlled in a coordinated fashion for the manipulator to perform a desired motion cycle. Microprocessor-based controllers are commonly used today in robotics as the control system hardware. The controller is organized in a hierarchical structure, so that each joint has its own feedback control system, and a supervisory controller coordinates the combined actuations of the joints according to the sequence of the robot program. Different types of control are required for different applications. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 14 Robot Control System Hierarchical control structure of a robot microcomputer controller ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Robot Control Systems 1. Limited sequence control – pick-and-place operations using mechanical stops to set positions 2. Playback with point-to-point control – records work cycle as a sequence of points, then plays back the sequence during program execution 3. Playback with continuous path control – greater memory capacity and/or interpolation capability to execute paths (in addition to points) 4. Intelligent control – exhibits behavior that makes it seem intelligent, e.g., responds to sensor inputs, makes decisions, communicates with humans ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 15 Robot Control Systems 1. Limited sequence control The most elementary control type. It can be utilized only for simple motion cycles, such as pick-and-place operations (i.e.. picking an object up at one location and placing it at another location). It is usually implemented by setting limits or mechanical stops for each joint and sequencing the actuation of the joints to accomplish the cycle. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Robot Control Systems 1. Limited sequence control Feedback loops are sometimes used to indicate that the particular joint actuation has been accomplished so that the next step in the sequence can be initiated. However, there is no servo-control to accomplish precise positioning of the joint. Many pneumatically driven robots are limited sequence robots. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 16 Robot Control Systems 2. Playback with point-to-point control Playback robots represent a more sophisticated form of control than limited sequence robots. Playback control means that the controller has a memory to record the sequence of motions in a given work cycle as well as the locations and other parameters (such as speed) associated with each motion and then to subsequently play back the work cycle during execution of the program. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Robot Control Systems 2. Playback with point-to-point control In point-to-point (PTP) control, individual positions of the robot arm are recorded into memory. These positions are not limited to mechanical stops for each joint as in limited sequence robots; instead, each position in the robot program consists of a set of values representing locations in the range of each joint of the manipulator. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 17 Robot Control Systems 2. Playback with point-to-point control Thus, each “point” consists of five or six values corresponding to the positions of each of the five or six joints of the manipulator. For each position defined in the program, the joints are thus directed to actuate to their respective specified locations. Feedback control is used during the motion cycle to confirm that the individual joints achieve the specified locations in the program. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Robot Control Systems 3. Playback with continuous path control Continuous path robots have the same playback capability as the previous type. The difference between continuous path and point-to-point is the same in robotics as it is in NC. A playback robot with continuous path control is capable of one or both of the following: 1. Greater storage capacity for location Thus, the points constituting the motion cycle can be spaced very closely together to permit the robot to accomplish a smooth continuous motion. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 18 Robot Control Systems 3. Playback with continuous path control 2. Interpolation In point-to-point systems, the x,y, and z axes are controlled to achieve a specified point location within the robot’s work volume. In continuous path systems, not only are the x,y, and z axes controlled, but the velocities are controlled simultaneously to achieve the specified linear or curvilinear path. Servo-control is used to continuously regulate the position and speed of the manipulator. It should be mentioned that a playback robot with continuous path control has the capacity for PTP control. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Robot Control Systems 4. Intelligent control Industrial robots are becoming increasingly intelligent. An intelligent robot is one that exhibits behavior that makes it seem intelligent. Some of the characteristics that make a robot appear intelligent include the capacities to interact with its environment, make decisions when things go wrong during the work cycle, communicate with humans, make computations during the motion cycle, and respond to advanced sensor inputs such as machine vision. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 19 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 ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. End Effectors - Grippers Mechanical grippers, consisting of two or more fingers that can be actuated by the robot controller to open and close to grasp the workpart. Vacuum grippers, in which suction cups are used to hold flat objects. Magnetized devices, for holding ferrous parts. Adhesive devices, which use an adhesive substance to hold a flexible material such as a fabri. Simple mechanical devices, such as hooks and scoops. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 20 End Effectors – Mechanical Grippers Mechanical grippers are the most common gripper type. Some of the innovations and advances in mechanical gripper technology include: 1. Dual grippers consisting of two gripper devices in one end effector for machine loading and unloading. (With a single gripper, the robot must reach into the production machine twice.) 2. Interchangeable fingers that can be used on one gripper mechanism. To accommodate different parts, different fingers are attached to the gripper. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. End Effectors – Mechanical Grippers 3. Sensory feedback in the fingers that provide the gripper with capabilities such as: (1) sensing the presence of the workpart or, (2) applying a specified limited force to the workpart during gripping (for fragile workparts). 4. Multiple fingered grippers that possess the general anatomy of a human hand. 5. Standard gripper products that are commercially available, thus reducing the need to custom-design a gripper for each separate robot application. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 21 Robot Mechanical Gripper A two-finger mechanical gripper for grasping rotational parts. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Tools The robot uses tools to perform processing operations on the workpart. The robot manipulates the tool relative to a stationary or slowly moving object (e.g., workpart or subassembly). Examples of the tools used as end effectors by robots to perform processing applications include spot welding gun; arc welding tool; spray painting gun; rotating spindles for drilling, routing, grinding, and similar operations; assembly tool (e.g., automatic screwdriver); heating torch; ladle (for metal casting); and water jet cutting tool. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 22 Tools In each case, the robot must not only control the relative position of the tool with respect to the work as a function of time, it must also control the operation of the tool. For this purpose. the robot must be able to transmit control signals to the tool for starting, stopping, and otherwise regulating its actions. In some applications, the robot may use multiple tools during the work cycle. For example, several sizes of routing or drilling bits must be applied to the workpart. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Tools Thus the robot must have a means of rapidly changing the tools. The end effector in this case takes the form of a fastchange tool holder for quickly fastening and unfastening the various tools used during the work cycle. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 23 Sensors in Robotics Two basic categories of sensors used in industrial robots: 1. Internal - used to control position and velocity of the manipulator joints. These sensors form a feedback control loop with the robot controller. Typical sensors used to control the position of the robot arm include potentiometers and optical encoders. Tachometers of various types are used to control the speed of the robot arm. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Sensors in Robotics 2. External - used to coordinate the operation of the robot with other equipment in the work cell. In many cases, these external sensors are relatively simple devices, such as limit switches that determine whether a part has been positioned properly in a fixture or that a part is ready to be picked up al a conveyor. Other situations require more advanced sensor technologies. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 24 Sensors in Robotics - External Tactile - touch sensors and force sensors Proximity - when an object is close to the sensor Optical (e.g. Photocell) Machine vision Machine vision is used in robotics for inspection. parts identification, guidance, and other uses. Other sensors - temperature, fluid pressure, fluid flow, electrical voltage, current, and various other physical properties. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Robot Application Characteristics General characteristics of industrial work situations that promote the use of industrial robots 1. Hazardous work environment for humans, 2. Repetitive work cycle, 3. Difficult handling task for humans (e.g., heavy parts), 4. Multishift operations, where workers should be changed, 5. Infrequent changeovers of the physical workplace, 6. Part position and orientation are established in the work cell, since most robots in today’s industrial applications are without vision capability. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 25 Industrial Robot Applications 1. Material handling applications Material transfer – pick-and-place, palletizing (e.g., Transferring parts from one conveyor to another.) Machine loading and/or unloading (e.g., Die casting, plastic molding, machining, forging, pressworking, heat treating, ...) 2. Processing operations Spot welding and continuous arc welding Spray coating Other – waterjet cutting, laser cutting, grinding, drilling, polishing, wire brushing, ... 3. Assembly and inspection 4. Changing tools, even the work holding devices in the machines. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Arrangement of Cartons on Pallet The robot retrieves parts, cartons, or other objects from one location and deposits them onto a pallet or other container at multiple positions on the pallet. Although the pickup point is the same for every cycle, the deposit location on the pallet is different for each carton. Either the robot must be taught each position on the pallet using the powered leadthrough method, or it must compute the location based on the dimensions of the pallet and the center distances between the cartons (in both x- and y-directions). ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 26 Arrangement of Cartons on Pallet ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Depalletizing Other applications similar to palletizing include depalletizing, which consists of removing parts from an ordered arrangement in a pallet and placing them at another location (e.g., onto a moving conveyor), stacking operations, which involve placing flat parts on top of each other, such that the vertical location of the drop-off position is continuously changing with each cycle, and inspection operations, in which the robot inserts parts into the compartments of a divided carton. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 27 Robotic Arc-Welding Cell Robot performs flux-cored arc welding (FCAW) operation at one workstation while fitter changes parts at the other workstation ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 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 - uses 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 leadthrough methods ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 28 Leadthrough Programming Leadthrough programming dates from the early 1960s before computer control was prevalent. The same basic methods are used today for many computer controlled robots. In leadthrough programming, the task is taught to the robot by moving the manipulator through the required motion cycle, simultaneously entering the program into the controller memory for subsequent playback. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Leadthrough Programming Two types: 1. Powered leadthrough Common for point-to-point robots Uses teach pendant to move joints to desired position and record that position into memory 2. Manual leadthrough Convenient for continuous path control robots Human programmer physical moves manipulator through motion cycle and records cycle into memory ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 29 Teach Pendants for Powered Leadthrough Programming ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Manual Leadthrough Programming Manual leadthrough programming is convenient for programming playback robots with continuous path control where the continuous path is an irregular motion pattern such as in spray painting. This programming method requires the operator to physically grasp the end-of- arm or the tool that is attached to the arm and move it through the motion sequence, recording the path into memory. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 30 Manual Leadthrough Programming ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Manual Leadthrough Programming ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 31 Manual Leadthrough Programming Because the robot arm itself may have significant mass and would therefore he difficult to move, a special programming device often replaces the actual robot for the teach procedure. The programming device has the same joint configuration as the robot and is equipped with a trigger handle (or other control switch), which the operator activates when recording motions into memory. The motions are recorded as a series of closely spaced points. During playback, the path is recreated by controlling the actual robot arm through the same sequence of points. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Leadthrough Programming Advantages Advantages: Can readily be learned by shop personnel A logical way to teach a robot Does not required knowledge of computer programming Disadvantages: Downtime - Regular production must be interrupted to program the robot Limited programming logic capability Not readily compatible with modern computer-based technologies ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 32 World and Tool Coordinate Systems Coordinating the individual joints with the teach pendant is an awkward and tedious way to enter motion commands to the robot. For example, it is difficult to coordinate the individual joints of a jointed-arm robot (TRR configuration) to drive the endof-arm in a straight-line motion. Therefore, many of the robots using powered leadthrough provide two alternative methods for controlling movement of the entire manipulator during programming in addition to controls for individual joints. With these methods the programmer can move the robot’s wrist end in straight line paths. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. World and Tool Coordinate Systems The names given to these alternatives are (1) world-coordinate system and (2) tool-coordinate system. Both systems make use of a Cartesian coordinate system. In a world-coordinate system, the origin and axes are defined relative to the robot base. In a tool-coordinate system, the alignment of the axis system is defined relative to the orientation of the wrist faceplate (to which the end effector is attached). In this way, the programmer can orient the tool in a desired way and then control the robot to make linear moves in directions parallel or perpendicular to the tool. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 33 World Coordinate System Origin and axes of robot manipulator are defined relative to the robot base ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Tool Coordinate System Alignment of the axis system is defined relative to the orientation of the wrist faceplate (to which the end effector is attached) ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 34 Robot Programming Languages Textural programming languages provide the opportunity to perform the following functions that leadthrough programming cannot readily accomplish: Enhanced sensor capabilities Improved output capabilities to control external equipment Program logic not provided by leadthrough methods Computations and data processing similar to computer programming languages Communications with other computer systems ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Motion Programming Commands MOVE P1 HERE P1 - used during leadthrough of manipulator MOVES P1 DMOVE(4, 125) APPROACH P1, 40 MM DEPART 40 MM DEFINE PATH123 = PATH(P1, P2, P3) MOVE PATH123 SPEED 75 ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 35 Interlock and Sensor Commands Input interlock: WAIT 20, ON Output interlock: SIGNAL 10, ON SIGNAL 10, 6.0 Interlock for continuous monitoring: REACT 25, SAFESTOP ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Gripper Commands Basic commands OPEN CLOSE Sensor and and servo-controlled hands CLOSE 25 MM CLOSE 2.0 N ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 36 Simulation and Off-Line Programming In conventional usage, robot programming languages still require some production time to be lost in order to define points in the workspace that are referenced in the program They therefore involve on-line/off-line programming Advantage of true off-line programming is that the program can be prepared beforehand and downloaded to the controller with no lost production time Graphical simulation is used to construct a 3-D model of the robot cell in which locations of the equipment in the cell have been defined previously ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Simulation and Off-Line Programming ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 37 Robot Accuracy and Repeatability Three terms used to define precision in robotics, similar to numerical control precision: 1. Control resolution - capability of robot's positioning system to divide the motion range of each joint into closely spaced points 2. Accuracy - capability to position the robot's wrist at a desired location in the work space, given the limits of the robot's control resolution 3. Repeatability - capability to position the wrist at a previously taught point in the work space ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. Control Resolution, Accuracy, and Repeatability (from NC Chapter) Desired position Addressable position 0 Î CR/2 Possible region for the actual position ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 38 Robot Accuracy and Repeatability ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 39
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