Robotics 1

Industrial Robotics

Prof. Alessandro De Luca

Robotics 1 1

What is a robot?n industrial definition (RIA = Robotic Institute of America)

re-programmable multi-functional manipulatordesigned to move materials, parts, tools, or specialized devices through variable programmed motions for the performance of a variety of tasks,

which also acquire information from the environmentand move intelligently in response

n ISO 8373:2012 definitionan automatically controlled, reprogrammable, multipurpose manipulator

programmable in three or more axes, which may be either fixed in place or mobile for use in industrial automation applications

n more “visionary” definitionintelligent connection between perception and action

Robotics 1 2

Robots !!

Waseda WAM-8 (1984)

Comau H4 (1995)

Spirit Rover(2002)

Robotics 1 3

A bit of history

n Robota (= “work” in slavic languages) are artificial human-like creatures built for being inexpensive workers in the theater play Rossum’s Universal Robots (R.U.R.) writtenby Karel Capek in 1920

n Laws of Robotics by Isaac Asimov in I, Robot (1950)1. A robot may not injure a human being or, through inaction, allow a

human being to come to harm2. A robot must obey orders given to it by human beings, except

where such orders would conflict with the First Law3. A robot must protect its own existence as long as such protection

does not conflict with the First or Second Law

Robotics 1 4

Evolution toward industrial robots

n with respect to the ancestorsn flexibility of usen adaptability to a priori unknown conditionsn accuracy in positioningn repeatability of operation

computer numerically controlled

(CNC) machines

mechanicaltelemanipulators

1950

robotmanipulators

1970Unimation PUMA

Robotics 1 5

The first industrial robot

G. Devol and J. Engelberger (Unimation)

US Patent General Motor plant, 1961

Robotics 1 6

Historical pictures and clips

Robotics 1 7

bimanual remote manipulation at Oak Ridge Nat’l Labs Unimate 6-dof robots

video

video

Robot manipulators

ASEA IRB-6(1973)

first robotall-electric-drives

Robotics 1 8

Hirata AR-300(1978)

first SCARArobot

CincinnatiMilacron T3

(1974)first micro-computer controlled

robot

UnimationPUMA 560

(1979)6R with

human-likedexterity

robots – a 50-year journeyrobotics research up to 2000

Video compiled for the IEEE ICRA 2000 conference, S. FranciscoRobotics 1 9

World Robotics 2020

Robotics 1 10

n total worldwide stock at end 2019: 2.7 million units of operational industrial robots (+12% w.r.t. 2018, +13% CAGR since 2014)

n new robot sales in 2019: ~373K (-12%, 3rd highest ever, +11% CAGR since 2014)n robot market value in 2019: $13.8 billion (without software and peripherals)n robotic systems market value: ~4 times as muchn China expanded further as the largest market since 2013, now with a 38% sharen 73% of new robot installations in 5 countries: China, Japan, USA, Korea, Germany

executive summary for 2020 statistics by IFR

issued yearly in late September(for back issues since 2007,

check course web site)

Compound Annual Growth Rate: CAGR = &'()&*'+,(

-//0123− 1

Technology & application trends in service robotics

Page 30 | 24 Sept 2020

Important markets to watch out:• Unbroken scale-up of logistic systems (AGV, AMR)• Mergers & acquisitions activities, e.g. in medical robotics• Heavy construction machinery become robotized allowing multi-machine operation by one

single person• Information interaction (telepresence, advisory); >30 new disinfection robot models in 2020• Covid-19 raised attention on healthcare robots Major Technology Accelerators • Cloud technologies and 5G: e.g., remote procedures using surgical robots and 5G in China• Business models like Robot-as-a-Service lower the entrance level, especially in new markets• Standardization & “platformization”: e.g. for peripherals (app store), sales platform, plug& play

Diffusionindustrial robots in operation worldwide

Robotics 1 11

(as reference, industrial robots in 1973 = 3K, 1983 = 66K, 1993 = 575K, 2003 = 800K) length of robot service life is estimated in 12-15 years

preview in 2020: ～3M robots in operation

Diffusionindustrial robots in operation by world area

Robotics 1 12preview in 2020: almost 1M robots operating in China!

Diffusionrobots in industrial sectors

Robotics 1 13

70% of robots are deployed in three main industries

Diffusionrobots by main applications

Robotics 1 14

almost 70% of robots are used for material handling or welding

Annual supplynew industrial robots worldwide

Robotics 1 15

year of highest everselling of new robots

stop of growth rate in 2019: automotive transition, trade & political headwindspreview in 2020: deferred investments, plummeted consumer demand, travel restrictions,

disrupted supply chains (due also to Covid-19)medium term preview: crisis will be a digitalization booster creating growth opportunities

for robotics industry worldwide

Annual supplynew robots by industrial sectors

Robotics 1 16

the two major industries struggled in 2019 (especially in Asia)

Annual supplynew installations in top markets (countries)

Robotics 1 17

China well ahead, with 5 markets accounting for 73% of total supply

Italy (2nd EU market): double as many new robots installed as in 2015

Density of robots

Robotics 1 18

number of robots per 10000 employeesin the manufacturing industry

almost doubled in last 5 years!

Collaborative robots

Robotics 1 19

a small but steady growing market in the industrial setting

Industrial & service robots

Robotics 1 20

Industrial robots§ automatically controlled, programmable, multipurpose, 3+ axes § for use in industrial automation applications § equipped with application-specific end-effectors Service robots§ perform tasks excluding industrial automation § usually application-specific design, often fewer than 3 axes § sometimes not fully autonomous but remote-controlled

different customers, pricing, machinery, distribution channels, suppliers

… but separationline is blurring:

same unit can actas both, dependingon the application

Personal/domestic service robotsdata (2018-19) and forecast*

Robotics 1 21

vacuuming and floor cleaning: true tasks for robotssteady growth of turnover expected

10 billions $ value*

1,9 billions $ value*

5,7 billions $ value (+20%)

Professional service robotsdata (2018-19) and forecast*

Robotics 1 22

robots (AGV, AMR) in logistics are still the growth driversEurope is the main supplier of service robots (with many young start-ups!)

Industrial robotand its auxiliary equipments

1. Comau SMART H robot 2. C3G Plus controller3. Welding control box4. Application software5. Air/water supply 6. SWIM Board 7. Integrated cables8. Welding gun9. Auxiliary devices in the

robotic cell(servo-controlled axes)

SWIM = Spot Welding Integrated Module

Robotics 1 23

ABB IRB 7600

Robotics 1 24

commercial video by ABB

Industrial applications• manipulation (pick-and-place, handling,

machine feeding)• assembly and packaging• spray painting and coating (nozzles)• arc welding or spot welding (with

pneumatic or servo-controlled guns)• laser cutting and welding• gluing and sealing• mechanical machining operations

(milling, drilling, deburring, grinding, …)

Robotics 1 25

video

A day in the life of an industrial robot• At BMW car production line with ABB robots

Robotics 1 26

videovideo

pick-and-placewith end-effectorto reorient part

pick-and-placewith support

to reorient part

A day in the life of an industrial robot

Robotics 1 27

videovideo

pick-and-placeheavy parts and

human intervention

metal cuttingon a supporting

machine with dofs(video speeded up

at some point)

A day in the life of an industrial robot

Robotics 1 28

videovideo

glue deposit(on fancy paths!)

cooperation ofmultiple robotsfor handling and inspecting/sealing

a car body

A day in the life of an industrial robot

Robotics 1 29

videovideo

coating partsfor rust and corrosion

protection

spray painting

A day in the life of an industrial robot

Robotics 1 30

videovideo

hood deburringwith a suspended tool

test measurementswith assembly on a AGV

What a robot should do and what cannot do

Robotics 1 31

video

spray paintingvery unhealthy

for human operators

assembly of flexibleor complex parts

(here a car dashboard)

videoyet

⇒ human-robot collaboration(co-bots or co-workers)

Plasma cutting

Robotics 1 32

video

small KUKA robot used for plasma cutting of a stainless steel toilet(courtesy of Engenious Solutions Pty)

electrode

nozzle

hot plasma

gaschamber

Robotized workcells

Robotics 1 33

3D simulation of robotic tasks

• analysis of operative cycle times• off-line programming and optimization• layout design and collision checking• 3D graphic simulation

Robotics 1 34

Welding - 1

• spot with servo-controlled gun • stud welding

Robotics 1 35

Welding - 2

• spot (discrete) or arc (continuous)

Robotics 1 36

Two cooperating robots in arc welding

ABB video at Laxa, Sweden

Robotics 1 37

Palletizing

pallet = a portable platform on which goods can be moved, stacked, and stored

Robotics 1 38

Palletizing of cheese forms

using Kawasaki robots (courtesy of Effedue Engineering)

Robotics 1 39

video

Folding

with loading of sheets under the press

Robotics 1 40

Deburring

• car windshields may have large manufacturing tolerances and a sharp contour profile

• the robot follows a given predefined Cartesian path

• the contact force between cutting blade and glass must be feedback controlled

• deburring robot head mounts a force load cell and is pneumatically actuated

Robotics 1 41

Deburring center

deburring center for steel partsusing Comau SMART NJ 110-3.0/foundry robot (courtesy of Adami srl)

Robotics 1 42

video

Off-line robot workstation

articulated robot in metal surface finishing operation

Robotics 1 43

Safety in robotic cells

commercial video from ABBSafeMove (2008) cell monitoring system: no fences!

Robotics 1 44

Robot manipulator kinematics

ComauSmart H4

closed kinematic chain

Kuka 150_2 S2000open kinematic chain(series of rigid bodies connected by joints)

FanucF-200iB

parallel kinematics

Robotics 1 45

SCARA-type robots

SCARA (Selective Compliant Arm for Robotic Assembly)

• 4 degrees of freedom (= joints): 3 revolute + 1 prismatic (vertical) axes • compliant in horizontal plane for micro-assembly and pick-and-place

Mitsubishi RP(repeatability 5 micron,

payload 5 kg)

Mitsubishi RH(workspace 850 mm,

velocity 5 m/s)Bosch Turbo

Robotics 1 46

Adept Cobra i600

fastest SCARA robot for pick-and-place tasks!

Robotics 1 47

video

Other types of robots

Comau Mastgantry robot

(payload up to 560 kg)

ABB Flexpicker(150 pick-and-place operations/minute)

Robotics 1 48

Chocolate packaging withlightweight parallel robots

test video withABB Flexpicker

Robotics 1 49

video withAdept Quatro s650

Distribution by robot type

for 59600 articulated robots installed back in 2004(90% of all robots installed in America, 74% in Europe, only 49% in Asia)

Robotics 1 50

of kinematic configuration

Robot data sheet

Fanuc R-2000i/165F

Robotics 1 51

Workspace

Robotics 1 52

Visualization of workspace and mobility

Robotics 1 53

kinematic simulation of a 6-dof Comau robot (all revolute joints)

video

Visualization of workspace and mobility

Robotics 1 54

V-REP simulation of the 7-dof KUKA LWR4+ robot (all revolute joints)

video

Robot end-effector sensors and tools

Robotics 1 55

Calibration of robot kinematics

Robotics 1 56

Man-machine interface

• teach-box pendant used as robot programminginterface

• cabinet with power electronicsfor robot supervision and control

Robotics 1 57

Programming and control environment

Robotics 1 58

control modulesand interfaces(Reis Robotics)

Motion programming and scaling

Robotics 1 59

commercial video from ABBTrueMove & QuickMove fast motion control performance

Mobile base robots in industry

• AGV (Automated Guidance Vehicles) for material and parts transferon the factory floor: wire- or laser-driven along predefined paths

Robotics 1 60

Lifting AGV for warehouses

video by Elettric80

Robotics 1 61

Kiva Systems

company acquired in 2012 for $775 million by Amazon (store automation)

Robotics 1 62

Intelligent AGV in factories

commercial video of ADAM mobile robot (RMT Robotics)

Robotics 1 63

What’s next in industrial robotics?

Robotics 1 64

changing nature of manufacturing and work

n shift from high volume/low mix to low volume/high mix is having a profound impact on manufacturing

n many industries are facing acute shortages of skilled laborn quicker return-of-investment (ROI) of automation and rising

wages are eventually discouraging labour arbitragen increased focus is being placed on workplace safety

Source: Steven Wyatt (IFR). “Today’s trends, tomorrow’s robots!” Frankfurt, 27 September 2017

What’s next in industrial robotics?

Robotics 1 65

addressing some real facts opens huge opportunities

answers to these challenges lie in Simplification, Digitalisation, and Collaboration

What’s next in industrial robotics?

Robotics 1 66

Simplification (critical for SME, but also for large global manufacturers)n robots easier to install, program (with open source) and operate will unlock entry

barriers to the large market of small and medium enterprises (SMEs)n trend towards having production closer to the end consumer is driving the

importance of standardisation & consistency across global brandsDigitalisation (Big Data allows taking better decisions on factory operations)n “Industry 4.0”, linking the real-life factory with a virtual/digital one, will play an

increasingly important role in global manufacturingn vision and sensing devices, coupled with analytics platforms, will pave the way

for new industry business modelsn IoT/AI/Machine Learning will drive many robotics developments in coming yearsCollaborationn collaborative robots are shifting the traditional limits of “what can be automated?” n collaborative robots increase manufacturing flexibility as ‘low-volume, high-mix’

becomes the main standardn collaboration is also about productivity with increased physical and cognitive

human/robot interaction

What’s next in industrial robotics?

Robotics 1 67

“connected” future of robotics

connected and collaborative robots will enable SMART Manufacturing for both SMEs & Global Enterprises

n robots doing the same task connect across all global locations so performance can be easily compared and improved

self-optimizing production

n robots automatically download what they need to get started from a cloud library and then optimize through “self-learning”

self-programming robots

Franka Emika robot

Robotics 1 68

... one possible example (dated 2016) video