industrial robotics
DESCRIPTION
NIE Mysore E-Learning Industrial Robotics Notes.TRANSCRIPT
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Industrial RoboticsIndustrial Robotics
IntroductionRobot configurationProgrammingEnd effectorsSensorsIndustrial applications
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IntroductioIntroductionn
Brief history of developmentDefinition of the ‘Robot Institute of
America’:A robot is a programmable, multi-function manipulator designed to move material, tools or special devices through variable programmed motions for the performance of a variety of tasks
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Robot Physical ConfigurationRobot Physical Configuration
1. Polar coordinate configuration2. Cylindrical coordinate configuration3. Jointed arm configuration4. Cartesian coordinate configuration
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Polar coordinate configuration
• Also called Spherical Coordinate configuration• Ex: Unimate 2000 series
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Cylindrical coordinate configuration
Ex: Unimate 3000 series
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Jointed arm configuration
• Cincinatti Milacron T model• Unimate PUMA model
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Cartesian coordinate configuration
• Rexroth robotic system
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Robot motions: six degrees of freedom
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Cartesian Robot
Cartesian robot is formed by 3 prismatic joints, whose axes are coincident with the X, Y and Z planes.
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Gantry Robot
Cartesian coordinate robots with the horizontal member supported at both ends are sometimes called Gantry robots.
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Parallel Robot
Parallel robot is a complex mechanism which is constituted by two or more kinematics chains between, the base and the platform where the end-effectors are located. Good examples are the flying simulator
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Spherical Robot
It is still in the research laboratory, the Spherical robot is actually a spherical shape robot, which has an internal driving source.
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Configuration Advantages Disadvantages
Cartesian coordinates
3 linear axes, easy to visualize, rigid structure, easy to program
Can only reach front of itself, requires large floor space, axes hard to seal
Cylindrical coordinates
2 linear axes +1 rotating, can reach all around itself, reach and height axes rigid, rotational axis easy to seal
Can’t reach above itself, base rotation axis as less rigid, linear axes is hard to seal, won’t reach around obstacles
SCARA coordinates 1 linear + 2 rotating axes, height axis is rigid, large work area for floor space
2 ways to reach point, difficult to program off-line, highly complex arm
Spherical coordinates
1 linear + 2 rotating axes, long horizontal reach Can’t reach around obstacles, short vertical reach
Revolute coordinates
3 rotating axes can reach above or below obstacles, largest work area for least floor space
Difficult to program off-line, 2 or 4 ways to reach a point, most complex manipulator
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Other Technical Other Technical FeaturesFeatures
Work volumePrecision of movementSpeed of movementPayload capacityType of drive system
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Accuracy and Repeatability
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Robot Programming
1. Manual method
2. Walkthrough method
3. Leadthrough method
4. Off-line programming
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Manual method
• It is more like setting up the machine rather than programming
• Used for simple robots
• Involves setting stops, cams, switches and relays
• Uses low technology for short work cycles
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Walkthrough method
• The programmer manually moves the robot’s arm and hand through the motion sequence of the work cycle
• Each movement is recorded into memory for subsequent playback during production
• Once the motion sequence is recorded, the speed of movement can be controlled independently
• Appropriate for spray painting, arc welding, etc
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Leadthrough method
• Uses a teach pendent to power drive the robot through its motion sequence
• Each motion is recorded into memory for future playback during the work cycle
• Popular because it is easy and convenient
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Off-line programming
• Uses off-line programming language
• Since programming is done off-line, it means higher utilisation of the robot and the equipment with which it operates
• Ensures integration of the robot with FMS and CIM systems
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Robot Programming Languages
VAL
• Developed by Victor Scheinman for the PUMA robot
• Stands for Victor’s Assembly Language
• Two types of statements: Monitor commands and Programming instructions
• Program instructions are written in VAL, while various point locations are defined using a teach pendent
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Monitor Commands
• Preparing the system for the user to write programs
• Defining points in space
• Commanding the robot to execute a program
• Listing programs on the CRT
• Examples: EDIT, EXECUTE, SPEED, HERE, etc
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Program Instructions
• MOVE: Moves the robot to the location and orientation specified by the symbol
• MOVES: Moves the robot along a st.-line trajectory, to the specified location
• APPRO: Moves the end effector to the position defined, but offset along the Z-axis by the specified distance in mm
• APPROS: Similar as above, but along a st.-line trajectory
• DEPART: Moves the tool the distance given along the current Z-axis of the tool
• OPENI: Opens the gripper immediately
• CLOSEI: Closes the gripper immediately
• EXIT: Exits from the program and transfers control to monitor mode
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VAL Programming Example
TASK:
• Pick and place operation
• Robot should pick up a part from one conveyor (Point A)
• Place the part on another conveyor (Point B)
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VAL Programming Example
• PROGRAM PICK
1.APPRO A, 502.MOVES A3.CLOSEI 4.DEPART 505.APPRO B, 506.MOVES B7.OPENI 8.DEPART 50
LISTL AX/JT1 Y/JT2 Z/JT3 P/JT4 Q/JT5-105.5 87.8 119.0 -25.6 100.9
LISTL BX/JT1 Y/JT2 Z/JT3 P/JT4 Q/JT5-50.0 115.8 55.5 -10.7 100.2
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End Effectors
• It is a device which is attached to the robot’s wrist to perform a specific task
• It is a special purpose tooling which enables the robot to perform a particular job
• It is usually custom engineered for the job
• Most robot manufacturers have engineering groups which design and fabricate end effctors or provide advice to their customers on end effector design
• There are two types of end effectors: Grippers and tools
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Grippers
• Mechanical Grippers: Friction or the physical configuration of the gripper retains the object
• Suction cups: also called vacuum cups, used for flat fragile objects
• Magnetic Grippers: for ferrous objects
• Hooks: to lift parts off conveyors
• Scoops/Ladles: for handling fluids, powder, pellets, or granular substance
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Grippers
Pivot action Gripper
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Grippers
Slide action Gripper
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Grippers
Double Gripper Pivot action mechanism
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Grippers
Vacuum Gripper
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Tools as End Effectors
• Spot welding gun
• Arc welding tools (and wire-feed mechanism)
• Spray painting gun
• Drilling head
• Routers, grinders, wire brushes
• Heating torches
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SENSORS IN SENSORS IN ROBOTICSROBOTICS
Internal: for controlling position and veleocity of
various joints. Ex: optical encoders,
potentiometers, etc
External: for workcell control.
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Types of Sensors in Types of Sensors in RoboticsRobotics
Tactile and Proximity sensors
Voice sensors
Machine vision
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Tactile and Proximity sensors
• Provides the robot with capability to respond to contact forces with other objects within the work volume
• Two types: Touch sensors and stress sensors (tactile sensors)
• touch sensors will simply indicate that a contact has been made with an object. A simple micro switch can serve the purpose
• Stress sensors measure the magnitude of the contact force. Starin gauges are the most popular choice
• Tactile sensors are useful in assembly and inspection operations.
• In assembly, the robot can perform delicate part alignment and joining operations
• In inspection, touch sensing would be useful in gauging operations and dimensional measuring activities
• Proximity sensors are used to sense when one object is close to another
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Voice sensors
• Used for voice programming
• A speech recognition system analyses the voice inputs and compares it with a set of stored word patterns
• when a match is found between the input and the stored vocabulary word, the robot performs some action which corresponds to that word
• It can speed up robot programming
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Machine Vision
Machine vision can be defined as the acquisition of image data, followed by processing and interpretation of this data by computer for some useful application
Classification: 2D and 3D vision systems
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Basic Functions of Vision system
• Image acquisition and
digitisation
• Image processing and analysis
• Interpretation
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Image Acquisition and Digitization
A camera captures the image
Image is obtained by dividing the viewing area into a matrix of discrete picture elements(pixels)
Each pixel has a value that is proportional to the light intensity of that portion of the scene
The intensity value for each pixel is converted into equivalent digital value by an ADC
Selection of appropriate lighting system is important to establish contrast between the object and the background
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Image Acquisition and Digitization
Binary vision: light intensity of each pixel is ultimately reduced to either of two values, white or black, depending on whether light intensity exceeds some threshold level
Gray scale system: capable of distinguishing and storing different shades of gray in the image. It can highlight the object’s texture and colour.
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Each set of pixel values is referred to as a frame and stored in computer memory as frame buffer
The process of reading all the pixel values in a frame is performed with a frequency of 25-30 times per second
Cameras used: Vidicon and Solid-state
Types of illumination: front lighting, back lighting and side lighting
Image Acquisition and Digitization
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The data for each frame must be analysed within the time required to complete one scan (1/30 sec)
Segmentation: define and separate regions of Interest within the image
segmentation techniques: thresholding and edge preparation
Feature extraction: length, width, perimeter, c.g., aspect ratio, etc
Image Acquisition and Digitization
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Interpretation
Object/pattern recognition
Template matching
Feature weighting
Image Acquisition and Digitization
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Machine Vision Applications
1. Inspection
2. Part identification
3. Visual guidance and control
4. Safety monitoring
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Robotic Applications
Material handling: material transfer and machine loading/unloading
Processing operations: spot welding, continuous welding, spray painting, drilling, grinding, laser cutting, riveting, etc
Assembly and inspection