Robots and Systems in Smart Manufacturing Unit 1 PDF

RO5001 ROBOTS AND SYSTEMS IN SMART MANUFACTURING Unit - 1 INTRODUCTION by Dr.S.Sathish Assistant Professor Department of Production Technology Anna University Madras Institute of Technology...

RO5001 ROBOTS AND SYSTEMS IN SMART MANUFACTURING Unit - 1 INTRODUCTION by Dr.S.Sathish Assistant Professor Department of Production Technology Anna University Madras Institute of Technology Chrompet, Chennai  VISION OF THE DEPARTMENT To develop educational avenues for the students to emerge as disciplined researchers, technocrats and entrepreneurs making transformative impact on establishing a world class society in the domain of Production Engineering and Automation.  MISSION OF THE DEPARTMENT 1. To impart students with knowledge on modern manufacturing and automated systems by incorporating critical thinking, leadership qualities, communication with interpersonal skills. 2. To create a conducive environment for exchange of multidisciplinary ideas towards research, creativity, innovation and entrepreneurship to meet the societal needs with optimal solutions. 3. To follow the values of integrity and honesty through curricular, co- curricular and extracurricular activities.  Programme Educational Objectives 1. The program aims to produce proficient engineers in Robotics and Automation field to serve the various technological needs of Industry and Society. 2. To impart graduates with multidisciplinary engineering knowledge in Robotics and Automation system. 3. The program shall create graduates to continuously uplift the knowledge, skill, attitude, self-learning, and teamwork, constantly able to practice the ethical values and protect the environmental eco systems. Programme Outcomes Engineering Graduates will be able to: 1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals, and an engineering specialization to the solution of complex engineering problems. 2. Problem analysis: Identify, formulate, review research literature, and analyze complex engineering problems reaching substantiated conclusions using first principles of mathematics, natural sciences, and engineering sciences. 3. Design/development of solutions: Design solutions for complex engineering problems and design system components or processes that meet the specified needs with appropriate consideration for the public health and safety, and the cultural, societal, and environmental considerations. 4. Conduct investigations of complex problems: Use research-based knowledge and research methods including design of experiments, analysis and interpretation of data, and synthesis of the information to provide valid conclusions. 5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern engineering and IT tools including prediction and modeling to complex engineering activities with an understanding of the limitations. 6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional engineering practice. 7. Environment and sustainability: Understand the impact of the professional engineering solutions in societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable development. 8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of the engineering practice. 9. Individual and team work: Function effectively as an individual, and as a member or leader in diverse teams, and in multidisciplinary settings. 10. Communication: Communicate effectively on complex engineering activities with the engineering community and with society at large, such as, being able to comprehend and write effective reports and design documentation, make effective presentations, and give and receive clear instructions. 11. Project management and finance: Demonstrate knowledge and understanding of the engineering and management principles and apply these to one’s own work, as a member and leader in a team, to manage projects and in multidisciplinary environments. 12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in independent and life-long learning in the broadest context of technological change. COURSE OBJECTIVES The objective of this course is 1. To get a knowledge of working on Industrial robots and their load handling capacity 2. To enlist with an application of robots in various operation 3. To familiar with a material handling system 4. To impart the knowledge on robotic welding 5. To obtain the knowledge on various type of robot welding operation COURSE OUTCOMES At the end of the course, the students are expected to CO 1: Learn about the basic concepts of Industrial Robot. CO 2: Ability in selecting the required robots CO 3: Apply their knowledge in handling the materials. CO 4: Learn about the Welding operation and also related to Programming CO 5: Know the various applications of robots. UNIT – I INTRODUCTION 7 Types of industrial robots - Load handling capacity - general considerations in Robotic material handling-material transfer - machine loading and unloading - CNC machine tool loading - Robot centered cell UNIT – II SELECTION OF ROBOTS AND OTHER APPLICATIONS 9 Factors influencing the choice of a robot - robot performance testing - economics of robotisation - Impact of robot on industry and society. Application of Robots in continuous arc welding - Spot welding - Spray painting -assembly operation - cleaning - robot for underwater applications. UNIT – III MATERIAL HANDLING 13 concepts of material handling - principles and considerations in material handling systems design - conventional material handling systems - industrial trucks - monorails - rail guided vehicles - conveyor systems -cranes and hoists - advanced material handling systems - automated guided vehicle systems - automated storage and retrieval systems(ASRS) – bar code technology - radio frequency identification technology -Introduction to Automation Plant design softwares. UNIT – IV ROBOTIC WELDING 8 Robotic welding system, Programmable and flexible control facility –Introduction-Types- Flex Pendant-Lead through programming, Operating mode of robot, Jogging-Types, programming for robotic welding, Welding simulation, Welding sequences, Profile welding UNIT – V APPLICATIONS OF ROBOTS IN WELDING AND ALLIED PROCESSES 8 Application of robot in manufacturing: Exploration of practical application of robots in welding: Robots for car body’s welding, robots for box fabrication, robots for microelectronic welding and soldering – Applications in nuclear, aerospace and ship building, case studies for simple and complex applications  Text books 1. Richard D Klafter, Thomas Achmielewski, MickaelNegin , "Robotic Engineering – An integrated Approach", Prentice Hall India, New Delhi, 2006. 2. Mikell P Groover, "Automation, Production Systems, and Computer-Integrated Manufacturing", Pearson Education, New York, 2021. 3. Pires J N, Loureiro A, Bolmsjo G, "Welding Robots: Technology, System Issues and Application", Springer, London, 2010. Reference books 1. Parmar R S, "Welding Processes and Technology", Khanna Publishers, New Delhi, 2nd Edition, 2013. 2. John A. piotrowski, William T. Randolph, "Robotic welding: A Guide to Selection and Application, Welding Division, Robotics International of SME", Publications Development Dept., Marketing Division, 1987. 3. Mikell P Groover, Mitchel Weiss, Roger N Nagel, N.G.Odrey, Ashish Dutta, "Industrial Robotics (SIE): Technology, Programming and Applications", 2nd Edition, McGraw Hill Education India Pvt Ltd, 2017. 4. Yoram Koren , "Robotics for Engineers", McGraw-Hill, 1987. Introduction Word ROBOT coined - Czech novelist Karel Capek - 1920 play titled Rassum’s Universal Robots (RUR) Robot in Czech is a word for worker or servant Isaac Asimov coined the word ROBOTICS in the early 1940s. George C. Devol patent application for a programmable manipulator was made in 1954 - Patent number 2,988,237 in 1961. The first market study for robotics was also started in 1956 with field trips to some 15 automotive assembly plants and some 20 other diverse manufacturing operations. Introduction Devol and Engelberger being served cocktails by a prototype Unimate robot. First robot installation (die casting machine in a General Motors plant).  Frames which surround human limbs, or even the whole human frame, and which amplify the available power of Artificial replacements for the man or woman. parts of the human body used to add distance to the motions of a human limb, so that the operator can work outside the environment in which work has to be done  CHEETAROID - Four-legged a team from Sogang University's Robotic Systems Control Laboratory, led by Professor Kyoungchul Kong imitate human beings or animals by walking on legs instead of the more usual mechanical method of wheels Shall we can call this as a Robots? Robot Robots are defined as man made mechanical device whose motion must be modeled, planed, sensed, actuated and controlled. Whose motion behavior can be influence by programming. Robotics Industry Association (RIA) A re-programmable, multifunctional manipulator designed to move material, parts, tools or specialized devices through variable programmed motion for a variety of tasks. Parts of a robot Parts of a robot Basic Motions Degrees of freedom - Vertical transverse Robot’s freedom of motion Radial transverse Rotational transverse in a 3 dimensional space Pitch Yaw Dof – Human parts ? Roll Law of Robotics Three “Laws of Robotics ” proposed by Asimov Law 1: A robot may not injure a human being or through inaction, allow a human being to come to harm, unless this would violate a higher order law Law 2: A robot must obey orders given to it by human beings, except where such orders would conflict with a higher order law Law 3: A robot must protect its own existence as long as such protection does not conflict with a higher order law Types of industrial robots Based on Coordinate system/ Arm configuration 1. Cylindrical Coordinate Robot 2. Spherical Coordinate Robot/Polar Coordinate Robot 3. Cartesian Coordinate/Rectangular Coordinate Robot Cantilever Robot Gantry Robot 4. Jointed arm Robot/Articulated robot/Anthropomorphic Robot/Revolute robot pure spherical, parallelogram spherical cylindrical 5. SCARA Robot Based on Method of control Servo Controlled Point to point servo controlled continuous path servo controlled Non servo controlled Types of industrial robots Based on Power supply 1. Electrical 2. Pneumatic 3. Hydraulic Based on degrees of freedom 1,2,3,4,5,6 dof Based on movement Fixed robot Mobile Walking or legged Based on design (generation) First Second Third Based on technology Low Medium High LERT Classification LERT Classification – Linear, Extensional, Rotational, Twisting Types of industrial robots – Based on Coordinate system Cylindrical Coordinate Robot z x = r cos q z y y = r sin q r q r = 𝑥2 + 𝑦2 𝑦 (r,z,q) x q = tan −1 𝑥 Full 360° rotation is not permitted, due to restrictions imposed by hydraulic, electrical, or pneumatic connections or lines. Types of industrial robots – Based on Coordinate system Spherical Coordinate Robot (r,q,f) z r Because of mechanical and/or actuator connection limitations, the work envelope of such a robot is a portion of a sphere. Types of industrial robots – Based on Coordinate system Spherical Coordinate Robot r = r sin f f (r,q,f) z = r cos f z f z r x = r cos q = r sin f cos q r y = r sin q = r sin f sin q z = r cos f r = 𝑟2 + 𝑧2 r = 𝑥2 + 𝑦2 + 𝑧2  Assignment/Activity 1. A. Convert the cylindrical coordinates (5,10,p/4) to rectangular coordinates B. Convert the rectangular coordinates (10,15,15) to spherical coordinates C. identify the work volume for the equation x2+y2=16 and x2+y2+z2=16 Types of industrial robots – Based on Coordinate system Jointed arm Robot – Pure Spherical Links of the robot are pivoted and hence can move in a rotary or revolute. Major advantage - possible to reach close to the base of the robot and over any obstacles that are within its workspace Work envelope of a robot having this arrangement is approximately spherical. Pivot point is often referred to as an "elbow" joint Types of industrial robots – Based on Coordinate system Jointed arm Robot – Parallelogram Single rigid-member upper arm is replaced by a multiple closed-linkage arrangement in the form of a parallelogram Major advantage of this configuration is that it permits the joint actuators to be placed close to, or on the base of, the robot itself - arm inertia and weight are considerably reduced. Larger load capacity than is possible in a jointed spherical device for the same-size actuators. Major disadvantage of the parallelogram arrangement is that the robot has a limited workspace compared to a com parable jointed spherical robot Types of industrial robots – Based on Coordinate system Jointed arm Robot – Cylindrical Single r-axis member in a pure cylindrical device is replaced by a multiple-linked open kinematic chain Precise and fast but limited vertical (z direction) reach. Z-axis motion is controlled using simple (open-loop) air cylinders or stepper motors, other axes by electrical actuation Types of industrial robots – Based on Coordinate system Jointed arm Robot – Cylindrical - SCARA Subclass of the jointed cylindrical manipulator is the selective compliance assembly robot arm (SCARA) Types of industrial robots – Based on Coordinate system Cartesian Links of the manipulator are constrained to move in a linear manner. Often called as prismatic Cantilever Gantry The arm is connected to a trunk, which in turn is Extremely heavy loads with precise movement attached to a base. More rigid but may provide less access to the Members of the robot manipulator are constrained workspace to move in directions parallel to the Cartesian x, y, and z axes Have good repeatability and accuracy Easier to program because it has natural coordinate system. Types of industrial robots – Based on Control system Non servo controlled Other names often used to described such a manipulator are end point robot, pick- and-place robot, or bang-bang robot. Axes remain in motion until the limits of travel for each are reached. Once the manipulator has begun to move, it will continue to do so until the appropriate end stop is reached No monitoring of the motion at any intermediate points. Programming - by setting a desired sequence of moves and adjusting the end stops for each axis accordingly Manipulator "brain" consists of a controller/sequencer "Sequencer" portion - a motor-driven rotary device with a number of electrical contacts Such enabled contact will cause power to be switched to an axis actuator by the controller portion (pneumatic or hydraulic valve/piston arrangement) Types of industrial robots – Based on Control system Non servo controlled Typical operating sequence Start - the controller/sequencer sends to signal control valves on the manipulator's actuators - appropriate valves to open - manipulator begin to move. Members continue to move until it reach placed end stops (Limit switches). Sequencer now indexes to the next step. Controller again outputs signals to actuator valves - causing other members of the manipulator to move. Signals can be sent to gripper," causing it to open or close as desired. Process is repeated until all steps in the sequence are executed. Types of industrial robots – Based on Control system Non servo controlled Advantages Relatively high speed machines - small size of the arm Low cost and easy to maintain and operate Repeatability of about t0.01 inch Limitations Coordinated motion cannot be produced Types of industrial robots – Based on Control system Servo controlled Information about the position & velocity is continuously monitored and sends fed back to the control system associated with each of the joints of the robot Control permits the manipulator's members to be commanded to move and stop anywhere within the limit of travel Possible to control the velocity, acceleration, deceleration, and jerk Manipulator vibration can be reduced significantly. Larger memory capacity – store more positions Robot to be used in a variety of applications with a minimum of downtime Types of industrial robots – Based on Control system Servo controlled Point-to-point motion (pick-and-place robot) Straight line motion Continuous-path motion (spray painting, polishing, grinding, and arc welding) Not every servo-controlled robot is capable of performing straight-line and/or continuous-path motion. Joint actuators are usually either hydraulic valve/piston arrangements or servomotors. Programming is generally done by teach mode: possible to program each axis to move to almost any point along its entire. Coordinated motion can be achieved whereby two or more joints move simultaneously - manipulator is capable of tracing out an extremely complex path. May be more expensive and somewhat less reliable Great flexibility Cost-effective in large number of applications. Types of industrial robots – Based on Control system Servo controlled Typical operating sequence Actual position of all of the manipulator joints is obtained from appropriately mounted sensors Desired position information is sent out to the individual axes by a command. The actual and desired positions are compared for each joint and error is observed. Members of the robotic manipulator is moved. Position, velocity, and any other physical parameter of the motion are monitored and controlled by its feedback. The members stop moving and the manipulator is home position at the desired final point in space. Master computer then sends out the next taught point and the procedure repeats. Load handling capacity The maximum weight that a robot can handle satisfactorily during its normal operations and extensions – Payload Payload. Most robot assembly is done on parts that weigh less than 2 kg, and the large majority weigh only a few grams. The robot usually carries a tool that weighs much more, so the payload is usually dominated by tool weight. Both the weight of the tool and any part's it may carry must be considered since together they constitute the payload. Robot’s accuracy and repeatability relies on the payload Compromise between maximum payload and maximum speed Payload higher than that usually specified for the robot may be acceptable provided that the speed range is limited. Significance of payload is different with respect to the application. Application related to material handling has a significance over the payload capacity. Whereas the electronics industry requires higher accuracy and rapid cycle time and Payload is insignificant Load handling capacity  Assignment/Activity 2. List the industrial robots by its applications and compare the weight of each parts and payload of that robots. 3. CALCULATE ROBOT PAYLOAD - HTTPS://DIY- ROBOTICS.COM/PAYLOAD/ https://diy-robotics.com/the-importance-of-calculating-robot-payload- for-optimal-performance/ General considerations in Robotic material handling Part positioning and orientation Gripper design Minimum distances moved Robot work volume Robot weight capacity Accuracy and repeatability Robot configuration, degree of freedom and control Machine utilization Source : Groover - Industrial Robotics_ Technology Programming And Applications (Special Indian Edn), 2Nd Edn-MC GRAW HILL INDIA (2012) Material Handling - Material transfer Move parts from one location to another- Pick-and-place operation Parts must be presented to the robot in a known position and orientation - Reorientation of parts A low-technology robot (e.g., limited-sequence type) is often sufficient. Pneumatically powered robots are often used. Delta robots are used for many high-speed picking and packaging operations. Robot is equipped with a gripper that must be designed to handle the specific part or parts to be moved. Palletizing retrieves parts, cartons, or other objects from one location and deposits them onto a pallet or other container at multiple positions on the pallet robot must be taught each position on the pallet using the powered- lead through 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, and in the z-direction if the pallet is stacked. Depalletizing Removing parts from an ordered arrangement in a pallet and placing them at another location Stacking placing flat parts on top of each other, such that the vertical location of the drop-off position is continuously changing with each cycle Insertion Inserts parts into the compartments of a divided carton Material Handling - Material transfer How the Large objects and Large area coverage can be achieved? Team robot Material Handling - Material transfer Material Handling - Machine loading and unloading Loading and/or unloading – transfer of parts into and/or from a production machine. Grasp a workpiece from a supply point, transport it to a machine, orient it correctly, and then insert it into the workholder on the machine Do we need the communication between robot and machine? Yes After it placed in the right position the machine tool has to hold it, then robot withdraws the hand machine loading alone machine unloading alone machine loading and unloading Material Handling - Machine loading and unloading Automated loading and unloading Automated loading and unloading Automated loading and unloading CNC machine tool loading and unloading CNC machine tool loading CNC machine tool loading Robot centered Cell/Robotic manufacturing cells Linked cell manufacturing system (L-CMS) Manufacturing cells Manned manufacturing cell Manned manufacturing cell Single worker Two worker Manufacturing cells U-shaped cell with standing, walking workers Robotic manufacturing cells Tracking - robot is able to maintain the positions of the programmed points, including the orientation of the end effector and the motion velocities, in relation to the moving work part along a conveyor. Robot have computational and control capability to track. In-line robot workcell Sensing of the part on the conveyor. 1. Intermittent transfer - Moves the parts with a start-and-stop 3. Non-synchronous transfer/ power-and-free system motion from one workstation along the line to the next Each part moves independently along the conveyor in a stop- 2. Continuous transfer – Work parts are moved continuously and-go fashion. along the line at a constant speed. When a particular workstation has completed its processing of A moving baseline tracking system – robot is position a part, that part proceeds to move toward the next workstation as required in the line. A stationary baseline tracking system – manipulator design and operation of this type of transfer system is more will be moved complicated Robotic manufacturing cells Mobile robotic cell Track on floor system Overhead rail system Robotic manufacturing cells Robotic centered cell for gear manufacturing Considerations in workcell design Changes to other equipment in the cell. Part position and orientation Part identification Robot protection from environment Control of the workcell Utilities Safety  Assignment/Activity 4. Create a robotic centered work cell for a manufacturing industry 5. Identify the possible issues while deal with multiple robots