ABB History of Robots

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© ABB GroupDecember 9, 2011 | Slide 1

History, applications, market2011-12-05,




Outline

Robot history

Introducción a la Robótica,Morfologia, Tipos de Robots,Principlaes Aplicaciones

Main Applications

Arc Welding, Material Handling, SpotWelding

ABB Robotics history and trends

Robotics market




The world’s first robot?

Al-Jazari (1136-1206), an Arab Musliminventor, designed and constructed anumber of automatic machines, includingkitchen appliances, musical automatapowered by water, and the firstprogrammable humanoid robot in 1206.

Al-Jazari's robot was a boat with fourautomatic musicians that floated on alake to entertain guests at royal drinkingparties. His mechanism had aprogrammable drum machine with pegs

(cams) that bump into small levers thatoperate the percussion. The drummercould be made to play different rhythmsand different drum patterns by movingthe pegs to different locations

http://upload.wikimedia.org/wikipedia/en/2/2f/Al-jazari_robots.jpg





Leonardo da Vinci’s robot

design from 1495

A knight in German-Italian medieval armour • Sitting up• Moving its arms• Moving its neck• Moving its jaw

http://upload.wikimedia.org/wikipedia/commons/4/45/Leonardo-Robot3.jpg





17th century





Digesting Duck

created by Jacques deVaucanson in 1739was able to eat grains, flapit wings and excrete

http://upload.wikimedia.org/wikipedia/commons/7/75/Duck_of_Vaucanson.jpg





The human machine

Barbarossa with hiscreator 1900

Automaton =

self-operating machine




What is a robot?




IFR uses ISO definition

There are many definitions

ISO defines a robot as "an automaticallycontrolled, reprogrammable, multipurpose,manipulator programmable in three ormore axes, which may be either fixed inplace or mobile for use in industrialautomation applications

IFR = International Federation of Robotics




The Father of the Industrial Robot

1954: George Devol patented the first teachable robot

1956: George Devol and Joseph Engelberger started thefirst robot company

1961: Joseph Engelberger sold the first Unimate robotto GM for tending a die casting machine.

Unimate: hydraulic driven, polar type

Joseph

George

http://upload.wikimedia.org/wikipedia/en/6/67/George_C_Devol_Color_Photo.jpg




The Father of the Electrical Robot

Oct 1971 – April 1972Björn Weichbrodt created a concept for a

completely new type of robot April 1972 – February 1973

Björn and his project team of 20 personsdeveloped the first microprocessor controlled,electrically driven, antropomorphic type robot

1974The first IRB 6 was sold to Magnusson inGenarp, Sweden, for polishing of stainless steeltubes




Some milestones of the industrial robot

1960’s, Hudraulic and pneumatic robotsUnimate, Electrolux MHU

1971, Cincinnati Milacron, first mini computer controlledrobot

1973, ASEAFirst electrically driven, micro-processor controlled,antropomorphic robot, IRB 6

1970’s, Many new suppliers

Robots & Humans in competition 1981, Asea buys Electrolux MHU robots

1985, Asea buys Trallfa paint robots

1980’s, Shake-out, acquisitions1986: some 300 robot suppliers globally

1990’s, Robots for non-industrial use

Robots & Humans in coexistence 2000’s, Robots & Humans in collaboration

and what’s next?

2010’s, Robots & Humans colleagues? IRB 6




The first years

1960’s 1970’s 1980’s

Thanks to ABB




Outline

Robot history

Applications

ABB Robotics history and trends Robotics market




Major applications

Arc welding

Spot welding

Material handling




Growing applications

Packaging/palletizing

Picking

Bio applications



© ABB GroupDecember 9, 2011 | Slide 23 23

Dedicated robots

4-axis

palletizingrobot

Integrated

arc weldingmedia supply

Integratedspot weldingmedia supply




Surgery robots

CyberKnife ® Stereotactic Radiosurgery System




Luggage handling robots at airports




Library robots sorting books




Entertainment robots




Cow milking robots




Dumper cleaning robots




Robots Unlimited?

Today

Home – vacuum cleaner s, lawn movers…..

Care – surgery, transport, feeding, artificial muscles…..

Controlled via internet – games, surgery, toys

Hobby – building and programming own robots

Others – ventilation, subwater, nuclear…..

…….

http://upload.wikimedia.org/wikipedia/commons/0/0d/Laproscopic_Surgery_Robot.jpg


http://upload.wikimedia.org/wikipedia/en/4/4b/Robocup_Team_Osaka%27s_VisiON.jpg



http://upload.wikimedia.org/wikipedia/en/0/04/Pyxis_Pharmacy_Robot_by_Nurse_Station.JPG



http://upload.wikimedia.org/wikipedia/commons/8/84/Toyota_Robot_at_Toyota_Kaikan.jpg



http://upload.wikimedia.org/wikipedia/commons/8/84/Toyota_Robot_at_Toyota_Kaikan.jpg



http://upload.wikimedia.org/wikipedia/en/4/4b/Robocup_Team_Osaka%27s_VisiON.jpg




Robots Unlimited?

Tomorrow

Personal robots

Repairing blood vessels (micro robots)

Repairing machines (mini robots)

…..




Outline

Robot history

Applications





We developed the world's first paint robot

Developed 1964 - 67

First sold 1969




We developed the world’s first electrical robot

IRB 6

1974-1991

IRB 60

1975-1990

IRB 90

1982-1991




IRB 1000

1984 to 1990

IRB 300

1985-1986

Manipulators for assembly

IRBM

Magazine




First modular robot

IRB 60001991 - 1994




Controllers

S2 1983 - 1991 S3 1987 - 1996 S4 1994 - 1999

S4C 1996 - 2000

S4Cplus 2000 - 2007

S1 1974 - 1982

IRC5 2004 -

http://stage-www.abb.com/global/gad/gad02477.nsf/vwImages/86105DCB2F7AF5DDC125739F003CB4EC/$File/IRC5P.jpg




Auxiliary products

S2 Offline programming system PC software

First 1981

Vision system

S2 integrated, some 200 unitssold 1982 -1989

LaserTrak Seam tracker for arc welding

applications 1983 - 1988




General trends

Robots have over the last 25 years:

Increased accuracy 1.0 - 0.1 mm Increased performance i. e. acceleration

Increased functionality from 16 to several hundred)

Improved user interfaces (4 digits Windows type indefinite)

Increased communication interfaces(16 in/out 1024 signals, field buses, Ethernet)

Increased process control

Increased computational power (8 kb 13 Mb)

Improved quality, MTBF, uptime




Acquisitions

1989

1990

1990

1991

19921992

1993

1995

1996

1996

1989

1990

1990

1991

19921992

1993

1995

1996

1996

Powertrain Assembly

Spot Welding

Waterjet Cutting

Robotics Painting

Arc WeldingPackaging and Palletizing

B-I-W / Robotics

Paint Application

Powertrain Assembly

B-I-W and Press Automation

Powertrain Assembly

Spot Welding

Waterjet Cutting

Robotic Painting

Arc WeldingPackaging and Palletizing

B-I-W / Robotics

Paint Application

Powertrain Assembly

B-I-W and Press Automation

DEMTA, Germany

Cincinnati Milacron, USA

JV ABB Ingersoll Rand

Graco Robotics, USA

ESAB Robotics, Europe, AmericasAstrobotic, France

Preciflex Systems / ACMA, France

Capponi Alesina, Italy

Wilson Automation, USA

Olofström Automation, Sweden, Canada

DEMTA, Germany

Cincinnati Milacron, USA

JV ABB Ingersoll Rand

Graco Robotics, USA

ESAB Robotics, Europe, AmericasAstrobotic, France

Preciflex Systems / ACMA, France

Capponi Alesina, Italy

Wilson Automation, USA

Olofström Automation, Sweden, Canada




Outline

Robot history

Applications





ABB experience – about 200,000 installations

Other Appl.

12%

Paint

Finishing

8%

Other

Processing

10%

Spot

Welding

20%

MT/MH

35%

Arc Welding

15%




Robotics market by industry – Worldwide




Annual shipments per geographic area




Robot market – Mexico

Robot shipments to Mexico slightly increased in 2009to1,100 units

European and Asian motor vehicle suppliers orderedindustrial robots to increase their capacities

Mexico started to gain importance as a production site forthe automotive industry for financial reasons




IRC5 Basic Programming

The Fundamentals of Robot Programming



IRC5 Program File structure

MODULE MainModule

PROC main()

Rotuine1;

Routine2;

ENDPROC

PROC Routine1()

MoveL;

ENDPROC

PROC Routine2()

MoveL;

ENDPROC

ENDMODULE

<?xml version="1.0" encoding="ISO-8859-1" ?>

<Program>

<Module>ModuleA.mod</Module>

<Module>MainModule.mod</Module>

</Program>

NewProgramName.pgf

MainModule.mod

Folder NewProgramName

MODULE ModuleA

PROC RoutineA1()

MoveL;

MoveL;

ENDPROC

ENDMODULE

ModuleA.mod



There are two types of Modules:

Program (.mod)

System (.sys)

A module consists of:

Routines

Data

Module Types

MainModuleMain

Data

rPickUp rDropOff



MoveJ or MoveL?

Joint interpolation is often the fastest way to move between two pointsas the robot axes follow the closest path between the start point and thedestination point (from the perspective of the axis angles). Use when in

open spaces such as moving from one fixture to another.

LINEAR interpolation is the most accurate motion between two points.The robot will maintain a straight line of the TCP from the starting point tothe end point. If this is not possible an event will be generated. Use

when robot is moving close to other objects such as fixtures or

parts.

MoveJ

MoveL



Move Instructions

MoveL pHome, v500, z5, tGripper

In the instruction above:

The robot is moving to _________________

At a speed of ________________________

With a zone of _______________________

And a TCP of ________________________

pHome

v500

z5

tGripper

MoveJ pHome, v500, z5, tGripper

M I i



Move Instructions

B i I/O I t ti



Basic I/O Instructions

The two instructions for turning an output ON are

_________ and __________.

The two instructions for turning an output OFF are _________ and __________.

To just change the status of an output use _______________.

Set SetDO

Reset

InvertDO

SetDO

To turn an output on for a short time, then off againuse _____________.

To change the amount of Pulse time go into ____________.

PulseDo

Opt. Arg.

B i I/O I t ti



Basic I/O Instructions

The ______________ instruction is used for waitingfor a single input.

The ______________ instruction is used to wait for acomplicated condition.

The ______________ instruction is used for waitingfor an amount of time.

WaitDI

Waittime

WaitUntil

I/O I t ti



I/O Instructions



I/O Timing

p40

p30 p20DT

DT is a time dependant on processor load.

p10

Indicates when output comes on.

I/O Ti i



P40

P30

I/O Timing

P20

p10

Indicates when output comes on.



Sistema Motor Drive

Ci it M t D i



Circuitos Motor Drive

Vista General del Sistema de Drives



Vista General del Sistema de Drives

DIAGRAMA DE BLOQUES DELSISTEMA DE DRIVES.

COMPUTADORA DE EJES

COMPUTADORA

PRINCIPAL DRIVE UNIT MOTOR

RESOLVER

Serial Measurement Board

CONTROL DE

CORRIENTE

CONTROL DE

VELOCIDAD

CONTROL DE

POSICIÓN

GENERADOR

MOVIMIENTO M

R

Dentro del controlador

Dentro del manipulador

Flexible Controller



Flexible Controller Control module

Contains computer unit, safety interface,

control panel, space for standard andcustomer options

Drive module

Contains drive system, axis computer,transformer, mains connection & filter

Building block for MultiMove application (up to4 drive cabinets connected to a single controlcabinet)

Height 1250 mm, footprint 700 * 700 mm

Motor IRC5



El rectificador provee 340 VDC a los drives a través de laBarra Bus

Motor – IRC5

BarrasBus

Drives

Rectificador

Módulo de Potencia: Robot pequeño con ejes ext



Módulo de Potencia: Robot pequeño con ejes ext.

Rectificador Drives*Capacitor

Computadora

de ejes

* Vacío para robots pequeños, si no hay ejes externos

Drives paraejes ext.

K42K43

Motor IRC5



Estructura del motor

Motor – IRC5

Magnetos delRotor

Bobina del Estator Rodamientos

Resolver Freno

Flecha



Entradas y Salidas en

IRC5



Entradas y Salidas en IRC 5

Estructura del diseño de E/S Buses de Campo Maestros en IRC5

Ejemplos de configuración de E/S

E/S Simuladas



Buses de campo Maestros soportados en IRC5

Ethernet IP Maestro/Esclavo

ABB History of Robots

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