Robotics 1

Industrial Robotics

Prof. Alessandro De Luca

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What is a robot?

  industrial definition (RIA = Robotic Institute of America) re-programmable multi-functional manipulator

designed 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 environment and move intelligently in response

  ISO 8373 definition an 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

  more general definition (“visionary”) intelligent connection between perception and action

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Robots !!

Waseda WAM-8 (1984)

Comau H4 (1995)

Spirit Rover (2002)

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A bit of history

  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.) written by Karel Capek in 1920

  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 harm 2.  A robot must obey orders given to it by human beings, except

where such orders would conflict with the First Law 3.  A robot must protect its own existence as long as such protection

does not conflict with the First or Second Law

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Evolution toward industrial robots

  with respect to the ancestors   flexibility of use   adaptability to a priori unknown conditions   accuracy in positioning   repeatability of operation

computer numerically controlled

machines (CNC)

mechanical telemanipulators

1950

robot manipulators

1970 Unimation PUMA

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The first industrial robot

G. Devol and J. Engelberger (Unimation)

US Patent General Motor plant, 1961

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Robot manipulators

ASEA IRB-6 (1973)

first robot all-electric-drives

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Hirata AR-300 (1978)

first SCARA robot

Cincinnati Milacron T3

(1974) first micro- computer controlled

robot

Unimation PUMA 560

(1979) 6R with

human-like dexterity

World Robotics 2010

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  statistics by IFR available by the end of September of every year   executive summary for 2010

  industrial robot sales in 2009 slumped w.r.t. 2008 (–47%=–60K units)   lowest level since 1994   –62% in Japan, –48% in USA, –41% in Europe, –40% in Italy   –52% in automotive, ≈ only in food and pharmaceutical industries

  operational stock of industrial robots around 1M units in 2009 (–1%)   service robot sales for professional and personal/domestic still promising:

78K units sales in 2009, for $13.2 billion value   surveillance/military (30%), field/milking (25%), medical (8%), ...   1 million of robotic vacuum cleaners, 26K of lawn mowers, ...

World Robotics 2011

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  statistics by IFR available since September 2011   executive summary for 2011

  industrial robot sales in 2010 almost doubled w.r.t. 2009 (118K units)   Asia (70K units, +132%), tripled in China and Korea   total sales to Italy up by 57% (4.5K units)   automotive and electronics industry are drivers in the comeback

  operational stock of industrial robots >1.035M units in 2010 (+1%)   service robot sales increased again in 2010, both for professional (+4%)

and personal/domestic (+35%, 2.2M units)   professional use: defense (6125 units, 45% share), milking robots

(4200, 30%), medical/robot surgery (932, 7% but 43% in value)

Diffusion Industrial robots in operation worldwide

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length of robot service life is estimated in 12-15 years

Forecast of diffusion Industrial robots in operation by areas

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World Robotics 2011 between 1.035 and 1.3 million robots!

Annual Supply New robots worldwide

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World Robotics 2011

Annual Supply New robots by industrial sectors

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World Robotics 2011

Forecast of supply New robots by areas

Robotics 1 14 forecast: annual average increase of 10% in 2011–2013

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Robot prices

An articulated industrial robot with six degrees of freedom of medium/large size costs about 100 KEuro

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Density of robots - 1

number of robots per 10000 employees in the manufacturing industry in 2004

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Density of robots - 2

number of robots per 10000 employees in the automotive industry in 2002 and 2004

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Density of robots - 3

estimated number of operating robots per 10000 employees in various industries in 2010

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World Robotics 2010

Industrial robot and its auxiliary equipments

1. Comau SMART H robot 2. C3G Plus controller 3. Welding control box 4. Application software 5. Air/water supply 6. SWIM Board 7. Integrated cables 8. Welding gun 9. Auxiliary devices in the

robotic cell (servo-controlled axes)

SWIM = Spot Welding Integrated Module

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ABB IRB 7600

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commercial video by ABB

Industrial applications

•  manipulation (pick-and-place) •  assembly •  spray painting and coating •  arc welding •  spot welding with pneumatic or servo-controlled gun •  laser cutting and welding •  gluing and sealing •  mechanical finishing operations (deburring, grinding)

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Plasma cutting

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video

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

electrode

nozzle

hot plasma

gas chamber

Robotized workcell

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3D simulation of robotic tasks

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

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Welding - 1

•  spot with servo-controlled gun •  stud welding

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Welding - 2

•  spot (discrete) or arc (continuous)

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Two cooperating robots in welding

ABB video at Laxa, Sweden

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Palletizing

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

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Palletizing of cheese forms

using Kawasaki robots (courtesy of Effedue Engineering)

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video

Folding

with loading of sheets under the press

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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

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Deburring center

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

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video

Off-line robot workstation

articulated robot in metal surface finishing operation

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Safety in robotic cells

commercial video from ABB SafeMove cell monitoring system (no fences!)

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Robot manipulator kinematics

Comau Smart H4

closed kinematic chain

Kuka 150_2 (series 2000)

open kinematic chain (rigid bodies

connected by joints)

Fanuc F-200iB

parallel kinematics

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Other types of robots - 1

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

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Adept Cobra i600

fastest SCARA robot for pick-and-place tasks!

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video

Other types of robots - 2

Comau Mast gantry robot

(payload up to 560 kg)

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

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Chocolate packaging with lightweight parallel robots

test video with ABB Flexpicker

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video with Adept Quatro s650

Distribution by robot type

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

of kinematic configuration

63%15%

10%

12%

articulated cartesian/gantry cylindric SCARA

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Robot data sheet

Fanuc R-2000i/165F

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Workspace

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Visualization of workspace

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

video

Robot end-effector sensors and tools

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Calibration of robot kinematics

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Man-machine interface

•  teach-box pendant used as robot programming interface

•  cabinet with power electronics for robot supervision and control

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Programming and control environment

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control modules and interfaces (Reis Robotics)

Motion programming and scaling

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commercial video from ABB TrueMove & QuickMove fast motion control performance

Mobile base robots in industry

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

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Lifting AGV for warehouses

video by Elettric80

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Intelligent AGV in factories

commercial video of ADAM mobile robot (RMT Robotics)

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