Introduction to Robotics In CIM Systems Third Edition

James A. Rehg The Pennsylvania State University Altoona Campus

Prentice Hall Upper Saddle River, New Jersey Columbus, Ohio

Contents

Introduction to Industrial Robotics

1-1 Introduction 1

1-2 History of the industry 2

1-3 Thirty-year-old industry 4

1-4 Integrated systems—meeting the external and internal challenges External challenges, 6

Internal challenge, 9 Meeting the internal challenge, 10

1 -5 The problem and a solution 13

1-6 Definition of robotics and computer-integrated manufacturing 13

1-7 Manufacturing system classification 15 Project, 15 Job shop, 16 Repetitive, 17 Line, 17 Continuous, 17

1-8 Robot systems 19 Basic system, 19 Mechanical arm, 19 Production tooling, 21

IX

External power source, 22 Robot controller, 22 Teach stations, 24

1-9 Some basic terms 26

1-10 Robot standards 32 R15 standards, 32

A15 standards, 32

1-11 Summary 33 Questions, 33 Problems, 34 Projects, 35

2 Robot Classification 36

2-1 Introduction 36

2-2 Robot arm geometry 36 Cartesian geometry, 36 Cylindrical geometry, 40 Spherical geometry, 44 Articulated geometry, 44

2-3 Power sources 49 Hydraulic drive, 49 Pneumatic drive, 51 Electric drive, 52

2-4 Application areas 54 Assembly, 54

Nonassembly, 55

2-5 Control techniques 55 Closed-loop systems, 55 Open-loop systems, 63

2-6 Path control 67 Stop-to-stop control, 68 Point-to-point control, 70 Controlled path, 72 Continuous path, 73

2-7 Classification by the International Standards Organization 74 Sequenced, 74 Trajectory, 74 Adaptive, 74 Teleoperated, 74

x Contents

External power source, 22 Robot controller, 22 Teach stations, 24

1-9 Some basic terms 26

1-10 Robot standards 32 R15 standards, 32

Al 5 standards, 32

1-11 Summary 33 Questions, 33 Problems, 34 Projects, 35

2 Robot Classification 36

2-1 Introduction 36

2-2 Robot arm geometry 36 Cartesian geometry, 36 Cylindrical geometry, 40 Spherical geometry, 44 Articulated geometry, 44

2-3 Power sources 49 Hydraulic drive, 49 Pneumatic drive, 51 Electric drive, 52

2-4 Application areas 54 Assembly, 54 Nonassembly, 55

2-5 Control techniques 55 Closed-loop systems, 55 Open-loop systems, 63

2-6 Path control 67 Stop-to-stop control, 68 Point-to-point control, 70 Controlled path, 72 Continuous path, 73

2-7 Classification by the International Standards Organization 74 Sequenced, 74 Trajectory, 74 Adaptive, 74 Teleoperated, 74

x Contents

2-8 Summary 75

Questions, 75

Problems, 76

Projects, 77

Automated Work Cells and CIM Systems

3-1 Introduction 78

3-2 The CIM implementation process 79

Step 1: Assessment of enterprise technology, human resources, and syst

Step 2: Simplification—elimination of waste, 81

Step 3: Implementation with performance measures, 83

3-3 Making the process work 85

3-4 Automated production 86

3-5 Flexible automation 87

Case: Electronic assembly of odd-form surface-mount devices, 89

Case: Through-hold printed circuit board assembly, 91

3-6 Fixed automation 93

In-line fixed automation, 93

Rotary-type fixed automation, 93

3-7 Implementing automated work cells 94

New versus existing production machines, 94

Fixed versus flexible automation, 94

3-8 Automation case study 96

Case: CIM Automation at West-Electric, 96

Part 1: Introduction, 96

Part 2: Turbine blade production, 99

Part 3: CDM improvement process, 107

Part 4: The automation plan, 109

3-9 Summary 112

Questions, 113

Problems, 114

Case projects, 114

End-of-Arm Tooling

4-1 Introduction 116

4-2 Classification 117

Standard grippers, 117

Vacuum grippers, 121

Vacuum surfaces, 124

Vacuum suckers, 124

Magnetic grippers, 124

Air-pressure grippers, 125

special-purpose grippers, 128

4-3 Gripper selection and system intelligence 1

4-4 Special-purpose tools 130

4-5 Robot assembly 131

4-6 Compliance 131

Active compliance, 132

Passive compliance, 133

4-7 Multiple end-effector systems 138

Wrist interface, 138

Multiple-gripper systems, 138

4-8 Automation case study 141

Case: CIM Automation at West-Electric, 141

Work-cell technical design checklist, 142

Robot selection checklist, 143

4-9 Summary 148

Questions, 148

Problems, 149

Case projects, 149

Automation Sensors

5-1 Introduction 151

Discrete sensors, 152

Analog sensors, 152

5-2 Contact sensors 153

Discrete devices, 153

Artificial skin, 157

5-3 Noncontact sensors 160

Proximity sensors, 161

Photoelectric sensors, 167

5-4 Process sensors 173

5-5 Automation case study 173

Case: Automation at West-Electric, 173

Performance measures, 174

Technical issues, 174

Oven modification, 178

5-6 Summary 179 Questions, 181 Problems, 182 Case projects, 182

6 Work-cell support systems

6-1 Introduction 184

6-2 Machine vision systems 184 Vision standards, 185 Vision system components, 185 Image measurement, 188 Image analysis, 189 Image recognition, 190

6-3 Lighting for machine vision 191 Selection of the light source, 191 Lighting techniques, 192 Illumination sources, 192

6-4 Material handling 194

Automated transfer systems, 195

6-5 Part feeding 196

6-6 Inspection 197

6-7 Automatic tracking 198

6-8 Automation case study 200 Case: CIM automation at West-Electric, 200

6-9 Summary 205 Questions, 207

Case projects, 207

7 Robot and System Integration

7-1 Introduction 209

7-2 System overview 211 Hardware overview, 211 Software overview, 212

7-3 Work-cell architecture 212 Cell controllers, 212

Cell control software structure, 212 Work-cell management software, 214

7-4 Programmable logic Controllers 215 PLC system components, 215 Basic PLC system operation, 216

7-5 Computer numerical control 218

7-6 Controller architecture 219 Nonservo robot controllers, 219

Servo robot controllers, 220

7-7 Interfaces 224 Simple sensor interface, 224 Complex sensor interface, 225 Enterprise data interface, 228

7-8 An integrated system 228 Machining cell, 228 Assembly cell, 228 Signal types, 230 Work-cell controller, 230 Programmable logic controller, 231

7-9 Automation case study 231 Case: CIM automation at West-Electric, 231

7-10 Summary 231 Questions, 234

Case projects, 235

8 Work-Cell Programming 236 8-1 Introduction 236

8-2 Work-cell controller programming 237 In-house-developed software, 237 Enabler software, 238 OSI solution, 238

8-3 Programming sequential cell activity 239 PLC programming, 240

Other sequential programming options, 242

8-4 Robot language development 242

8-5 Language classification 243 Joint-control languages, 243 Primitive motion languages, 244 Structured programming languages, 245 Task-oriented languages, 245

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8-6 Robot program fundamentals 246

8-7 Translation or position points for servo robots 249 Reference frames, 249

Application Note: robot system simulation, 251 Programming servo robot translation points, 252 Programming nonservo robot translation points, 256

8-8 Program statements for servo robots 256 Basic program structure, 256

Process analysis, 257 Tasks and subtasks, 257

Task point graph, 258 On-line and off-line programming, 258

Translation points and system variables, 260

8-9 Automation case study 261 Case: CIM automation at West-Electric, 261

8-10 Summary 263 Questions, 264

Problems, 265

Case projects, 265

Justification and applications of work cells

9-1 Introduction 266

9-2 Capital equipment justification 267 Return on investment method, 268 Cash flow method, 268 Time value of money, 268 Justifying robotics applications, 269

9-3 Automation applications 269 Material handling, 269

Application note: Material handling of electrical relays, 270 Application note: Cookie packaging, 272

Machine tending, 273 Assembly, 273

Application note: Mechanical assembly of fluorescent light fixtures, 274 Application note: Mechanical assembly of dishwasher and vacuum

cleaner components, 275 Application note: Force sensor assists in automotive piston assembly, 277 Process, 278

Application note: Cookie sandwiching, 280

Welding, 281

Application note: Kendon Inc.'s peacock struts its stuff, 284

Painting, 282

9-4 Automation case study 287 Case: CIM Automation at West-Electric, 287

9-5 Summary 287 Questions, 287 Problems, 289 Case projects, 290

Safety

10-1 Introduction 291

10-2 Occupational Safety and Health Administration (OSHA) 292

10-3 American National Standards Institute/Robotic Industries

Association Standard for Robot Safety 293

10-4 Safeguarding a work cell 293 Safeguarding devices, 294 Safeguarding the operator, 295 Safeguarding the programmer, 295 Safeguarding maintenance and repair personnel, 295

10-5 Definitions 296

10-6 Automation case study 296 Case: CIM automation at West-Electric, 296

10-7 Summary 299 Questions, 300

Case projects, 300

Human Interface: Operator Training, Acceptance, and Problems

11-1 Introduction 301

11-2 General training 302 General training program, 302

11-3 Operator training 303

11-4 Maintenance training 303

11-5 Team-based manufacturing 304 Description of a self-directed work team, 305

Making work teams work, 305

11-6 Resistance 306

11-7 Organized labor 307

11-8 Automation case study 307 Case: CIM automation at West-Electric, 307

11-9 Summary 307 Questions, 308

Contents xvii