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Basic industrial Robots 2/8/2016 at FIBO

Basic Industrial Robots

By

Supachai Vongbunyong, Ph.D.

Institute of FIeld roBOtics | King Mongkut’s University of Technology Thonburi

Basic industrial Robots 2/8/2016 at FIBO

Outline

1. Overview

2. Robot Specifications

3. Coordinate System

4. Robot Control and Operation

5. Applications

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Basic industrial Robots 2/8/2016 at FIBO

Robot Population 1. Overview

“In Korea, Germany and Japan, there is a ratio of 270-400 robots for every 10,000 human workers “

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Robot Population 1. Overview

Thailand is one of the rapidly growing robot markets in Asia

http://www.ifr.org/industrial-robots/statistics

Estimated yearly shipment of multi-purpose industrial robots

(Number of units)

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Robots vs Fixed Automation 1. Overview

Pro

du

ctio

n V

olu

me

Product Variety

Robotics

https://somemmec.wordpress.com/2013/03/09/what-are-different-types-of-automation-or-compare-hard-automation-and-soft-automation/

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Industrial Revolution 1. Overview

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Robot Selection 1. Overview

• Speed and motion • Weight to be handled (Payload) • Accuracy and repeatability • Axes, reach, and volume (Workspace) • Program and controller

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Components of Industrial Robots 1. Overview

• Robot arm • Robot controller • Teach pendant • Robot tooling

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Types of Robots 2. Robot Specification

Types of robots typically used in industrial applications

• Cartesian • SCARA • Articulated • Delta

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Cartesian Robot (XYZ Robot) 2. Robot Specification

• Payload: very high • High accuracy • Not flexible • Easy to program

http://www.designworldonline.com http://seamco.be

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SCARA 2. Robot Specification

• Payload: 3-20 kg • Fast • Good for pick-and-place

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Articulated Robot 2. Robot Specification

• Payload: 3-2000 kg • Highly flexible • Advance programming

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Delta Robots 2. Robot Specification

• Payload: < 3 kg • High speed • Small payload

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Axes & Reach & Volume 2. Robot Specification

• Degree of Freedom (DOF) • Workspace

• Reachable Workspace • Dexterous workspace

ABB Fanta challenge https://youtu.be/SOESSCXGhFo

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Degree of Freedom (DOF) 2. Robot Specification

4 DOF Robot (RRRR)

3 DOF Robot (RRP)

R = Revolute Joint P = Prismatic Joint

http://www.societyofrobots.com/

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Degree of Freedom (DOF) 2. Robot Specification

How many DOFs of these robots ?

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Workspace 2. Robot Specification

Workspace Volume of space which can be reached by the end effector

Dextrous workspace

Volume of space where the end- effector can be arbitrarily oriented

Reachable Workspace

Volume of space which the robot can reach in at least one orientation

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Workspace 2. Robot Specification

Product datasheets normally show reachable workspace

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Workspace of Common Configuration 2. Robot Specification

Cartesian Cylindrical Spherical Articulated

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Coordinate System 3. Robot coordinate

Frames - Robot frame - World frame - Base frame - Tool frame

http://www.learnchannel.de/de/robo/kos-roboter

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Position and Orientation 3. Robot coordinate

Position X, Y, Z Orientation roll, Pitch, Yaw

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Kinematics – Forward & Inverse 3. Robot coordinate

• Forward Kinematics (joint angle XYZ) • Inverse Kinematics (XYZ Joint angle)

http://www.slideshare.net/hirokazutanaka/computational-motor-control-kinematics-dynamics-jaist-summer-course

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Kinematics - Singularity 3. Robot coordinate

https://youtu.be/zlGCurgsqg8

Kinematic singularity is a point in the workspace where the robot loses its ability to move the end effector in some direction no matter how it moves its joints. It typically occurs when two of the robot's joints line up, making them redundant.

http://blog.robotiq.com/why-singularities-can-ruin-your-day

Wrist Singularities - the robot's wrist axes (joints 4 and 6) line up with each other. This can cause these joints to try and spin 180 degrees instantaneously. Shoulder Singularities - the center of the robot's wrist aligns with the axis of joint 1. It causes joints 1 and 4 to try and spin 180 degrees instantaneously. Elbow Singularities - the center of the robot's wrist lies on the same plane as joints 2 and 3. Elbow singularities look like the robot has "reached too far", causing the elbow to lock in position.

https://youtu.be/1zTDmiDjDOA

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Dynamics 3. Robot coordinate

Dynamic model

T1

I2

m2

I1

m1

T2

T = Torque

m = Mass

I = Inertia

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Robot Movement 3. Robot coordinate

• Point – to – Point Motion: • All Axes start and end simultaneously • All Geometry is computed for targets and relevant Joint changes

which are then forced to be followed during program execution

• Path or Trajectory Controller Motion • Motion is performed through a time sequence of intermediate

configurations computed ahead of time or in real time • Paths are “Space Curves” for the n-Frame to follow

Path Control in Robotics ME 4135, Lecture series 8 – by Richard R. Lindeke, Ph. D

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Trajectory 3. Robot coordinate

• Joint motion

• Cartesian motion

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Repeatability and Accuracy 3. Robot coordinate

Accuracy Difference between the requested task and the obtained task

Repeatability Ability to achieve repetition of the same task

Precision: “Reproducibility” & “Repeatability”

Accurate & Repeatable

Inaccurate & Non-repeatable

Accurate & Non-repeatable

Inaccurate & Repeatable

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Connections 4. Robot Control & Operations

• Communication (TCP/IP, DIO, Serial) • Multiple Robots

ABB IRC5 Controller

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Connections

• Multiple axes • Integrated I/O Controller • Integrated vision system

ABB IRC5 Controller

4. Robot Control & Operations

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Robot Programming

• Number of programs • Program Length • Programming Language • User Interface

ABB FlexPendant RobotStudio

• Program with Pendant • Program with software • Program by teaching

4. Robot Control & Operations

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Sensors

• Force/Torque sensors • 2D vision • 3D vision • Safety sensors • Collision detection

4. Robot Control & Operations

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Sensors - Force/Torque sensors

4. Robot Control & Operations

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Sensors – Vision System

Eye-in-hand or end-point closed-loop control, where the camera is attached to the moving hand and observing the relative position of the target.

Eye-to-hand

or end-point open-loop control, where the camera is fixed in the world and observing the target and the motion of the hand.

4. Robot Control & Operations

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Sensors – 2D Vision

http://www.vision-systems.com/articles/print/volume-19/issue-7/features/vision-guided-robot-speeds-optical-filter-analysis.html

4. Robot Control & Operations

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Sensors – 3D Vision

• Stereo Cameras • Depth Camera • Laser scanner • 3D scanners

4. Robot Control & Operations

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Sensors – Vision System Applications • Code reading & print verification • Visual guidance • Pick & Place • Assembly • Dimension gauging • Defect detection and sorting

https://www.youtube.com/watch?v=v9oeOYMRvuQ

https://www.youtube.com/watch?v=6iXIoCDW7_Y https://youtu.be/vNgz96-AVFo

4. Robot Control & Operations

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Sensors – Safety Sensors

http://www.fabricatingandmetalworking.com/2013/05/design-considerations-for-robotic-welding-cell-safety

4. Robot Control & Operations

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End Effectors and Tools

• Grippers • Mechanical Grippers • Vacuum Grippers • Other Grippers

• Spray • Welding • Tool changer

4. Robot Control & Operations

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Robot Safety

Normal Safety Standard • Risk Assessment • Safeguarding Technology • Perimeter Guarding

New Safety Standard • ANSI/RIA R15.06-2012 & • ISO 10218:2011 • “Collaborative operation” • “Safety-rated soft axis” • “Space limiting technology”

4. Robot Control & Operations

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New Robot Safety – Collaborative Operation 4. Robot Control & Operations

“Collaborative operation” which is the introduction of a worker to the loop of active interaction during automatic robot operation. Systems can now be designed for the operator to directly load/unload the robot or manually drive the robot to a selected location thus eliminating costly fixtures.

ABB - YuMi

http://www.robotics.org/content-detail.cfm/Industrial-Robotics-News/New-Robot-Safety-Standard-Approved/content_id/4118

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New Robot Safety - Safety-rated soft axis & space Limiting

4. Robot Control & Operations

Pilz SafetyEyes

“Safety-rated soft axis” and “space limiting” technology Safety-rated software is used to control the robot motion so that restricted space can be more flexibly designed. Case studies have shown that that this saves both floor space and cost in the system design.

Collision Avoidance

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Small Robots 4. Robot Control & Operations

“Low cost robots like Baxter, UR5 and UR10 successfully entering small and medium enterprises (SMEs)” Frank Tobe , May 14, 2013 [ROBOHUB]

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Small Robots – When to Use ? 4. Robot Control & Operations

• Tasks with low payload • Low budget • Small space • Need robot that works closely with human • Not familiar with robot programming language

Rethink - Sawyer vs Universal Robot Fanuc LR Mate & UR5 & ABB IRB120

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Small Robots – When to Use ? 4. Robot Control & Operations

Baxter Rethink – Sawyer Universal Robot – UR3

http://www.allied-automation.com/battle-of-the-bots-universal-robots-ur3-vs-rethink-roboticss-sawyer

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Typical Robot Applications Conclusions

• Welding

• Painting

• Loading & Unloading

• Palletizing & Packaging

• Grinding & Forming

Examples • Motoman pick & place https://youtu.be/jPCiT8INik0 • ABB Palletizing food https://youtu.be/taTL_nozwJs • Palletizing sugar bag https://youtu.be/OBeb0bxp3F8 • KUKA grinding implant https://youtu.be/gO_8spCu29M • BMW Welding Shop https://youtu.be/-CRPcHH6uJ8 • FANUC bottles loading https://youtu.be/gvthU89BwQM • Disassembly Robot https://youtu.be/Sfjt2pvaNEg

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Modern Robot Applications Conclusions

• Food Handling

• Agriculture

• Medicine

• Entertainment

• Military & Security

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Smart Factory - Industrie 4.0 5. Applications

• Machine to Machine Communication (M2M)

• Smart Products know process and destination

• IoT - Cloud & Big Data

• Mass customization

• Self optimization

Networked Factory

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Robotics in Industrie 4.0 Conclusions

• Machine to Machine Communication (M2M)

• Human robot collaboration

Source - http://www.advantech.com/iretail-hospitality Source- TU Vienna Learning & Innovation Factory

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Industrial Services at FIBO Conclusions

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Industrial Services at FIBO Conclusions

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Industrial Services at FIBO Conclusions

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Thank you

Supachai Vongbunyong, PhD

Innovation and Advanced Manufacturing (I AM) Research Group http://www.fibo.kmutt.ac.th/iam

Supachai_von@fibo.kmutt.ac.th Lecturer at Institute of FIeld robotics (FIBO)

King Mongkut's University of Technology Thonburi