Course 6: Digital Factory Robotics and Automation in ... · In the 1990s, robotics really took off:...
Transcript of Course 6: Digital Factory Robotics and Automation in ... · In the 1990s, robotics really took off:...
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Curriculum Development
of Master’s Degree Program in
Industrial Engineering for Thailand Sustainable Smart Industry
Course 6: Digital FactoryRobotics and Automation in Industrial Applications
Pisut Koomsap, AIT
Athakorn Kengpol, KMUTNB
Supapan Chaiprapat, PSU
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Robotics Foreword
The world of robotics is changing rapidly, and
the future of automation is only set to be more
innovative and ground-breaking in the coming
years. Robots are becoming part of our daily
lives, and in the world of manufacturing,
industrial robots have become the essential
component to drive efficiencies; the epitome of
a modern factory.
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The History of Robotics
In 1913 the first conveyer belt assembly line
was installed by Henry Ford,
and in 1920 the word ‘robot’ was fist coined by
Karel Čapek.
Henry Ford
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The History of Robotics
In 1928 the first humanoid robot that could
move its hands and head went on display in
London, and by 1929
Makoto Nishimura had created a robot that
had facial expressions.
In just a few years robots that could walk were
being shown, and more inventions to speed up
work were introduced.
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The History of Robotics
In 1942 the DeVilbiss Company designed a
paint spraying robot that could work much
faster than a human.
In 1950 Alan Turing proposed tests to
determine if machines could think for
themselves.
paint spraying robot5/100
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The History of Robotics
The world’s first robotic arm was created in
1963 and was quickly followed by multi-
jointed arms, and robotic arms controlled by
computers. By 1970 we were seeing robots
that could detect their own surroundings
and react accordingly.
And, at the same time in Japan, the first
android robot was launched that could walk,
grip, transport objects, sense objects and
communicate.
robotic arms
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The History of Robotics
Major advancements in movement and walking
robots started in the 1970s.
KUKA built the first industrial robot with six
electromechanical axes, and in 1973 WABOT-1 was
created. It was the first full-scale humanoid robot
with full control of its limbs, vision and conversation.
WABOT-1 7/100
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The History of Robotics
The 1980s saw robots with more legs and a
greater degree of freedom, and Honda
began humanoid research and development
In 1989 MIT created a six-legged robot
controlled by four microprocessors, 22
sensors and 12 servomotors
six-legged robot
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The History of Robotics
In the 1990s, robotics really took off: from
RoboTuna, which explored the oceans, to
advances in healthcare with the Cyber Knife –
a radiosurgery-performing robot, designed to
operate on tumours.
RoboTuna
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The History of Robotics
Robots even went into space. NASA launched
its Pathfinder robot, which landed on Mars,
ready to explore the Red Planet and send
brand new information back to Earth.
Pathfinder robot
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The History of Robotics
The 21st century has seen so many new and amazing innovations in robotics and
automation. In 2000 the United Nations estimated that there were over 742,000 industrial
robots being used around the world
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The History of Robotics
In 2006 Cornell University revealed its
Starfish robot, a four-legged robot capable of
self-modelling that could learn to walk after
being damaged
four-legged robot
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The History of Robotics
In 2011 Robonaut 2 was launched on Space
Shuttle mission STS-133 the first humanoid
robot in space and the next year Mars Rover
Curiosity landed and began exploring,
sending detailed analysis back to us about
the Red Planet’s structure.
Robonaut 2
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The History of Robotics
In 2015 Nadine, the most human-like robot
we’ve seen, was created by the Nanyang
Technological University. And in 2017 the first
robot was granted Saudi Arabian citizenship:
‘her’ name is Sophia
Sophia
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Robot Types and Applications
The most common types of industrial robots
are :
Articulated: feature rotary joints and can
range from two joints to over 10 joint
structures.
Articulated robot
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Video : Articulated robot
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Robot Types and Applications
Cartesian: also known as gantry or
rectilinear robots.
They have three linear joints, and usually a
‘wrist’ to allow for rotational movement.
Cartesian robot
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Video : Cartesian robot
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Robot Types and Applications
Cylindrical: features at least one rotary joint
at the base and one prismatic joint to
connect the links. They work in a cylindrical-
shape work area.
Cylindrical robot
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Robot Types and Applications
Polar: also known as spherical robots.
The arm is connected to the base with
a twisting joint and a combination of two rotary
joints and one linear joint. They work in a
spherical area.
Polar robot
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Robot Types and Applications
Delta: spider-like robots, built from jointed
parallelograms connected to one base.
Capable of delicate and precise movements,
they are often found in food, medical and
electronic industries.
Delta robot
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Video : Delta robot
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Domestic, Household and Service
Mainly created for household chores, domestic robots come
in many shapes and sizes.
Carpet cleaning robot Floor washing robot
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Video : Carpet cleaning robot
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Video : Floor washing robot
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Domestic, Household and Service
Kitchen robotSecurity robot
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Video : Security robot
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Video : Kitchen robot
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Domestic, Household and Service
Garden robot Pool cleaner robot
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Video : Garden robot
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Video : Pool cleaner robot
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Domestic, Household and Service
Home service robot
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Video : Home service robot
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Medical
Used in medical sciences, medical robots include surgical robots, rehabilitation robots,
bio robots, telepresence robots, pharmacy robots and disinfection robots.
Surgical robot Rehabilitation robot
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Video : Surgical robot
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Video : Rehabilitation robot
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Medical
With a robot being able to work more exactly and precisely than a human hand, surgical
robots are starting to be used in operating theatres all over the world.
Cyber knife robot37/100
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Medical
Rehabilitation robots are used for helping people who have lost the use of part or all
of their body.
Rehabilitation robots
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Medical
Pharmaceutical robots enable medicines to be handled and distributed with absolute
accuracy.
Pharmaceutical robot
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Video : Pharmaceutical robot
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Military and space
A number of forces around the world
now use robots as part of their
operations, including helping with
transport, search and rescue, defence
and attack.
Bomb disposal robot
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Video : Bomb disposal robot
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Industrial Robots
Industrial robots are driving competitive advantage across manufacturing, enabling
companies to respond to the challenges of faster business cycles, greater variety
in customer demand, competitive pressure and the challenge of reducing emissions.
The falling costs of industrial robots has lowered capital investment requirements,
increasing adoption across all industrial sectors.
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Industrial Robots Trends
Overall, usage of industrial robots has increased year-on-year
(Source: IRF 2017 Report)
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Types of Industrial Robots
Most industrial robots are classified
as stationary robots, with a robotic
arm moving above a stationary base.
Stationary robots break down into six
main types, shown in Table 1
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Operating parameters of industrial robots
Number of axes/ degrees of freedom
source: yaskawa-global
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Operating parameters of industrial robots
Working envelope
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Operating parameters of industrial robots
Kinematics
The arrangement of rigid members and joints in the robot, determining the robot's
possible motions. Classes include articulated, cartesian, parallel and SCARA
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Operating parameters of industrial robots
Carrying capacity/ payload
How much weight a robot can lift
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Operating parameters of industrial robots
Speed
The speed at which the robot can position the end of its arm, defined in terms of the
angular or linear speed of each axis or as a compound speed.
Acceleration
How quickly an axis can accelerate. Since this is a limiting factor a robot may not be
able to reach its specified maximum speed for movements over a short distance or
a complex path requiring frequent changes of direction
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Operating parameters of industrial robots
Accuracy
The absolute position of the robot compared to the commanded position is a
measure of accuracy. Accuracy can be improved with external sensing, e.g. vision
systems or infrared. Accuracy can vary with speed and position within the working
envelope and with payload (compliance)
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Operating parameters of industrial robots
Power source
Examples include electric motors and hydraulic actuators
Pneumatic actuators in robotics
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Operating parameters of industrial robots
Motion control
For applications such as simple pick-and-place assembly, the robot only needs to
return repeatedly to a number of pre-taught positions. For applications such as
welding and finishing, motion must be continuously controlled to follow a path in
space, with controlled orientation and velocity
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Programming Industrial Robots
Programming a robot involves the establishment
of a physical or geometrical relationship between
the robot and the equipment or task to be
serviced by the robot. In doing so it is necessary
to control the robot manually and physically
teach it the coordinate points within its working
envelope.
Fanuc robot programming
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Programming Industrial Robots
There are three commonly used programming or
teaching methods:
• Lead-through programming or teaching
• Walk-through programming or teaching
• Offline programming or teaching
Robot Programming Methods
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Video : Robot Programming Methods
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Programming Industrial Robots
You can program, communicate and interrogate a robot by different methods: commonly
computers and teach pendants. The Teach Pendant (HMI) is the main source of
information for robot fault diagnosis.
Kuka KRC4 Pendant
(Touchscreen)
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Video : Robot position teaching through Teach Pendant
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Programming Industrial RobotsKeypad
Function Keys
Motion Keys
Array Keys
Data Entry Keys
Axis Keys
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Video : How to Robot - Robot Jogging
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Beyond Manufacturing – Robots and the Supply Chain
Advanced robotics is a complex,
multi-faceted challenge
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Robotics in Logistics - The Time is Right
The main reason for the lack of logistics robots
is that, until recently, robots have been
simplistic – performing the same movements
over and over again, albeit with a high degree
of accuracy and precision.
One of DHL’s robots is capable of optimally loading a shipping
box with packages (Source: DHL Express © 2018)
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Video : DHL Supply Chain Robotic Picking Cell
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Making (and Keeping) the Connection
With thousands of connections, implemented
both wired and wirelessly,
interconnections must be 100% reliable if the
advantages of a long operating
life and high efficiency are to realize the cost
benefits robotic systems are
designed to deliver.
Cables and connectors can fail over time;
contactless connectors can overcome these issues
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Networking Connectivity
A number of industrial networking protocols are
available to organise
the movement of data packages within the
TCP/IP architecture.
TCP/IP architecture
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Wireless Connectivity
Wireless protocol comparison
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Cloud Robotics and 5G
5G technology, with gigabit connectivity, may negate the need for other types of wireless
networks
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Sensing the Real World
Today’s robots are becoming more human-like, not only in terms of movement but also in
how they sense the real world. The rapid evolution of sensor technologies for robotic
applications is supporting this trend, and the ability of robots to make decisions based on
sensory feedback will have massive industrial and societal impact.
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Sound and Vision
Light detection and ranging (LIDAR) systems
are also a popular choice for robot vision.
This technology bounces light off nearby
surfaces to create a 3D map of the world
around it. LIDAR is like radar in its basic
mechanics.
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Touch
A sensing device that specifies contact
between an object and sensor is a tactile
sensor.
Smart skin sensor for robot
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Video : Smart skin sensor for robot
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Force/Torque
As vision gives eyes to a robot, force-torque
(FT) sensors give ‘feel’, enabling users to
know the force a robot applies with its end
effector.
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Proximity/Collision Detection
Proximity sensors that detect the presence
of nearby objects (or targets) without any
physical contact are placed
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Seeing, Hearing, Touching, Moving
Cameras can be used to recognize
the location and orientation of objects on
a conveyor belt
Machine Vision
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Video : Machine Vision
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AI in Robotics
One of the key problems in robot design lies in
providing the machine with an understanding
of the world around it. The robot needs to be
able not only to detect obstacles and dangers
but to understand their nature so it can react to
each situation appropriately.
Collaborative robot (cobot)
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Video : Collaborative robot
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AI in Robotics
A deep learning platform delivers a statistical likelihood of the object captured by
the camera being the desired object, in this case a bolt
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Automation Introduction
What is Industrial Automation?
Automation takes a step further mechanization that uses a particular machinery
mechanism aided human operators for performing a task. Mechanization is the manual
operation of a task using powered machinery that depends on human decision making.
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Automation Introduction
On the other hand, automation replaces
the human involvement with the use of
logical programming commands and
powerful machineries.
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Automation Introduction
Industrial Automation is the replacement
with computers and machines to that of
human thinking. The word Automation
gives the meaning ‘self dictating’ or ‘a
mechanism move by itself’ that derived
from the Greek words Auto and Matos
where auto means self while Matos
means moving.
figure shows the power plant automation
provided by Siemens
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Hierarchy of an Industrial Automation System
Industrial automation systems can be
very complex in nature, having large
number of devices working in
synchronization with automation
technologies. The figure describes
the hierarchical arrangement of the
automation system consisting of different
hierarchical levels.
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Types of Industrial Automation Systems
1. Fixed or Hard Automation
This type of automation is employed to perform fixed and repetitive operations in order to
achieve high production rates. It uses special purpose or dedicated equipment to automate the fixed
sequence assembling or processing operations. Once it is employed, it is relatively hard to change or
vary the product design.
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Types of Industrial Automation Systems
2. Programmable Automation
In this automation, a specific class of product changes and also assembling or processing
operations can be changed with the modification of control program in the automated equipment.
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Types of Industrial Automation Systems
3. Flexible or Soft Automation
This automation system provides the automatic control equipment that offers a great flexibility
for making changes in the product design. These changes can be performed quickly through the
commands given in the form of codes by the human operators
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Advantages of Automation System
To increase productivity
To provide optimum cost of operation
To improve product quality
To reduce routine checks
To raise the level of safety
Source : https://www.electricaltechnology.org/2015/09/what-is-industrial-automation.html#what-is-industrial-automation
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Automated Guided Vehicles : History of AGV
The first AGV was brought to market
in the 1950s, by Barrett Electronics of
Northbrook, and at the time it was simply a tow
truck that followed a wire in the floor instead of
a rail
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Automated Guided Vehicles : What is AGV?
AGV is a material handling system
that uses independently operated, self-
propelled vehicles guided along defined
pathways.
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Automated Guided Vehicles : Types of AGV’S
Driverless trains
It consists of a towing vehicle that pulls one
or more trailers to form a train.
This type is applicable in moving heavy pay
loads over large distance in warehouses or
factories with or without intermediate pickup
and drop off points along the route.
It consists of 5-10 trailers and is an efficient
transport system.
The towing capacity is up to 60,000 pounds
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Automated Guided Vehicles : Types of AGV’S
AGV Pallet Trucks
Pallet trucks are used to move palletized
loads along predetermined routes.
The capacity of an AGV pallet truck ranges
up to several thousand kilograms and some
are capable of handling two pallets.
It is achieved for vertical movement to reach
loads on racks and shelves.
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Automated Guided Vehicles : Types of AGV’S
Unit load carriers
These are used to move unit loads from one
station to another.
It is also used for automatic loading and
unloading of pallets by means of rollers.
Load capacity ranges up to 250 kg or less.
Especially these vehicles are designed to
move small loads.
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Automated Guided Vehicles : Why consider AGVs?
Reduces the labor cost.
Flexible.
Intelligent.
Time consuming.
Can significantly reduce production & warehouse costs.
Transforming the materials handling industry.
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Automated Guided Vehicles : Types of navigation in AGV’S
Wired navigation
The wired sensor is placed on bottom of the AGV’S and is placed facing the ground.
A slot is cut in the ground and a wire is placed approximately 1 inch below the ground.
The sensors detects the radio frequency being transmitted from the wire and follows it.
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Automated Guided Vehicles : Types of navigation in AGV’S
Guide tape navigation
The AGV’S use magnetic tape for the guide
path.
The AGC’S is fitted with the appropriate
guide sensors to follow the path of the tape.
It is considered a “passive” system since it
does not require the guide medium to be
energized as wire does.
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Videos : Guide tape navigation (AGV)
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Automated Guided Vehicles : Types of navigation in AGV’S
Laser target navigation
The AGV’S carry’s a laser transmitter and
receiver on a rotating turret.
The laser is sent off then received again the
angle and distances are automatically
calculated and stored into AGV’S memory.
The AGV’S has reflector map stored in
memory and can correct its position based
on errors between the expected and received
measurements.
It can then navigate to a destination target
using the constantly updating position.
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Videos : Laser target navigation (AGV)
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Example Applications
Here we look at two examples of industrial robots which have been developed by their
manufacturers to meet the specific needs of their intended application.
Audi Smart factory
Hitachi smart factory
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Videos : Audi Smart factory
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Videos : Hitachi smart factory
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