Chapter Industrial Applications 5 Objectives Describe how robots

Chapter Industrial Applications 5

Objectives • Describe how robots are integrated into the manufacturing process. • Discuss factors to consider in selecting the proper robot for a given task. • Identify applications where robots are used in industry. Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Integrating Robots into the Manufacturing Process • Two key factors: – Design of manufactured products – Safety considerations Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Design for Manufacturability • Considers robots in product planning process • Parts assembled by robots vs. assembled by dedicated equipment – Dedicated equipment designed to perform one function Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Design for Manufacturability • Minimize number of parts Goodheart-Willcox Publisher Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Design for Manufacturability • Simplify fastening Goodheart-Willcox Publisher Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Design for Manufacturability • Parts as close to symmetrical as possible Goodheart-Willcox Publisher Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Robotic Safety Considerations • Safe working environment must be considered – Relationship of end effector to work fixtures and other equipment – Include barriers – Control panels outside work envelope – Interlocks Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Selecting a Suitable Robot • • Perform repetitive tasks without tiring Operate in hostile environments Maintain greater precision than humans Not suited for: – Extended, high-speed production of identical items – Short, complex tasks with high hand-eye coordination Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Work Envelope • Different for each robot configuration • Type of joints and degrees of freedom • Greater flexibility with wall and ceiling mountings Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Degrees of Freedom • Determines robot’s ability to move within work envelope • Two categories of six degrees of freedom: – Body – Wrist Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Degrees of Freedom Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Resolution • Smallest incremental movement robot can make • Smallest segment of work space • Command resolution is closest distance between movements – Divide travel distance of each joint by number of control increments Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Resolution • Spatial resolution is accuracy of tool tip movement – Considers command resolution and mechanical inaccuracy – Varies with tool location Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Accuracy • Accuracy is how precisely end effector is programmed to reach a point – Half of the spatial resolution – Affected by speed and weight of payload Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Repeatability • Repeatability is variation in movements – More desirable than accuracy – Can change with use due to mechanical inaccuracies Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Operational Speed • Operational speed is how fast robot can accelerate, decelerate, and come to a stop – Influenced by accuracy and payload – Cycle times consider variables in procedure Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Load Capacity • Payload is maximum weight of material robot can handle • Affected by configuration and placement of end effector • Reduced when boom is fully extended Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Using Robots in Industry • Completely automated factory possible – Advances in computing technology – Sensor applications Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Pick-and-Place Operations • Picking up parts and moving; includes palletizing FANUC Robotics Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Machine Loading and Unloading • Load and unload parts • Replace workers in unpleasant and dangerous operations • Gains in productivity and quality Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Machine Loading and Unloading Motoman Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Die-Casting Operations • Pumping molten metals into dies • 200% to 300% increase in productivity • Robots work more consistently than humans Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Die-Casting Operations Sterling Detroit Company Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Welding Operations • Resistance welding, arc welding, and spot welding • Accomplish movement and angles difficult for human operator • Sensory tracking for alignment and positioning Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Welding Operations FANUC Robotics Servo-Robot Inc. Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Spraying Operations • • Spray nozzle mounted on robot’s wrist Must use continuous-path programming Not affected by toxic and explosive vapors Specialized end-of-arm tooling for sealing and gluing Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Spraying Operations Motoman Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Machining Processes • Routing, cutting, drilling, grinding, polishing, riveting, and sanding • Must have high degree of repeatability • Fixturing is ability to provide precise points in locating parts Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Machining Processes • Gas torch cutting Motoman Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Machining Processes • Force sensors adjust tool pressure Motoman Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Assembly Operations • Robots are small – Designed to accurately move small parts at high speeds • Vision systems detect orientation of parts • Tactile sensing systems detect misaligned, missing, or substandard parts Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Assembly Operations Motoman Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Inspection Operations • Quality assurance through non-contact gauging and inspection • Two subsystems – Accumulate data – Analyze data and present in a meaningful way Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Inspection Operations • Laser vision cameras inspect welded blanks Servo-Robot, Inc. Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Material Handling • Automated control and tracking of inventory • Handling parts and products • Automated guided vehicles (AGVs) are computercontrolled, battery-operated Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Material Handling Daifuku Co. , Ltd. Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Service Operations • Service robots can move to work area to perform tasks – Security services – Used in hazardous environments – Personal assistance Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.

Service Operations Mobile. Robots, Inc. i. Robot Corporation Copyright Goodheart-Willcox Co. , Inc. May not be posted to a publicly accessible website.