Robotics 1

Industrial Robotics
Prof. Alessandro De Luca

Robotics 1

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

Robotics 1

Robots !!

Spirit Rover (2002) Comau H4 (1995)

Robotics 1

Waseda WAM-8 (1984)

3

A bit of history

Robota (= work in slavic languages) are artificial humanlike creatures built for being inexpensive workers in the theater play Rossums 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

Robotics 1

Evolution toward industrial robots

computer numerically controlled machines (CNC) 1950 mechanical telemanipulators

robot manipulators 1970 Unimation PUMA

with respect to the ancestors

flexibility of use adaptability to a priori unknown conditions accuracy in positioning repeatability of operation
5

Robotics 1

The first industrial robot

US Patent

General Motor plant, 1961

G. Devol and J. Engelberger (Unimation)

Robotics 1 6

Robot manipulators
ASEA IRB-6 (1973) first robot all-electric-drives Hirata AR-300 (1978) first SCARA robot

Cincinnati Milacron T3 (1974) first microcomputer controlled robot

Robotics 1

Unimation PUMA 560 (1979) 6R with human-like dexterity

7

World Robotics 2010

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

Robotics 1

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

statistics by IFR available since September 2011 executive summary for 2011

Robotics 1

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)

Industrial robots in operation worldwide

Diffusion

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

Robotics 1 10

Industrial robots in operation by areas

Forecast of diffusion

between 1.035 and 1.3 million robots!

Robotics 1

World Robotics 2011

11

New robots worldwide

Annual Supply

World Robotics 2011

Robotics 1 12

New robots by industrial sectors

Annual Supply

World Robotics 2011

Robotics 1 13

Forecast of supply
New robots by areas

World Robotics 2011

forecast: annual average increase of 10% in 20112013

Robotics 1 14

Robot prices

An articulated industrial robot with six degrees of freedom of medium/large size costs about 100 KEuro
Robotics 1 15

Density of robots

-1

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

Robotics 1 16

Density of robots

-2

number of robots per 10000 employees in the automotive industry in 2002 and 2004
Robotics 1 17

Density of robots

-3

World Robotics 2010

Robotics 1

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

18

and its auxiliary equipments

Industrial robot

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

Robotics 1

19

ABB IRB 7600

commercial video by ABB

Robotics 1 20

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)

Robotics 1

21

Plasma cutting
electrode

video

gas chamber

nozzle

hot plasma

small KUKA robot used for plasma cutting of a stainless steel toilet (courtesy of Engenious Solutions Pty)
Robotics 1 22

Robotized workcell

Robotics 1

23

3D simulation of robotic tasks

analysis of operative cycle times off-line programming and optimization layout design and collision checking 3D graphic simulation
Robotics 1 24

Welding - 1

spot with servo-controlled gun

stud welding

Robotics 1

25

Welding - 2

spot (discrete) or arc (continuous)

Robotics 1 26

Two cooperating robots in welding

ABB video at Laxa, Sweden

Robotics 1 27

Palletizing

pallet = a portable platform on which goods can be moved, stacked, and stored
Robotics 1 28

Palletizing of cheese forms

video

using Kawasaki robots (courtesy of Effedue Engineering)

Robotics 1 29

Folding

with loading of sheets under the press

Robotics 1 30

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
Robotics 1 31

Deburring center
video

deburring center for steel parts using Comau SMART NJ 110-3.0/foundry robot (courtesy of Adami srl)
Robotics 1 32

Off-line robot workstation

articulated robot in metal surface finishing operation

Robotics 1 33

Safety in robotic cells

commercial video from ABB SafeMove cell monitoring system (no fences!)
Robotics 1 34

Robot manipulator kinematics

Kuka 150_2 (series 2000) open kinematic chain (rigid bodies connected by joints)
Robotics 1

Comau Smart H4 closed kinematic chain

Fanuc F-200iB parallel kinematics

35

Other types of robots - 1

(repeatability 5 micron, payload 5 kg)

Mitsubishi RP

(workspace 850 mm, velocity 5 m/s)

Mitsubishi RH

Bosch Turbo

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
Robotics 1 36

Adept Cobra i600

video

fastest SCARA robot for pick-and-place tasks!

Robotics 1 37

Other types of robots - 2

(payload up to 560 kg)

Comau Mast gantry robot

(150 pick-and-place operations/minute)

ABB Flexpicker

Robotics 1

38

Chocolate packaging with lightweight parallel robots

test video with ABB Flexpicker

Robotics 1

video with Adept Quatro s650

39

Distribution by robot type

of kinematic configuration
12% 10%

15%

63%

articulated

cartesian/gantry

cylindric

SCARA

for 59600 articulated robots installed in 2004 (90% of all robots installed in America, 74% in Europe, only 49% in Asia)
Robotics 1 40

Robot data sheet

Fanuc R-2000i/165F
Robotics 1 41

Workspace

Robotics 1

42

Visualization of workspace
video

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

Robotics 1 43

Robot end-effector sensors and tools

Robotics 1

44

Calibration of robot kinematics

Robotics 1

45

Man-machine interface

teach-box pendant used as robot programming interface

Robotics 1

cabinet with power electronics for robot supervision and control

46

Programming and control environment

control modules and interfaces (Reis Robotics)

Robotics 1

47

Motion programming and scaling

commercial video from ABB TrueMove & QuickMove fast motion control performance
Robotics 1 48

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
Robotics 1 49

Lifting AGV for warehouses

video by Elettric80
Robotics 1 50

Intelligent AGV in factories

commercial video of ADAM mobile robot (RMT Robotics)

Robotics 1 51