industrial applications of robots
TRANSCRIPT
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INDUSTRIAL APPLICATIONS
OF ROBOTS
CHAPTER # 10
ROBOTICS AND MANUFACTURING
AUTOMATION
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WELDING
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WHY A ROBOT TO BE USED FOR WELDING?
Welding has two types w.r.t roboticapplications Spot welding
Arc welding1. Safety hazards
2. Undesirable job for workers (due toprotective equipment that must be worn)
3. Heavy loads are sometimes involved
4. To achieve quality and product uniformity
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BENEFITS OF ROBOTIC WELDING
Automatic line tracking is sometimes
required, on assembly lines where welding
is to be done
Arc-on-time conceptManual welding (arc-on-time percentage is 20-30%)
Robotic welding (production level of 4 welders
Weave Patterns for weld pathsWeave patterns .. Zigzag path
A robot can be programmed for weave patterns
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MACHINE LOADING
Why robots to be used for machine loading?
Safety and relief
Safety and relief from handling heavy equipment
Risk of amputations while feeding punch press by hand
To eliminate production slowdowns
To achieve high operating speed
Small clearances make manual feeding a tricky job
Reduction of scrap is a side benefit
1. Single robot for single machine loading and unloading
2. Multiple robots for multiple machine loading
3. Sequential machine loading
4. Robots in forging and die-casting
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MACHINE LOADING (Contd.)
Positioning problem thatmay occur (fig 10.4)
A robot has to pick andplace on differentelevation levels whererobot is an axis-limit,polar configuration robot
RemediesWork envelop
Suction cup pickup
devicesRacks design
End effecter with greaterflexibility
Double handed grippers
Figure 10.5
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PROBLEM(Robot Machine Loading System Productivity)
The robot machine loading / unloading system
diagrammed in figure has an eight seconds
cycle time and a daily two shift production level
of over 28,000 workpieces. Do the four millingmachines perform sequential operations upon
each workpieces in series, or do all four milling
machines perform the complete machining cycle
in parallel with each other that is, is each partprocessed completely by only one machine, not
all four?
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PROBLEM(Robot Machine Loading System Productivity)
Series operation:Production rate / day
= 1part / 8sec X 60 sec/min X60min / hr X 16hr/day
=7200 parts per day (two shifts)
Parallel Operation:Production rate / day
= 1 part/8sec X 60 sec/min X 60min/hr X 16hr/day X 4 machines
=28,800 parts per day (two shifts)
=> system runs onparallel basis
Discussion
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SEQUENTIAL MACHINE LOADING
Single robot to load / unloadseveral machines (figures)
One robot to load and unloadthree machines with help oftwo conveyors
60% increase in productionlevel is observed
Double handed grippers are oflittle value We intend to work on single
work piece sequentially
When one job is complete onone machine, the workpiecewould be unloaded and loadedto the 2nd machine and so on
Also because there is no roomfor semi-finished parts in theworkcell
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Robots for Forging and Die-casting
Why robots for forgingand die-casting?
Piece parts are hot
Environmental heat andnoise
Risk of amputation whilefeeding
Normally a robot forforging is programmed todip its hand into a coolingbath at appropriateintervals
Gripper must be capableto handle shape changesduring forging.
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SPRAY PAINTING
Environment in spray painting booths is verydifficult to maintain according to safety andhealth standards
A level of consistency is difficult to achieve when
human workers are employed Line tracking capability for continuous feed
conveyors
A robot can be taught (only once), by a skilled
spray painter Failures can be expected, so a manual touchup
area is sometimes required
Equipment utilization is very important factor to
consider
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FABRICATION
Welding (already discussed) Drilling
For small workpieces (PCB Drilling, fixtured parts)
For large workpieces (aircraft parts) Drill must be oriented perpendicular to the surface
A human achieves this by visual determination (source of error)
A robot with deterministic approach can replace a human worker
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ASSEMBLY
3D criteria is useless for robotic assemblyapplications
Assembly requires precision, repeatability,
variety of motions, sophisticated gripper devices,and sometimes compound gripper mechanisms.
Basis of decision for assembly robot:Save labor costs
Repetitive job is a boring jobFast and efficient work requirement
Accuracy
Eliminate omissions or substitutions
Eliminate intentional omissions
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ENGINE ASSEMBLY
Engine blocks travelon a pallet transfermechanism
Robots facilitated byauxiliary conveyorsfor subassembliesand vibratory bowlsfor screws and bolts
Different grippers areprovided in amagazine, mainly todo a variety of jobs
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Electrical / Electronic Machine Assembly
Indexed, palletized carrier typetransfer mechanisms
Tactile sensing
Visual feedback loops Since assembly operations
require more feel for theobjects being handled
Defects can also be detected
Even more sophisticated /flexible robots are required forflexible manufacturing systems
General Assembly Robots: That can sense and assemble
virtually any thing ofappropriate size
When combined withjudgment, these robots can beused for humanoid robots
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UNUSUAL APPLICATIONS
Sheep shearing
robots
Robots in
ConstructionRobots for Hazardous
Material cleaning
Sojourner Rover
Nano-robots
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QUESTIONS & ANSWERS