introduction to robotics in cim systems...introduction to industrial robotics 1-1 introduction 1 1-2...
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Introduction to Robotics In CIM Systems Third Edition
James A. Rehg The Pennsylvania State University Altoona Campus
Prentice Hall Upper Saddle River, New Jersey Columbus, Ohio
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Contents
Introduction to Industrial Robotics
1-1 Introduction 1
1-2 History of the industry 2
1-3 Thirty-year-old industry 4
1-4 Integrated systems—meeting the external and internal challenges External challenges, 6
Internal challenge, 9 Meeting the internal challenge, 10
1 -5 The problem and a solution 13
1-6 Definition of robotics and computer-integrated manufacturing 13
1-7 Manufacturing system classification 15 Project, 15 Job shop, 16 Repetitive, 17 Line, 17 Continuous, 17
1-8 Robot systems 19 Basic system, 19 Mechanical arm, 19 Production tooling, 21
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External power source, 22 Robot controller, 22 Teach stations, 24
1-9 Some basic terms 26
1-10 Robot standards 32 R15 standards, 32
A15 standards, 32
1-11 Summary 33 Questions, 33 Problems, 34 Projects, 35
2 Robot Classification 36
2-1 Introduction 36
2-2 Robot arm geometry 36 Cartesian geometry, 36 Cylindrical geometry, 40 Spherical geometry, 44 Articulated geometry, 44
2-3 Power sources 49 Hydraulic drive, 49 Pneumatic drive, 51 Electric drive, 52
2-4 Application areas 54 Assembly, 54
Nonassembly, 55
2-5 Control techniques 55 Closed-loop systems, 55 Open-loop systems, 63
2-6 Path control 67 Stop-to-stop control, 68 Point-to-point control, 70 Controlled path, 72 Continuous path, 73
2-7 Classification by the International Standards Organization 74 Sequenced, 74 Trajectory, 74 Adaptive, 74 Teleoperated, 74
x Contents
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External power source, 22 Robot controller, 22 Teach stations, 24
1-9 Some basic terms 26
1-10 Robot standards 32 R15 standards, 32
Al 5 standards, 32
1-11 Summary 33 Questions, 33 Problems, 34 Projects, 35
2 Robot Classification 36
2-1 Introduction 36
2-2 Robot arm geometry 36 Cartesian geometry, 36 Cylindrical geometry, 40 Spherical geometry, 44 Articulated geometry, 44
2-3 Power sources 49 Hydraulic drive, 49 Pneumatic drive, 51 Electric drive, 52
2-4 Application areas 54 Assembly, 54 Nonassembly, 55
2-5 Control techniques 55 Closed-loop systems, 55 Open-loop systems, 63
2-6 Path control 67 Stop-to-stop control, 68 Point-to-point control, 70 Controlled path, 72 Continuous path, 73
2-7 Classification by the International Standards Organization 74 Sequenced, 74 Trajectory, 74 Adaptive, 74 Teleoperated, 74
x Contents
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2-8 Summary 75
Questions, 75
Problems, 76
Projects, 77
Automated Work Cells and CIM Systems
3-1 Introduction 78
3-2 The CIM implementation process 79
Step 1: Assessment of enterprise technology, human resources, and syst
Step 2: Simplification—elimination of waste, 81
Step 3: Implementation with performance measures, 83
3-3 Making the process work 85
3-4 Automated production 86
3-5 Flexible automation 87
Case: Electronic assembly of odd-form surface-mount devices, 89
Case: Through-hold printed circuit board assembly, 91
3-6 Fixed automation 93
In-line fixed automation, 93
Rotary-type fixed automation, 93
3-7 Implementing automated work cells 94
New versus existing production machines, 94
Fixed versus flexible automation, 94
3-8 Automation case study 96
Case: CIM Automation at West-Electric, 96
Part 1: Introduction, 96
Part 2: Turbine blade production, 99
Part 3: CDM improvement process, 107
Part 4: The automation plan, 109
3-9 Summary 112
Questions, 113
Problems, 114
Case projects, 114
End-of-Arm Tooling
4-1 Introduction 116
4-2 Classification 117
Standard grippers, 117
Vacuum grippers, 121
Vacuum surfaces, 124
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Vacuum suckers, 124
Magnetic grippers, 124
Air-pressure grippers, 125
special-purpose grippers, 128
4-3 Gripper selection and system intelligence 1
4-4 Special-purpose tools 130
4-5 Robot assembly 131
4-6 Compliance 131
Active compliance, 132
Passive compliance, 133
4-7 Multiple end-effector systems 138
Wrist interface, 138
Multiple-gripper systems, 138
4-8 Automation case study 141
Case: CIM Automation at West-Electric, 141
Work-cell technical design checklist, 142
Robot selection checklist, 143
4-9 Summary 148
Questions, 148
Problems, 149
Case projects, 149
Automation Sensors
5-1 Introduction 151
Discrete sensors, 152
Analog sensors, 152
5-2 Contact sensors 153
Discrete devices, 153
Artificial skin, 157
5-3 Noncontact sensors 160
Proximity sensors, 161
Photoelectric sensors, 167
5-4 Process sensors 173
5-5 Automation case study 173
Case: Automation at West-Electric, 173
Performance measures, 174
Technical issues, 174
Oven modification, 178
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5-6 Summary 179 Questions, 181 Problems, 182 Case projects, 182
6 Work-cell support systems
6-1 Introduction 184
6-2 Machine vision systems 184 Vision standards, 185 Vision system components, 185 Image measurement, 188 Image analysis, 189 Image recognition, 190
6-3 Lighting for machine vision 191 Selection of the light source, 191 Lighting techniques, 192 Illumination sources, 192
6-4 Material handling 194
Automated transfer systems, 195
6-5 Part feeding 196
6-6 Inspection 197
6-7 Automatic tracking 198
6-8 Automation case study 200 Case: CIM automation at West-Electric, 200
6-9 Summary 205 Questions, 207
Case projects, 207
7 Robot and System Integration
7-1 Introduction 209
7-2 System overview 211 Hardware overview, 211 Software overview, 212
7-3 Work-cell architecture 212 Cell controllers, 212
Cell control software structure, 212 Work-cell management software, 214
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7-4 Programmable logic Controllers 215 PLC system components, 215 Basic PLC system operation, 216
7-5 Computer numerical control 218
7-6 Controller architecture 219 Nonservo robot controllers, 219
Servo robot controllers, 220
7-7 Interfaces 224 Simple sensor interface, 224 Complex sensor interface, 225 Enterprise data interface, 228
7-8 An integrated system 228 Machining cell, 228 Assembly cell, 228 Signal types, 230 Work-cell controller, 230 Programmable logic controller, 231
7-9 Automation case study 231 Case: CIM automation at West-Electric, 231
7-10 Summary 231 Questions, 234
Case projects, 235
8 Work-Cell Programming 236 8-1 Introduction 236
8-2 Work-cell controller programming 237 In-house-developed software, 237 Enabler software, 238 OSI solution, 238
8-3 Programming sequential cell activity 239 PLC programming, 240
Other sequential programming options, 242
8-4 Robot language development 242
8-5 Language classification 243 Joint-control languages, 243 Primitive motion languages, 244 Structured programming languages, 245 Task-oriented languages, 245
xiv Contents
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8-6 Robot program fundamentals 246
8-7 Translation or position points for servo robots 249 Reference frames, 249
Application Note: robot system simulation, 251 Programming servo robot translation points, 252 Programming nonservo robot translation points, 256
8-8 Program statements for servo robots 256 Basic program structure, 256
Process analysis, 257 Tasks and subtasks, 257
Task point graph, 258 On-line and off-line programming, 258
Translation points and system variables, 260
8-9 Automation case study 261 Case: CIM automation at West-Electric, 261
8-10 Summary 263 Questions, 264
Problems, 265
Case projects, 265
Justification and applications of work cells
9-1 Introduction 266
9-2 Capital equipment justification 267 Return on investment method, 268 Cash flow method, 268 Time value of money, 268 Justifying robotics applications, 269
9-3 Automation applications 269 Material handling, 269
Application note: Material handling of electrical relays, 270 Application note: Cookie packaging, 272
Machine tending, 273 Assembly, 273
Application note: Mechanical assembly of fluorescent light fixtures, 274 Application note: Mechanical assembly of dishwasher and vacuum
cleaner components, 275 Application note: Force sensor assists in automotive piston assembly, 277 Process, 278
Application note: Cookie sandwiching, 280
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Welding, 281
Application note: Kendon Inc.'s peacock struts its stuff, 284
Painting, 282
9-4 Automation case study 287 Case: CIM Automation at West-Electric, 287
9-5 Summary 287 Questions, 287 Problems, 289 Case projects, 290
Safety
10-1 Introduction 291
10-2 Occupational Safety and Health Administration (OSHA) 292
10-3 American National Standards Institute/Robotic Industries
Association Standard for Robot Safety 293
10-4 Safeguarding a work cell 293 Safeguarding devices, 294 Safeguarding the operator, 295 Safeguarding the programmer, 295 Safeguarding maintenance and repair personnel, 295
10-5 Definitions 296
10-6 Automation case study 296 Case: CIM automation at West-Electric, 296
10-7 Summary 299 Questions, 300
Case projects, 300
Human Interface: Operator Training, Acceptance, and Problems
11-1 Introduction 301
11-2 General training 302 General training program, 302
11-3 Operator training 303
11-4 Maintenance training 303
11-5 Team-based manufacturing 304 Description of a self-directed work team, 305
Making work teams work, 305
11-6 Resistance 306
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11-7 Organized labor 307
11-8 Automation case study 307 Case: CIM automation at West-Electric, 307
11-9 Summary 307 Questions, 308
Contents xvii