Robotics. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 1

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1 Robotics 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 1

2 Course objective To provide a broad understanding of the use of industrial robots And an experience in specifying, designing and presenting a new robot application in oral and written formats. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 2

3 SYLLABUS TOPIC 1. Realistic and Safe Use of Robots 2. Applications of Industrial Robots Project 3. Economic Justification Excel Template 4. Robot Implementation 5. Arm Configurations Quiz 1 Take Home 6. Wrist Configurations 7. End Effectors and Tooling 8. Methods of Actuation 9. Non-servo Operation 10. Servo Controlled Robots 11. Cell Control, Hierarchical Design 12. Performance Measures Sample Report 1 - Welding Sample Report 2 - Painting Sample Report 3 - Soldering Sample Report 4 - Batch Manufacturing Sample Report 5 - Machine Loading 13. Joint Control Programming 14. Path Control Programming 15. High Level Languages 16. Simulation and Programming 17. Vision and Sensor Systems 18. Work Cell Interfacing; REPORT DUE 19. Intelligent Robot Cells 20. Flexible Manufacturing 21. FINAL ORAL EXAM 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 3

4 Objective Determine the relationship between various robot applications and the wrist configurations available on commercial robots or automated guided vehicles. Be able to select the appropriate configuration for a robot application. Be able to recognize and discuss a certain configuration when you see one. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 4

5 Arm recognition Can you recognize the following arm types? 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 5

6 Spherical robot arm The linear extending arm is capable of being rotated around the horizontal and vertical axes. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 6

7 Cylindrical arm The linear extending arm can be moved vertically up and down around a rotating column. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 7

8 Cartesian arm Three orthogonal sliding or prismatic joints. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 8

9 Vertical articulated Three joints arranged in an anthropomorphic configuration. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 9

10 Horizontally articulated arm Two rotary axes and a linear joint. Selective Compliance Assembly Robotic Arm, SCARA 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 10

11 Purpose of the Robot Wrist Orientation To orientate the tools, three additional joints are require, these are normally mounted at the end of the arm in an assemble termed the wrist: it is conventional to define the joints of a wrist roll, pitch and yaw. The arm and wrist give the robot the required six degrees of freedom, that permit the tool to be positioned and orientated as required by the task. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 11

12 Wrist Degrees of Freedom 1 DOF roll roll 2 DOF roll-roll pitch and roll or yaw and roll bend roll pitch and roll 3 DOF bend-bend-roll bend=roll-roll roll-bend-roll roll-roll-roll pitch-yaw-roll 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 12

13 Comments and observations The selection of a robot is a significant problem to the design engineer and depends on the task to be performed. One of the earliest applications was to operate in the foundry, the environment being considered to be a hazard to a human operator, due to the noise, heat and fumes from the process. This is the classic type of application where a robot is used to replace workers because of the hazards. Other reasons include, repetitive work cycles, difficult or hazardous materials to be moved, and the requirements for multi-shift operation. The robots that have been installed in manufacturing industry are normally employed in one of four application groups; material handling, process operations, assembly and inspection. To control a robot so that it is capable of performing the required task, all the joints need to be accurately controlled. The work volume depends on the actual joint limits of motion. A rotary motion is normally quicker that the equivalent linear motion. However to achieve linear motion using rotary joints, a co-ordinated move is required. Not all robotic applications require 6 axes, for example paint spraying, this requires a five axis robot as spraying is symmetrical about the roll axis. R M Crowder January /17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 13

14 Pitch Rotation about horizontal axis 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 14

15 Yaw Rotation about a vertical axis 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 15

16 Roll Rotation about arm axis 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 16

17 Work space Cylindrical 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 17

18 Work space Spherical 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 18

19 Work space Jointed arm 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 19

20 Types of robots 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 20

21 Components 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 21

22 End of Arm Tooling EOA Systems, Inc. End Effector Calculator INTRODUCTION EOA Home Page Calculator Calculator Definitions Conversion Factors Thank you for your interest in the EOA Product line. This web end effector calculator is provided for your convenience. EOA s End Effector moment and inertia End Effector Calculator allows you to determine approximately the moment and inertia that your robot will experience. You enter pertinent information about your End Effector and robot. The moment, payload, and inertia acting on the robot are then instantly calculated. Every attempt has been made to determine accurate acceleration, moment and inertia calculations. Actual values may vary depending upon the final robot motions made, differences between the calculator End Effector model and your End Effector, and the actual capabilities of the robot you use. These rough calculations should be used only to size products and not for final design considerations. All units must be entered in inches, and pounds. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 22

23 Sample part Definitions 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 23

24 DEFINITIONS MOMENT The effectiveness of a force to produce rotation about an axis, measured by the product of the force and the perpendicular distance from the line of action of the force to the axis. If a force F acts to produce rotation about a center at a distance d from the line in which the force acts, the force has a torque. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 24

25 ROTATIONAL INERTIA ROTATIONAL INERTIA is a measure of the effectiveness of mass in rotation. In the rotation of a rigid body not only the body s mass, but the distribution of the mass about the axis of rotation determines the change in the angular velocity resulting from the action of a given torque for a given time. Moment of inertia in rotation is analogous to mass (inertia) in simple translation. If m1,m2,m3,... represent the masses of infinitely small particles of a body; r1,r2,r3,... their respective distances from an axis of rotation, the moment of inertia about this axis will be I=m1r12 + m2r22 + m3r32 + m4r /17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 25

26 INERTIA If a body is considered to be composed of a number of parts, its moment of inertia about an axis is equal to the sum of the moments of inertia of the several parts about the same axis or I=I1 + I2 + I3 + I /17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 26

27 INERTIA The moment of inertia of an area or solid about any given axis is equal to the moment of inertia about a parallel axis through the center of gravity plus the square of the distance between the two axis times the area or mass. The End Effector calculator takes all of the dimensions and weights you have entered into account when determining inertia s. Because your CG and part dimensions will vary, the inertia will vary for each axis of rotation. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 27

28 INERTIA The moment of inertia of a solid is often called the flywheel effect in the solution of problems dealing with rotating bodies. The kinetic energy goes up with the square of the distance of the mass from the center of rotation and the square of the rotational speed. Therefore, End Effectors should be tightly designed, especially when high accelerations are expected. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 28

29 INERTIA Robot literature states a maximum allowable inertia on the robot arm. This is to keep the drive motors from becoming unstable with unwieldy End Effectors and parts and from overloading the arm during high acceleration. After you have determined your and effector and part inertia, you should make certain that you do not exceed the inertia of the robot you anticipate using. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 29

30 INERTIA The torque exerted on the motor axis can be determined by multiplying the inertia times the angular acceleration or T=I * rad/sec2. There is a torque associated with each axis of rotation as the robot moves in it s gyrations. This software only uses the wrist roll and the Iz inertia to determine moment on the z axis. Portions from: CRC Handbook of Physics, 57th Edition, pg F113 and Mark s Mechanical Engineer Handbook, section 3 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 30

31 Convenient Conversion Factors WEIGHT Pounds X constant below=desired Units killograms = newtons = 4.45 ounces = 16 MOMENT Inch Pounds X constant below=desired Units Ft-lb = Kg-cm = nm = kg-m = /17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 31

32 INERTIA In-lb-sec2 * constant below= Desired Units ft-lb-sec2 = in-oz-sec2 = 16 g-cm-sec2 = kg-cm-sec2 = kg-m-sec2 = lb-in2 = 386 lb-ft2 = 2.68 oz-in2 = g-cm2 = kg-cm2 = kg-m2 = nm2 = /17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 32

33 DISTANCE Inches X constant below=desired Units feet = 1 / 12 cm = 2.54 mm = 25.4 meters = 1 / PRESSURE PSI X constant below=desired Units kpa = bar = 1 / 14.7 nt/m2 = /17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 33

34 Use calculator at: END EFFECTOR (Tool) Tool Weight (lb) X to Tool CG inches Tool Width inches Y to Tool CG inches Tool Height inches Face to Tool CG inches Tool Length inches % Acceleration assuming 1g=100% % PART Part Weight (lb) X to art CG inches PartWidth inches Y to Part CG inches Part Height inches Face to Part CG inches Part Length inches DESIRED OUTPUT MOMENT UNITS 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 34 DESIRED OUTPUT INERTIA UNITS

35 CALCULATION ALGORITHM Assumptions: K is a constant which varies for each calculation being performed based upon desired units. The software compensates for mass and weight and takes gravity into account when necessary based upon the units you have selected. Moment has static (standing still) and dynamic (due to acceleration) components. The absolute value of the static and dynamic components are added to give you the worst case scenario of the moment the robot will see. Because of the complex motions the robot can produce, moments will often be less. The robot acceleration can vary greatly. High acceleration robots can move near 2g s or more. Calculations are based upon 1g at 100%. You can vary the acceleration to 2g or more by changing the acceleration to 200%. Acceleration is extremely subjective and almost impossible to determine precisely without placing accelerometers on the robot since it is dependent upon so many variables such as axis movement and coordinated direction. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 35

36 Moments Scale K K is a constantly changing constant as different units are selected, normally K=1. STATIC MOMENT. Moment = Weight * Distance to Center of Gravity. ToolMx = K * ToolWeight * Sqr(FacetoToolCG2+ XtoToolCG2) ToolMy = K * ToolWeight * Sqr(FacetoToolCG2+ YtoToolCG2) ToolMz = K * ToolWeight * Sqr(YtoToolCG2+ XtoToolCG2) PartMx = K * PartWeight * Sqr(FacetoPartCG2+ XtoPartCG2) PartMy = K * PartWeight * Sqr(FacetoPartCG2+ XtoPartCG2) PartMz = K * PartWeight * Sqr(YtoPartCG2+ XtoPartCG 2) 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 36

37 INERTIA CALCULATIONS All End Effectors and parts are assumed to have uniform density. Weight can vary. All End Effectors and parts are assumed to have the inertia of a rectangular parallelepiped. Inertia through face ab parallel to edge c. Inertia=mass * (a2+ b2) / 12 + mass * distance to CG2 Inertia I through an axis offset and parallel to the moment of inertia Io which is through the CG. I = Io+x2m ToolIx = K * (((ToolMass / 12) * (ToolWidth2+ ToolHeight2)) + ToolMass * (XtoToolcg2+FacetoToolcg 2)) ToolIy = K* (((ToolMass / 12) * (ToolLength2+ ToolHeight2)) + ToolMass * (YtoToolCG2+FacetoToolcg 2)) ToolIz = K * (((ToolMass / 12) * (ToolWidth2+ ToolLength2)) + ToolMass * (XtoToolcg2+YtoToolCG 2)) PartIx = K * (((PartMass / 12) * (PartWidth2+PartHeight2)) +PartMass * (XtoPartCG2+FacetoPartcg2)) PartIy = K *(((PartMass / 12) * (PartLength2+PartHeight2)) +PartMass * (YtoPartCG2+FacetoPartcg2)) PartIz = K *(((PartMass / 12) * (PartWidth2+PartLength2)) +PartMass * (XtoPartCG2+YtoPartCG2)) 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 37

38 ACCELERATION MOMENTS Moment=weight*Acceleration*Distance to Center of Gravity in X and Y linear motion. Moments are assumed always positive to obtain the worst case scenario. Therefore, a moment induced by an off center load cannot be negated by a motion in the opposite direction. Complex multi-axis motions makes the use of inertia impractical when calculating moment about the face plate x and y axis. Therefore, linear acceleration is used instead. The robot faceplate roll angular acceleration about the face center is ideal for using inertia to determine moment about z. Ignoring friction Tz=Mz=Iz * angular acceleration in rad/sec2 The assumption is 0 to 400 deg/sec in 1/2 sec or 800 deg/sec2=13.9 rad/sec2 when you request 1g. ToolAccelMx = K * tool mass * Ax * Sqr(FacetoToolCG2+ XtoToolCG2) ToolAccelMy = K * tool mass * Ay * Sqr(FacetoToolCG2+ YtoToolCG2) ToolAccelMz = K * ToolIz * z rad/sec2 PartAccelMx = K * part mass * Ax * Sqr(FacetoPartCG2 + XtoPartCG2) PartAccelMy = K * part mass * Ay * Sqr(FacetoPartCG2 + YtoPartCG2) PartAccelMz = K * PartIz * z rad/sec2 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 38

39 Arm and wrist The first three links, called the major links, carry the gross manipulation tasks. Examples of robots that use the major links include arc welding, spray painting, and water jet cutting applications. The last three links, or the minor links, carry the fine force and tactile manipulation tasks. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 39

40 Robot requirements that need to be determined for the application Payload and working range Arm and wrist configuration End-effector required Method of actuation Operation (servo or non-servo) Precision required Special features Commercial units available 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 40

41 Configurations fit applications Cartesian Application assembly and machine loading Configuration PPP Percentage 18 Advantage equal resolution, simple kinematics Disadvantage Poor space utilization, slow speed 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 41

42 Commercial robot selection worksheet Criteria Requirement Commercial Robot Candidate 1 Payload capacity Commercial Robot Candidate 2 Commercial Robot Candidate 3 Arm configuration Outer reach Inner reach Upper reach Lower reach Horizontal reach or sweep Wrist configuration 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 42

43 Robot Selection (Cont.) Criteria Requirement Commercial Robot Candidate 1 Pitch rotation Commercial Robot Candidate 2 Commercial Robot Candidate 3 Yaw rotation Roll rotation Method of actuation Type of operation (servo or nonservo) Repeatibility No of signals in No of signals out 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 43 Cost

44 Keep benefits in mind Five benefits that frequently are achieved through the application of industrial robots. Reduced costs Improved productivity Improved quality Elimination of hazards Greater flexibility 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 44

45 Homework Assignment 2-Due Oct. 22, Select a robotics application topic for your project from the common proven applications or other innovative applications shown below. A. Spot welding B. Seam welding C. Material handling D. Machine loading/unloading E. Spray painting F. Finishing operation G. Assembly H. Other automated guided vehicle 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 45

46 HW 2 Prepare an annotated bibliography on your selected topic of 6 references in the SPIE format. The SPIE format is found under author guidelines on the SPIE web page at Annotation means that you read the article and provide a paragraph of two or three, well structured sentences that summarize the work. You cannot just copy the abstract or other sentences from the published work. To copy someone else s work and present it as your own is plagiarism! You also list the reference in the specified format. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 46

47 HW 2 Turn in a paper with your Name The Topic The annotated bibliography The list of references This is an individual assignment. Even if you plan to work on a team, conduct your own research and write your own bibliography. 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 47

48 Any questions? 10/17/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 48

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