chapter 4 basics of industial robots
TRANSCRIPT
VocTRA XXI 26-30.09.2011, Warsaw, Poland
Vocational Training in Robotics Automation - XXI Century
VocTRA XXI
26-30.09.2011, Warsaw, Polan
CHAPTER 4
Basics of Industial Robots
VocTRA XXI 26-30.09.2011, Warsaw, Poland
Overview
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Introduction to industrial robots
What is an industrial robot?
Present industrial robots in market and their categorisation
Robot system components
Basics of motion in industrial robots
Frame concept
VocTRA XXI 26-30.09.2011, Warsaw, Poland
Introduction
VILAROB – CHAPTER 4 – Basics of Industrial Robots
A robot the size of a person can easily carry a load over one
hundred pounds
It can move it very quickly with a repeatability of +/-0.006
inches
Robots can do the same motion 24 hours a day for years on
end
And with no failures whatsoever
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Introduction
VILAROB – CHAPTER 4 – Basics of Industrial Robots
A robot is made up of the very same components like human
being.
■ A typical robot has a movable physical structure
■ A motor of some sort
■ A sensor system
■ A power supply
■ A computer "brain" that controls all of these elements
Essentially, robots are man-made versions of animal life
They are machines that replicate human and animal
behaviour.
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What is an industrial robot?
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Industrial robots are automated machines that work on
assembly lines
With six joints closely resembles a human arm
They are machines that replicate human and animal
behaviour.
They have often six independent joints, also called six
degrees of freedom
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What is an industrial robot?
VILAROB – CHAPTER 4 – Basics of Industrial Robots
VocTRA XXI 26-30.09.2011, Warsaw, Poland
What is an industrial robot?
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Industrial robots are designed to do exactly
the same thing
In a controlled environment
Over and over again
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What is an industrial robot?
VILAROB – CHAPTER 4 – Basics of Industrial Robots
EXAMPLE
A robot should weld two metal
pieces to produce a car door again
and again
To teach a robot how to do its job,
the programmer guides the arm
through the motions using a
handheld controller
The robot stores the exact
sequence of movements in its
memory, and does it again and
again every time a new unit comes
down the assembly line
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What is an industrial robot?
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Robots can do a lot of this work more efficiently than
human beings because ■ They are so precise
■ They always drill in the exactly the same place
■ They always tighten bolts with the same amount of force
■ No matter how many hours they've been working
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Industrial robot categorisation
VILAROB – CHAPTER 4 – Basics of Industrial Robots
The industrial joint-arm robots are categorized in different
ways
■ “Limit of Payload”
■ “Field of applications”
■ “Kinematic type”
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Industrial robots categorisation
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Regarding with the application type, it may be possible to
use a more flexible or a less flexible robot
Some applications may need faster motion
Another application may need less speed but more
accurate
An application may need motion in 3 dimension and extra
rotation.
Another application may need motion only in two
directions.
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Industrial robot categorisation
VILAROB – CHAPTER 4 – Basics of Industrial Robots
WELDING ROBOTS
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Industrial robot categorisation
VILAROB – CHAPTER 4 – Basics of Industrial Robots
PALLETIZING ROBOTS
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Industrial robot categorisation
VILAROB – CHAPTER 4 – Basics of Industrial Robots
HANDLING ROBOTS
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Industrial robot categorisation
VILAROB – CHAPTER 4 – Basics of Industrial Robots
ASSEMBLING ROBOTS
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Industrial robot categorisation
VILAROB – CHAPTER 4 – Basics of Industrial Robots
LASER CUTTING ROBOTS
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Industrial robot categorisation
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Limit of payload of an industrial robot is the maximal
weight that the robot can carry during the motion.
Each robot has a maximum limit of payload
The weight of the tool/work-piece, mounted to the TCP of
robot will affect : ■ complete dynamic of the robot
■ motion planning
■ motion execution
“Pay attention in selection of the robot which is suitable
for the application that is automated”
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Industrial robot categorisation
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Type Max. Payload Description
Low Payload Category
(5 to 16 kg)
Robots with Low Payloads are particularly suitable for small-scale activities such as component testing, assembly of small parts, or grinding, polishing and bonding.
Medium Payload Category
(30 to 60 kg)
Potential applications for medium payload robots range from simple handling tasks to complex operations such as measuring air currents in the wind tunnel or sewing leather seat covers.
High Payload Category
(80 kg to 270 kg)
Robots from the high payload range are particularly sought after for spot welding, handling and loading/unloading tasks. Their long reach and great flexibility make them indispensable partners.
Heavy Duty (360 kg to 1000 kg)
With payloads of up to 1300 kg, these robots can e.g. handle side panels in automotive body-in-white construction or, in the palletizing variant, carry out tasks in the beverage or building materials industries.
In the following table, the it the payload categorization is done for the KUKA robots:
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Industrial robot categorisation
VILAROB – CHAPTER 4 – Basics of Industrial Robots In the following table, the it the payload categorization is done for the KUKA robots:
KR6 KR16 KR30
VocTRA XXI 26-30.09.2011, Warsaw, Poland
Industrial robot categorisation
VILAROB – CHAPTER 4 – Basics of Industrial Robots In the following table, the it the payload categorization is done for the KUKA robots:
KR60 KR100 KR150
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Industrial robot categorisation
VILAROB – CHAPTER 4 – Basics of Industrial Robots In the following table, the it the payload categorization is done for the KUKA robots:
KR360L KR500 KUKA
TITAN
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Industrial robot categorisation
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Parallel Kinematic: Axis are joined parallel to each
other. One or more Axes can be joined to another axis
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Industrial robot categorisation
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Forward Kinematic: Axis are joined with each other
serially, one to another
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Robot system components
VILAROB – CHAPTER 4 – Basics of Industrial Robots
A robot system consists of the following components: ■ Robot mechanics
■ Robot controller
■ Control panel - Teach pendant
■ Connecting cables
■ Software
■ Accessories
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Robot system components
VILAROB – CHAPTER 4 – Basics of Industrial Robots
1.Robot 2.Connecting cables 3.Robot controller 4.Teach pendant
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Robot system components
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Robot Mechanics
■ Majority of ind. robots feature six
axes, also called six degrees of
freedom.
■ Six axis robots allow for greater
flexibility and can perform a wider
variety of applications than robots
with fewer axes.
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Robot Mechanics
■ The axis ranges of main axes A 1 to
A 3 and wrist axis A 5 are limited.
▪ Mechanical limits
▪ Software limits
Robot system components
VILAROB – CHAPTER 4 – Basics of Industrial Robots
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Robot system components
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Robot Controller
The robot controller is the hardware component of the
robot system
Responsible from the controlling of the complete system
like: ■ motion planning
■ communication with other components
■ execution of robot program
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Robot system components
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Teach Pendant
Pendants are used to control and to program the
industrial robots.
A Pendant is a hand-held unit linked to the control system
with which a robot can be programmed or moved.
It is also referred as ■ Teach Pendant.
■ Control Panel (by KUKA),
■ iPendant (by FANUC)
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Robot system components
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Teach Pendant
Teach pendants are used as human robot interface in the
robot controller.
Most of the robot processes are achieved by the teach
pendant.
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Robot system components
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Teach Pendant – Important Input Buttons
The following buttons are placed on most teach pendant as
standard:
Name Functionality
Mode selector switch Selects operation mode
Drives on / off Switches the robot drives on/off
EMERGENCY STOP Stops the robot in hazardous situations.
Start key The Start key is used to start a program.
STOP key The STOP key is used to stop a program that is running.
Softkeys For diferent purposes
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Robot system components
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Teach Pendant- Emergancy Stop
In case of emergency, robots are required to halt immediately.
EN ISO 13850
This button provides a rapid means to disconnect the energy
source of the device to protect workers.
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Robot system components
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Teach Pendant- Deadman Switch
The deadman switch stops the robot,
and is a form of fail-safe
automatically operated in case the
human operator becomes
incapacitated
There are up to three deadman
switch are place on the control panel
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Robot system components
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Teach Pendant – Mode Selector
There are different operation modes
of robots
Each mode has different motion and
reaction specifications
Mode can be change by a switch
which is place on the control panel
• Test Mode
• Automatic Mode
• Extern Mode
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Robot system components
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Teach Pendant – Drive On/Off
This button is used to close the loop
to give power to the motors
When the robot program is started
the joint motors should have power
in order to move the joint.
This button is places on the control
panel to control the motor powers.
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Basics of industrial robot motion
VILAROB – CHAPTER 4 – Basics of Industrial Robots
The axis of the robot can be moved
in two different ways
■ move the robot manually axis specific
■ Motion with respect to a definite
Cartesian coordinate system
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Basics of industrial robot motion
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Axis Specific
Each robot axis can be
individually moved in
positive or negative
axis direction
The axis positions would change
independent of each other.
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Basics of industrial robot motion
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Cartesian
The robot can move with respect to a
definite coordinate system
Different coordinate system to be
used
Cartesian manual jogging is mostly
used. Since reaching a target point is
easier in a coordinate system rather
than moving the axis of the robot
specifically.
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Basics of industrial robot motion
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Cartesian
BASE coordinate system: Rectangular
coordinate system, whose origin is located
in the work piece.
WORLD coordinate system: A fixed,
rectangular coordinate system which has
its origin at the base of the robot.
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Basics of industrial robot motion
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Cartesian
TOOL coordinate system: Rectangular coordinate system, whose origin is
located in the tool.
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Frame Concept
VILAROB – CHAPTER 4 – Basics of Industrial Robots
The three dimension (x,y,z) modeling is enough for
representing a point(particle) in the space
but it is not enough for the representation of any rigid body
which has a volume.
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Frame Concept
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Therefore a position is represented with a FRAME
A frame of reference in physics, may refer to a coordinate
system or set of axes within which to measure the position and
orientation. A frame has the following components.
Component Meaning
X distance to the origin in X-Axis
Y distance to the origin in Y-Axis
Z distance to the origin in Z-Axis
A rotation angel over Z-Axis
B rotation angel over Y-Axis
C rotation angel over X-Axis
Eu
ler-Z
XY
no
tatio
n
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Frame Concept
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Position representation in 6D with Frames
The frames are widely used in industrial robots where all points
are represented as frames in robot programs
Linear motion with changes in orientation during linear motion
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Frame Concept: Robots with 3 Axes
VILAROB – CHAPTER 4 – Basics of Industrial Robots
Industrial robots which move only in three dimension called
Cartesian robots
Cartesian robots allow only x-y-z positioning
Three linear joints provide the three axes of motion
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Basics of Industrial Robots
VILAROB – CHAPTER 4 – Basics of Industrial Robots
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