Introduction to Robotics in Cim Systems

by Rehg, James A.

• ISBN13: 9780139012082
• ISBN10: 0139012087
• Edition: 4th
• Format: Hardcover
• Copyright: 1999-10-01
• Publisher: Pearson College Div

Summary

For courses in two- and four-year colleges in Introduction to Robotics, Manufacturing Automation, or Production Design. This text addresses the use of robots for flexible automation from a manufacturing systems viewpoint. It begins with what industrial robots were and how they were integrated into an automated manufacturing system. Emphasis is placed on the hardware and software that support the implementation of automated work cells and manufacturing systems.

Table of Contents

1 Introduction to Industrial Robots	1	(43)
1-1 Introduction	1	(1)
1-2 History of the Industry	2	(2)
1-3 Forty-Year-Old Industry	4	(2)
1-4 Integrated Systems--Meeting the External and Internal Challenges	6	(11)
External Challenges	7	(2)
Internal Challenge	9	(1)
Meeting the Internal Challenge	10	(7)
1-5 The Problem and a Solution	17	(1)
1-6 Definition of Robotics and Computer-Integrated Manufacturing	17	(2)
1-7 Manufacturing System Classification	19	(3)
Project	19	(1)
Job Shop	20	(1)
Repetitive	20	(2)
Line	22	(1)
Continuous	22	(1)
1-8 Robot Systems	22	(8)
Basic System	24	(1)
Mechanical Arm	25	(1)
Production Tooling	26	(1)
External Power Source	26	(1)
Robot Controller	27	(1)
Teach Stations	27	(1)
ABB Controller Interface	28	(2)
1-9 Some Basic Terms	30	(9)
1-10 Robot Standards	39	(1)
R15 Standards	39	(1)
A15 Standards	39	(1)
1-11 Summary	40	(1)
Questions	41	(1)
Problems	42	(1)
Projects	43	(1)
2 Robot Classification	44	(66)
2-1 Introduction	44	(1)
2-2 Robot Arm Geometry	44	(8)
Cartesian Geometry	44	(2)
Cylindrical Geometry	46	(2)
Spherical Geometry	48	(1)
Articulated Geometry	49	(2)
Selective Compliance Articulated Robot Arm (SCARA)	51	(1)
Horizontally Base-Jointed Arm	51	(1)
2-3 Power Sources	52	(6)
Hydraulic Power	52	(2)
Pneumatic Power	54	(3)
Electric Power	57	(1)
2-4 Drive Systems	58	(17)
Torque	59	(5)
Belts	64	(3)
Chains	67	(1)
Gear Drives	67	(4)
Gear Error	71	(1)
Ball Screw Drives	71	(2)
Harmonic Drives	73	(2)
2-5 Application Areas	75	(2)
Assembly	75	(1)
Nonassembly	75	(2)
2-6 Control Techniques	77	(16)
Closed-loop Systems	77	(12)
Open-loop Systems	89	(4)
2-7 Path Control	93	(7)
Stop-to-stop Path Control	95	(1)
Point-to-point Control	95	(3)
Controlled Path	98	(1)
Continuous Path	98	(2)
2-8 Design Guidelines	100	(2)
Robot Selection Criteria	100	(1)
Robot Survey	101	(1)
2-9 Classification by the International Standards Organization (ISO)	102	(1)
Sequenced	102	(1)
Trajectory	103	(1)
Adaptive	103	(1)
Teleoperated	103	(1)
2-10 Summary	103	(1)
Questions	104	(1)
Problems	105	(2)
Projects and Case Study Problems	107	(3)
3 Automated Work Cells and CIM Systems	110	(25)
3-1 Introduction	110	(1)
3-2 The CIM Implementation Process	111	(8)
Step 1: Assessment of Enterprise Technology, Human Resources, and Systems	111	(2)
Step 2: Simplification--Elimination of Waste	113	(2)
Step 3: Implementation with Performance Measures	115	(4)
3-3 Making the CIM Process Work	119	(1)
3-4 Automated Production	120	(1)
3-5 Flexible Automation	120	(7)
3-6 Fixed Automation	127	(1)
In-Line Fixed Automation	127	(1)
Rotary-Type Fixed Automation	127	(1)
3-7 Work-Cell Design Checklist	128	(1)
3-8 Implementing Automated Work Cells	129	(2)
New Versus Existing Production Machines	129	(1)
Fixed Versus Flexible Automation	130	(1)
3-9 Summary	131	(1)
Questions	132	(1)
Problems	133	(1)
Projects and Case Study Problems	133	(2)
4 End-of-Arm Tooling	135	(40)
4-1 Introduction	135	(1)
4-2 Standard Grippers	136	(8)
Gripping Force	140	(2)
Minimum Gripper Force	142	(2)
4-3 Vacuum Grippers	144	(6)
Lifting Capacity	145	(2)
System Components	147	(1)
Vacuum Surfaces	148	(2)
Vacuum Suckers	150	(1)
4-4 Magnetic Grippers	150	(1)
4-5 Air-Pressure Grippers	150	(5)
Gripping Force	152	(3)
4-6 Special-Purpose Grippers	155	(1)
4-7 Gripper Selection and System Intelligence	155	(1)
4-8 Special-Purpose Tools	156	(1)
4-9 Robot Assembly	157	(1)
4-10 Compliance	158	(6)
Active Compliance	159	(1)
Active Compliance Applications	159	(1)
Passive Compliance	160	(4)
4-11 Multiple End-Effector Systems	164	(3)
Wrist Interface	165	(1)
Multiple-Gripper Systems	165	(2)
4-12 Collision Systems	167	(3)
Breakable Link Devices	169	(1)
Spring and Pneumatic Collision Devices	169	(1)
4-13 Summary	170	(1)
Questions	171	(1)
Problems	171	(3)
Projects and Case Study Problems	174	(1)
5 Automation Sensors	175	(40)
5-1 Introduction	175	(2)
Discrete Sensors	176	(1)
Analog Sensors	177	(1)
5-2 Contact Sensors	177	(10)
Discrete Devices	177	(4)
Dogs	181	(3)
Artificial Skin	184	(3)
5-3 Noncontact Sensors	187	(20)
Proximity Sensors	187	(2)
Inductive Sensor Operation	189	(9)
Capacitive Sensors	198	(2)
Photoelectric Sensors	200	(7)
5-4 Sensor Selection Checklist	207	(1)
5-5 Smart Sensor Systems	207	(2)
DeviceNet Network	209	(1)
5-6 Process Sensors	209	(2)
5-7 Summary	211	(1)
Questions	211	(1)
Problems	212	(1)
Projects and Case Study Problems	213	(2)
6 Work-Cell Support Systems	215	(23)
6-1 Introduction	215	(1)
6-2 Machine Vision Systems	215	(7)
Vision Standards	216	(1)
Vision System Components	216	(2)
Image Measurement	218	(2)
Image Analysis	220	(1)
Image Recognition	221	(1)
6-3 Lighting for Machine Vision	222	(3)
Selection of the Light Source	223	(1)
Lighting Techniques	223	(2)
Illumination Sources	225	(1)
6-4 Material Handling	225	(5)
Automated Transfer Systems	226	(3)
Automatic Storage and Retrieval Systems	229	(1)
6-5 Part Feeding	230	(3)
Gravity Feeders	230	(1)
Tape Feeders	231	(1)
Waffle-Tray Feeders	232	(1)
Vibratory Feeders	232	(1)
6-6 Inspection	233	(1)
6-7 Automatic Tracking	233	(3)
6-8 Summary	236	(1)
Questions	237	(1)
Projects and Case Study Problems	238	(1)
7 Robot and System Integration	238	(26)
7-1 Introduction	239	(2)
7-2 System Overview	241	(1)
Hardware Overview	241	(1)
Software Overview	242	(1)
7-3 Work-Cell Architecture	242	(3)
Cell Controllers	242	(1)
Cell Control Software Structure	243	(1)
Work-Cell Management Software	244	(1)
7-4 Programmable Logic Controllers	245	(3)
PLC System Components	245	(1)
Basic PLC System Operation	246	(2)
7-5 Computer Numerical Control	248	(1)
7-6 Controller Architecture	249	(5)
Nonservo Robot Controllers	249	(2)
Servo Robot Controllers	251	(3)
7-7 Interfaces	254	(4)
Simple Sensor Interface	254	(3)
Complex Sensor Interface	257	(1)
Enterprise Data Interface	258	(1)
7-8 An Integrated System	258	(3)
Machining Cell	260	(1)
Assembly Cell	260	(1)
Signal Types	260	(1)
Work-Cell Controller	261	(1)
Programmable Logic Controller	261	(1)
7-9 Summary	261	(1)
Questions	262	(1)
Projects and Case Study Problems	263	(1)
8 Work-Cell Programming	264	(29)
8-1 Introduction	264	(1)
8-2 Work-Cell Controller Programming	265	(2)
Software Developed In-House	265	(1)
Enabler Software	266	(1)
OSI Solution	266	(1)
8-3 Programming Sequential Cell Activity	267	(3)
PLC Programming	268	(2)
Other Sequential Programming Options	270	(1)
8-4 Robot Language Development	270	(1)
8-5 Language Classification	271	(3)
Joint-Control Languages	271	(1)
Primitive Motion Languages	272	(1)
Structured Programming Languages	273	(1)
Task-Oriented Languages	274	(1)
8-6 Robot Program Fundamentals	274	(3)
8-7 Translation or Position Points for Servo Robots	277	(7)
Reference Frames	277	(4)
Programming Servo Robot Translation Points	281	(3)
Programming Nonservo Robot Translation Points	284	(1)
8-8 Program Statements for Servo Robots	284	(5)
Basic Program Structure--Step 1	284	(1)
Process Analysis--Step 2	285	(1)
Tasks and Subtasks--Step 3	285	(1)
Task Point Graph--Step 4	286	(1)
On-Line and Off-Line Programming	286	(3)
Translation Points and System Variables--Step 5	289	(1)
System Variables--Step 6	289	(1)
8-9 Summary	289	(2)
Questions	291	(1)
Problems	292	(1)
Projects and Case Study Problems	292	(1)
9 Justification and Applications of Work Cells	293	(24)
9-1 Introduction	293	(1)
9-2 Capital Equipment Justification	294	(3)
Return on Investment Method	295	(1)
Cash Flow Method	295	(1)
Time Value of Money	295	(1)
Justifying Robotics Applications	296	(1)
Justification Spreadsheet	296	(1)
9-3 Automation Applications	297	(17)
Material Handling	297	(4)
Machine Tending	301	(1)
Assembly	301	(5)
Process	306	(1)
Welding	306	(3)
Paint Spraying	309	(5)
9-4 Summary	314	(1)
Questions	314	(1)
Problems	314	(2)
Projects and Case Study Problems	316	(1)
10 Safety	317	(38)
10-1 Introduction	317	(1)
10-2 Safety Standards	318	(2)
Robot Systems and Integrated Work Cells	319	(1)
Corporate Standards	319	(1)
Governmental and Other Organizations	319	(1)
10-3 Occupational Safety and Health Administration (OSHA)	320	(1)
10-4 American National Standards Institute/Robotic Industries Association Standard for Robot Safety	321	(1)
10-5 Safeguarding a Work Cell	321	(2)
Safeguarding Devices	321	(1)
Safety Hardware	322	(1)
10-6 Presence Sensing Devices	323	(8)
Proximity Sensing Devices	323	(1)
Light Curtain Introduction	324	(1)
Light Curtain Operation	325	(1)
Light Curtain Applications	326	(1)
Calculating Safe Curtain Distance	327	(3)
Presence Sensing Mats	330	(1)
Sensing Mat Operation	330	(1)
10-7 Interlock Devices	331	(8)
Interlock Switch Operation	331	(1)
Interlock Positive Mode Operation	331	(1)
Forms of Interlock Devices	332	(1)
Power Interlocking	332	(1)
Control Interlocking	332	(1)
Calculating Safe Guard Distance	333	(1)
Mechanical Interlock Devices	334	(2)
Non-Contact Interlock Devices	336	(1)
Interlock Switches with Guard Locking	337	(1)
Unconditional Guard Unlocking	338	(1)
Conditional Guard Unlocking	338	(1)
10-8 Safeguarding the Operator	339	(1)
10-9 Safeguarding the Programmer	339	(1)
10-10 Safeguarding Maintenance and Repair Personnel	339	(1)
10-11 Developing a Safety Strategy	340	(7)
Risk Assessment-Three Steps	343	(2)
Final Assessment Rating	345	(1)
Hazard Reduction	346	(1)
Personnel Protection Equipment	347	(1)
10-12 Design Guidelines	347	(1)
10-13 Safety Justification	348	(1)
10-14 Summary	349	(1)
Questions	350	(1)
Problems	351	(2)
Projects and Case Study Problems	353	(2)
11 Human Interface: Operator Training, Acceptance, and Problems	355	(9)
11-1 Introduction	355	(1)
11-2 General Training	356	(1)
General Training Program	356	(1)
11-3 Operator Training	357	(1)
11-4 Maintenance Training	357	(1)
11-5 Team-Based Manufacturing	358	(2)
Description of a Self-Directed Work Team	359	(1)
Making Work Teams Work	359	(1)
11-6 Resistance	360	(1)
11-7 Organized Labor	361	(1)
11-8 Summary	361	(1)
Questions	362	(1)
Projects and Case Study Problems	363	(1)
12 Work-Cell Design Case Study	364	(50)
12-1 Introduction	364	(1)
12-2 Company Profile	364	(1)
12-3 Introduction to CIM Automation at West-Electric	365	(3)
West-Electric Automation Team	366	(1)
The First Meeting	366	(2)
12-4 Turbine Blade Production	368	(9)
Step 1: Raw Material Inspection	370	(1)
Step 2: Production of Slugs	370	(1)
Step 3: Slug Lubrication	371	(1)
Step 4: Extrusion	371	(2)
Step 5: Upset Forging	373	(1)
Step 6: Block Forge	373	(1)
Step 7: Final Forge and Trim	374	(1)
Step 8: Alternate Process for Small Airfoils	374	(1)
Step 9: Deburring	375	(1)
Step 10: Heat-Treating	375	(1)
Step 11: Measuring Airfoil Cross-Section	375	(1)
Step 12: Chemical Milling	376	(1)
Step 13: Machining Base	376	(1)
Additional Data on the Blade Production Line	376	(1)
12-5 CDM Improvement Process	377	(2)
Five-Step Design Process	378	(1)
12-6 The Automation Plan	379	(3)
12-7 Selection Criteria	382	(5)
Work-Cell Technical Design Checklist	383	(1)
Robot Selection Checklist	384	(3)
12-8 Performance Measures	387	(2)
12-9 Technical Issues	389	(4)
Performance Requirements	389	(1)
Layout Requirements	389	(1)
Production Characteristics	390	(1)
Equipment Modifications	390	(1)
Process Modifications	390	(3)
Robot Specifications	393	(1)
Oven Modifications	393	(1)
Work-Cell Simulation	393	(1)
12-10 Automation Cell Integration	393	(6)
12-11 Work-Cell Control	399	(1)
12-12 Cell Programming	399	(3)
12-13 Cost Justification	402	(1)
12-14 Safety Plan	403	(5)
Operational Overview	403	(2)
Work-Cell Safety	405	(3)
12-15 Final Performance Measures	408	(6)
Case Study Problems	409	(1)
Sections 12-1 to 12-4	409	(1)
Sections 12-5 to 12-8	409	(1)
Sections 12-8 to 12-9	410	(1)
Section 12-10	410	(1)
Section 12-11	411	(1)
Section 12-12	411	(1)
Section 12-13	412	(1)
Sections 12-14 to 12-15	412	(2)
Appendix A Robot Specifications	414	(9)
Appendix B Internet Resources	423	(3)
Thomas Register	424	(1)
Web Search Engines	424	(1)
Standard Organizations	424	(1)
Robot Vendors	424	(1)
Automation Sensors	424	(1)
Automation Support Components	424	(1)
Programmable Logic Controllers	425	(1)
Work-Cell Control Software	425	(1)
Material Handling Systems	425	(1)
Appendix C Justification Program	426	(6)
Index	432