Introduction to Robotics in Cim Systems

by Rehg, James A.

• ISBN13: 9780130602435
• ISBN10: 0130602434
• Edition: 5th
• Format: Hardcover
• Copyright: 2002-03-08
• Publisher: Pearson

Summary

Written from a manufacturing perspective, this book takes readers step-by-step through the theory and application techniques of designing and building a robot-driven automated work cellfrom selection of hardware through programming of the devices to economic justification of the project. All-inclusive in approach, it covers not only robot automation, but all the other technology needed in the automated work cell to integrate the robot with the work environment and with the enterprise data base. Robot and other required automation hardware and software are introduced in the order in which they would be selected in an actual industrial automation design. Includes system troubleshooting guides, case studies problems, and worked example problems.Robot Classification. Automated Work Cells and CIM Systems. End-of-Arm Tooling. Automation Sensors. Work-Cell Support Systems. Robot and System Integration. Work-Cell Programming. Justification and Applications of Work Cells. Safety. Human Interface: Operator Training, Acceptance, and Problems.For those interested in Robotics and Manufacturing Automation or Production Design.

Author Biography

James A. Rehg, CMfgE, is an associate professor of engineering at Penn State-Altoona. He earned a BS and MS in electrical engineering from St. Louis University and has completed additional graduate work at Wentworth Institute, University of Missouri, South Dakota School of Mines and Technology, and Clemson University. Before moving to Penn State, he was director of the Computer Integrated Manufacturing project and department head of CAD/CAM and Machine Tool Technology at Tri-County Technical College, and previous to that he was director of Academic Computing and the Manufacturing Productivity Center at Trident Technical College. Professor Rehg also served as director of the Robotics Resource Center at Piedmont Technical College and department head of Electronic Engineering Technology at Forest Park Community College. His industrial experience includes work in instrumentation at McDonnell Douglas Corporation and consulting in the areas of computer-aided design, robotics, computer-integrated manufacturing, and programmable logic controllers.

Professor Rehg has written five texts on robotics and automation and many articles on subjects related to training in automation and robotics. His most recent text is Computer-Integrated Manufacturing, 2nd ed., with coauthor Henry Kraebber of Purdue University, published by Prentice Hall in 2000. Professor Rehg has received numerous state awards for excellence in teaching, including the outstanding instructor in the nation by the Association of Community College Trustees and the Penn State Engineering Society Outstanding Teaching Award in 1998.

Table of Contents

Introduction to Industrial Robots	1	(52)
Chapter Goals and Objectives	1	(1)
Introduction	1	(1)
Career Spotlight	2	(1)
History of the Industry	2	(3)
Fifty-year-old Industry	5	(2)
Integrated Systems-Meeting the External and Internal Challenges	7	(11)
External Challenges	7	(3)
Internal Challenge	10	(1)
Meeting the Internal Challenge	11	(7)
The Problem and a Solution	18	(1)
Definition of Robotics and Computer-Integrated Manufacturing	19	(2)
Manufacturing System Classification	21	(4)
Project	21	(2)
Job Shop	23	(1)
Repetitive	23	(1)
Line	23	(1)
Continuous	23	(2)
Robot Systems	25	(7)
Robot Hardware	25	(1)
Mechanical Arm	25	(2)
Production Tooling	27	(1)
External Power Source	27	(2)
Robot Controller	29	(1)
Teach Stations	30	(1)
ABB Controller Interface	31	(1)
Some Basic Terms	32	(10)
Robot Safety Guidelines	42	(4)
Work Cell Safety Design Requirements	43	(1)
Guidelines for Safe Robot Use	43	(3)
Robot Standards	46	(1)
R15 Standards	46	(1)
A15 Standards	47	(1)
Summary	47	(6)
Questions	49	(1)
Problems	50	(1)
Projects	51	(2)
Robot Classification	53	(66)
Chapter Goals and Objectives	53	(1)
Career Spotlight	54	(1)
Introduction	54	(1)
Robot Arm Geometry	55	(12)
Cartesian Geometry	55	(3)
Cylindrical Geometry	58	(2)
Spherical Geometry	60	(3)
Articulated Geometry	63	(3)
Selective Compliance Articulated Robot Arm (SCARA)	66	(1)
Horizontally Base-jointed Arm	66	(1)
Power Sources	67	(6)
Hydraulic Power	67	(3)
Pneumatic Power	70	(1)
Electric Power	70	(3)
Drive Systems	73	(11)
Torque	73	(1)
Belts	74	(3)
Chains	77	(1)
Gear Drives	77	(4)
Gear Error	81	(1)
Ball Screw Drives	81	(2)
Harmonic Drives	83	(1)
Application Areas	84	(3)
Assembly	86	(1)
Nonassembly	86	(1)
Control Techniques	87	(15)
Closed-loop Systems	87	(1)
Position Sensors	88	(10)
Open-loop Systems	98	(4)
Path Control	102	(7)
Stop-to-stop Path Control	104	(1)
Point-to-point Control	104	(3)
Controlled Path	107	(1)
Continuous Path	108	(1)
Design Guidelines	109	(3)
Robot Selection Criteria	109	(1)
Robot Survey	110	(2)
Classification by the International Standards Organization (ISO)	112	(1)
Sequenced	112	(1)
Trajectory	112	(1)
Adaptive	112	(1)
Teleoperated	112	(1)
Summary	112	(7)
Questions	113	(2)
Problems	115	(1)
Projects and Case Study Problems	116	(3)
Automated Work Cells and CIM Systems	119	(41)
Chapter Goals and Objectives	119	(1)
Career Spotlight	120	(1)
Introduction	120	(1)
The CIM Implementation Process	121	(8)
Step 1: Assessment of Enterprise Technology, Human Resources, and Systems	122	(1)
Step 2: Simplification-Elimination of Waste	123	(2)
Step 3: Implementation with Performance Measures	125	(4)
Making the CIM Process Work	129	(1)
Automated Production	130	(2)
Flexible Automation	132	(5)
Fixed Automation	137	(1)
In-line Fixed Automation	137	(1)
Rotary-type Fixed Automation	138	(1)
Work-cell Design Checklist	138	(1)
Implementing Automated Work Cells	139	(2)
New versus Existing Production Machines	139	(1)
Fixed versus Flexible Automation	140	(1)
System Troubleshooting and Problem Solving	141	(14)
Introduction to Troubleshooting	141	(1)
Hardware versus Software Troubleshooting	142	(1)
Troubleshooting Techniques	143	(1)
Block Diagrams	144	(2)
Bracketing	146	(1)
Signal Flow	147	(2)
Signal Flow Analysis	149	(1)
Information Funneling	150	(3)
Symptoms and Use of System Data	153	(1)
Troubleshooting Sequence	154	(1)
Multiple Failures	154	(1)
Summary	155	(5)
Questions	156	(1)
Problems	157	(1)
Projects and Case Study Problems	158	(2)
End-of-Arm Tooling	160	(42)
Chapter Goals and Objectives	160	(1)
Career Spotlight	161	(1)
Introduction	161	(1)
Standard Grippers	162	(9)
Gripping Force	166	(2)
Minimum Gripper Force	168	(3)
Vacuum Grippers	171	(6)
Lifting Capacity	171	(3)
System Components	174	(2)
Vacuum Surfaces	176	(1)
Vacuum Suckers	176	(1)
Magnetic Grippers	177	(1)
Air-pressure Grippers	177	(5)
Gripping Force	180	(2)
Special-purpose Grippers	182	(1)
Gripper Selection and System Intelligence	183	(1)
Special-purpose Tools	183	(1)
Robot Assembly	183	(1)
Compliance	184	(7)
Active Compliance	186	(1)
Active Compliance Applications	187	(1)
Passive Compliance	188	(3)
Multiple End-effector Systems	191	(4)
Wrist Interface	191	(1)
Multiple-gripper Systems	192	(3)
Collision Systems	195	(2)
Breakable Link Devices	195	(1)
Spring and Pneumatic Collision Devices	196	(1)
Summary	197	(5)
Questions	198	(1)
Problems	198	(2)
Projects and Case Study Problems	200	(2)
Automation Sensors	202	(48)
Chapter Goals and Objectives	202	(1)
Career Spotlight	203	(1)
Introduction	203	(2)
Discrete Sensors	204	(1)
Analog Sensors	205	(1)
Contact Sensors	205	(7)
Discrete Devices	205	(2)
Dogs	207	(3)
Artificial Skin	210	(2)
Noncontact Sensors	212	(24)
Proximity Sensors	212	(5)
Inductive Sensor Operation	217	(8)
Capacitive Sensors	225	(1)
Photoelectric Sensors	226	(10)
Sensor Selection Checklist	236	(1)
Smart Sensor Systems	236	(3)
DeviceNet Network	236	(3)
Process Sensors	239	(1)
Troubleshooting Sensor Systems	239	(6)
Troubleshooting Tips for Proximity Sensors	241	(2)
Troubleshooting Tips for Photoelectric Sensors	243	(2)
Summary	245	(5)
Questions	246	(1)
Problems	247	(1)
Projects and Case Study Problems	248	(2)
Work-Cell Support Systems	250	(28)
Chapter Goals and Objectives	250	(1)
Introduction	250	(1)
Career Spotlight	251	(1)
Machine Vision Systems	251	(8)
Vision Standards	252	(1)
Vision System Components	252	(4)
Image Measurement	256	(1)
Image Analysis	256	(2)
Image Recognition	258	(1)
Lighting for Machine Vision	259	(3)
Selection of the Light Source	259	(1)
Lighting Techniques	259	(2)
Illumination Sources	261	(1)
Material Handling	262	(6)
Automated Transfer Systems	262	(4)
Automatic Storage and Retrieval Systems	266	(2)
Part Feeding	268	(4)
Gravity Feeders	268	(1)
Magazine Feeders	269	(1)
Tape Feeders	269	(1)
Waffle-tray Feeders	269	(2)
Vibratory Feeders	271	(1)
Inspection	272	(1)
Automatic Tracking	272	(3)
Summary	275	(3)
Questions	276	(1)
Projects and Case Study Problems	277	(1)
Robot and System Integration	278	(28)
Chapter Goals and Objectives	278	(1)
Career Spotlight	279	(1)
Introduction	279	(2)
System Overview	281	(2)
Hardware Overview	282	(1)
Software Overview	282	(1)
Work-cell Architecture	283	(2)
Cell Controllers	283	(1)
Cell Control Software Structure	283	(1)
Work-cell Management Software	284	(1)
Programmable Logic Controllers	285	(4)
PLC System Components	285	(1)
Basic PLC System Operation	286	(3)
Computer Numerical Control	289	(1)
Controller Architecture	290	(5)
Nonservo Robot Controllers	290	(2)
Servo Robot Controllers	292	(3)
Interfaces	295	(5)
Simple Sensor Interface	295	(1)
Simple Sensor Interface Design	296	(2)
Complex Sensor Interface	298	(2)
Enterprise Data Interface	300	(1)
An Integrated System	300	(4)
Machining Cell	302	(1)
Assembly Cell	302	(1)
Signal Types	302	(1)
Work-cell Controller	303	(1)
Programmable Logic Controller	303	(1)
Summary	304	(2)
Questions	304	(1)
Projects and Case Study Problems	305	(1)
Work-Cell Programming	306	(39)
Chapter Goals and Objectives	306	(1)
Introduction	306	(2)
Career Spotlight	307	(1)
Work-Cell Controller Programming	308	(3)
Software Developed In-house	309	(1)
Enabler Software	309	(1)
OSI Solution	310	(1)
Programming Sequential Cell Activity	311	(4)
PLC Programming	311	(3)
Other Sequential Programming Options	314	(1)
Robot Language Development	315	(1)
Language Classification	316	(3)
Joint-control Languages	316	(1)
Primitive Motion Languages	317	(1)
Structured Programming Languages	318	(1)
Task-oriented Languages	318	(1)
Robot Program Fundamentals	319	(3)
Translation or Programmed Points	319	(2)
Programmed Statements	321	(1)
Translation or Position Points for Servo Robots	322	(7)
Reference Frames	322	(2)
Programming Servo Robot Translation Points	324	(5)
Programming Nonservo Robot Translation Points	329	(1)
Program Statements for Servo Robots	329	(5)
Basic Program Structure-Step 1	329	(1)
Process Analysis-Step 2	330	(1)
Tasks and Subtasks-Step 3	330	(1)
Task Point Graph-Step 4	331	(1)
System Variables-Step 5	331	(1)
Write and Enter the Program-Step 6	331	(1)
Teach the Translation Points-Step 7	331	(2)
Test and Debug the Program-Step 8	333	(1)
On-line and Off-line Programming	333	(1)
Programming a Servo Robot	334	(7)
Command Modes	335	(1)
Coordinate Systems	335	(1)
Data Types	336	(1)
Axis Control Commands	336	(2)
I/O Control and Program Flow Commands	338	(3)
Summary	341	(4)
Questions	342	(1)
Problems	343	(1)
Projects and Case Study Problems	344	(1)
Justification and Applications of Work Cells	345	(25)
Chapter Goals and Objectives	345	(1)
Introduction	345	(2)
Career Spotlight	346	(1)
Capital Equipment Justification	347	(3)
Return on Investment Method	348	(1)
Cash Flow Method	348	(1)
Time Value of Money	348	(1)
Justifying Robotics Applications	349	(1)
Justification Spreadsheet	349	(1)
Automation Applications	350	(16)
Material Handling	350	(4)
Machine Tending	354	(1)
Assembly	355	(4)
Process	359	(1)
Welding	359	(4)
Paint Spraying	363	(3)
Summary	366	(4)
Questions	367	(1)
Problems	368	(1)
Projects and Case Study Problems	369	(1)
Safety	370	(37)
Chapter Goals and Objectives	370	(1)
Introduction	370	(1)
Career Spotlight	371	(1)
Safety Standards	371	(2)
Robot Systems and Integrated Work Cells	372	(1)
Corporate Standards	372	(1)
Governmental and Other Organizations	372	(1)
Occupational Safety and Health Administration (OSHA)	373	(1)
American National Standards Institute/Robotic Industries Association Standard for Robot Safety	373	(1)
Safeguarding a Work Cell	374	(2)
Safeguarding Devices	374	(1)
Safety Hardware	375	(1)
Presence Sensing Devices	376	(8)
Proximity Sensing Devices	376	(2)
Light Curtain Introduction	378	(1)
Light Curtain Operation	378	(2)
Light Curtain Applications	380	(2)
Calculating Safe Curtain Distance	382	(1)
Presence Sensing Mats	383	(1)
Sensing Mat Operation	383	(1)
Interlock Devices	384	(8)
Interlock Switch Operation	384	(1)
Interlock Positive Mode Operation	385	(1)
Forms of Interlock Devices	385	(1)
Power Interlocking	386	(1)
Control Interlocking	386	(1)
Calculating Safe Guard Distance	386	(1)
Mechanical Interlock Devices	387	(2)
Non-contact Interlock Devices	389	(2)
Interlock Switches with Guard Locking	391	(1)
Unconditional Guard Unlocking	391	(1)
Conditional Guard Unlocking	391	(1)
Safeguarding the Operator	392	(1)
Safeguarding the Programmer	392	(1)
Safeguarding Maintenance and Repair Personnel	392	(1)
Developing a Safety Strategy	393	(7)
Risk Assessment	393	(3)
Risk Estimation	396	(1)
Risk Assessment-Three Steps	396	(2)
Final Assessment Rating	398	(1)
Hazard Reduction	399	(1)
Personnel Protection Equipment	400	(1)
Design Guidelines	400	(1)
Safety Justification	401	(1)
Summary	402	(5)
Questions	403	(1)
Problems	404	(1)
Projects and Case Study Problems	405	(2)
Human Interface: Operator Training, Acceptance, and Problems	407	(10)
Chapter Goals and Objectives	407	(1)
Introduction	407	(1)
Career Spotlight	408	(1)
General Training	408	(2)
General Training Program	409	(1)
Operator Training	410	(1)
Maintenance Training	410	(1)
Team-based Manufacturing	411	(1)
Description of a Self-directed Work Team	411	(1)
Making Work Teams Work	412	(1)
Resistance	412	(1)
Organized Labor	413	(1)
Impact of 24-7	414	(1)
Summary	415	(2)
Questions	416	(1)
Projects and Case Study Problems	416	(1)
Work-Cell Design Case Study	417	(49)
Chapter Goals and Objectives	417	(1)
Career Spotlight	417	(1)
Introduction	418	(1)
Company Profile	418	(1)
Introduction to CIM Automation at West-Electric	418	(4)
West-Electric Automation Team	419	(1)
The First Meeting	420	(2)
Turbine Blade Production	422	(8)
Step 1: Raw Material Inspection	423	(1)
Step 2: Production of Slugs	424	(1)
Step 3: Slug Lubrication	424	(1)
Step 4: Extrusion	424	(1)
Step 5: Upset Forging	425	(2)
Step 6: Block Forge	427	(1)
Step 7: Final Forge and Trim	427	(1)
Step 8: Alternate Process for Small Airfoils	427	(1)
Step 9: Deburring	428	(1)
Step 10: Heat-treating	429	(1)
Step 11: Measuring Airfoil Cross-section	429	(1)
Step 12: Chemical Milling	429	(1)
Step 13: Machining Base	429	(1)
Additional Data on the Blade Production Line	430	(1)
CDM Improvement Process	430	(2)
Five-step Design Process	431	(1)
The Automation Plan	432	(3)
Selection Criteria	435	(5)
Work-cell Technical Design Checklist	436	(1)
Robot Selection Checklist	437	(3)
Performance Measures	440	(2)
Technical Issues	442	(5)
Performance Requirements	442	(1)
Layout Requirements	442	(1)
Production Characteristics	442	(1)
Equipment Modifications	443	(1)
Process Modifications	443	(1)
Robot Specifications	444	(2)
Oven Modifications	446	(1)
Work-cell Simulation	447	(1)
Automation Cell Integration	447	(5)
Work-cell Control	452	(1)
Cell Programming	452	(3)
Cost Justification	455	(1)
Safety Plan	456	(5)
Operational Overview	456	(2)
Work-cell Safety	458	(3)
Final Performance Measures	461	(1)
Case Study Problems	462	(4)
Sections 12-1 to 12-4	462	(1)
Sections 12-5 to 12-8	462	(1)
Sections 12-8 to 12-9	463	(1)
Section 12-10	463	(1)
Section 12-11	464	(1)
Section 12-12	464	(1)
Section 12-13	464	(1)
Sections 12-14 to 12-15	465	(1)
Appendix A: Hardware Specifications	466	(17)
Appendix B: Internet Resources	483	(3)
Thomas Register	484	(1)
Web Search Engines	484	(1)
Standard Organizations	484	(1)
Robot Vendors	484	(1)
Automation Sensors	484	(1)
Automation Support Components	485	(1)
Programmable Logic Controllers	485	(1)
Work-cell Control Software	485	(1)
Material Handling Systems	485	(1)
Appendix C: Justification Program	486	(5)
Appendix D: Glossary	491	(12)
Index	503

Excerpts

INTRODUCTION An industrial robot is just another industrial machine. This statement has been used frequently by those in education and industry to calm fears about mass worker displacement or to encourage corporate management to adopt flexible automation. Like the numerical control turning center or the lathe that preceded it, the industrial robot is a machine designed to increase productivity, improve quality, and reduce direct labor cost, but the robot is notjust another industrial machine. Robots are versatile: They can be used in every industry that provides goods and services; they can be adapted to numerous job functions; they can change job functions easily; and they work with uncanny skill and unmatched endurance. Robots are different from any industrial machine in the history of automated production. The potential of the robot as an agent of change in manufacturing and in our daily lives has not been fully realized. Employment in the robotics area has changed significantly from the early days of robots. Engineers and technicians working in the robotics field do not concentrate on just robot technology as they did when robots were first introduced. Today the engineer and technician must be capable of working on the entire production system, which often includes robot technology. The job might be in an automation system design company that designs, builds, and installs robot-based automation for other companies, or in an automation design department in a large manufacturing company that designs automation systems for its plants. The automotive industry is a good example of companies in the latter category. Engineers and technicians with robot and automation systems skills are also needed by companies using the technology to produce products. In these companies, they work either individually or in teams to make the automation system perform to specifications. This includes work on robots, programmable logic controllers, and computer numerical machines; system controller programming; troubleshooting system and production problems; performing system upgrades; and training operators on the proper use of the technology. Positions for robot technicians are not plentiful; however, the need for engineers and technicians who can design, develop, implement, and support automated production systems with robots is significant and expanding. Although robots are unique, they share one element with other automated production equipment; namely, to be effective, they must be integrated into the total solution. Education in robotics must reflect this emphasis on the total system as well. The first edition of this text focused on the robot as part of an integrated production cell. The interfaces between the robot and cell devices were emphasized. In the second through fourth editions, the integration of the robot-automated cell with the computer-integrated enterprise was introduced. Now this edition takes the integration of the robot with the automated cell and system to another level. While robots remain the primary focus of the text, additional emphasis is placed on the hardware, software, and programming that support the implementation of automated work cells and manufacturing systems. CHANGES TO THE FIFTH EDITION Major additions and changes to the fifth edition include the addition of chapter goals and objectives at the beginning of every chapter. A Career Spotlightsection was added at the start of every chapter as well. The Career Spotlight focuses on the career opportunities for the technology areas covered in the chapter. A major change in Chapter 1 was the addition of a robot safety section at the end. Safety is an important issue in robotics and in all manufacturing. While safety is addressed in great detail in Chapter 10, I was encouraged by users of the text to stress safety early. Another important skill for both engineers and technicians is the ability to troubleshoot technical systems. To help in learning these important skills, an introduction to troubleshooting was added to Chapter 3. That was followed with a discussion on troubleshooting sensor system at the end of Chapter 5. In addition, the sensor information in the chapter was revised and updated. Major updates and additions were made to the programmable logic controller and robot programming topics in Chapter 8. A full section was added covering the program commands for the Yaskawa robot. The chapter presentation gives students detailed information about the most frequently used commands and shows them how to translate a task point graph into a robot program using Yaskawa code. In addition, a number of new figures were added to help illustrate important concepts, and the text was changed at numerous places to make it easier to read and understand. I hope you find these changes useful and helpful. FOR THE STUDENTS More graduates of engineering and engineering technology programs are working in manufacturing automation because production systems have become increasingly complex and highly automated. As a result, students need to understand the theory and operation of robotics and automation as they apply to production systems in industry. The primary goal for this text was to create a clear and comprehensive text for students in two- and four-year engineering and engineering technology programs to learn industrial robotics and automation systems. Every effort was made to present the material in a logical order, to express the concepts in a fashion that a first-time reader could understand, and to keep the needs of the student foremost in every part of the text development. Authors often use technical terms to describe a new concept that have not been previously defined or that are not common knowledge for the students. A special effort was made in this text to not use any terms or technical language that were not introduced or defined earlier in the text. The text can be used in semester and quarter length courses. I hope this text helps you build a comprehensive understanding of the concepts that embody industrial robotics and automation systems. I have a friend and former student who once said, "There are things that I know and things that I know I know." This is an interesting observation on learning, and I asked him what he meant by "know I know." He said that certain lessons were presented in such a way that he could remember some of the concepts only as they were being presented. The lesson material was never internalized, though; he only knew it as it was presented. However, after working example problems and spending time thinking about a concept, he understood that idea in a new way. He had internalized the concept, theorem, or algorithm so that he could use it to solve problems that were different from the one in which it was originally presented. His depth of understanding meant that he would never forget the material. The concept just made sense; it was like remembering his name. To reach this level of understanding of a subject takes effort and time, and it often takes revisiting the concept numerous times. I hope you will reach that level of knowing you knowsome of the concepts presented in this text. If the presentations of some material help you get by previous learning barriers, I would like to know. Please e-mail me at [e-mail] share the learning experience. On the other hand, if you think that some area could be presented more clearly, I would like to know about that as well. I hope you enjoy the text and find it useful; it was written for you. CHAPTER CONTENT Industrial robots and the concept of a work-cell system are introduced in Chapter 1.A brief history of robots is included along with a rationale for the renewed interest in robot applications in the 1990s and in the new century. The definition of an industrial robot, a description of a basic