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Robotics 1 Lecture 2 Characteristics and Applications

Research · October 2015

DOI: 10.13140/RG.2.1.2977.8644

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 Robotics

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 1

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.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 2

 SYLLABUS
TOPIC
1. Realistic and Safe Use of Robots
2. Applications of Industrial Robots
3. Economic Justification; Project Assigned
Excel Template
4. Robot Implementation
5. Arm Configurations
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

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 3

Some web resources
 www.robotics.uc.edu
 http://www.robotics.org/body.cfm
 http://www.robotics.org/public/articles/index.cf
m?cat=6
 http://www.sme.org/cgi-
bin/membhtml.pl?/memb/mservices.html&&&
SME&
 http://www.sme.org/cgi-bin/get-
banner.pl?S&000001&
10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 4
Realistic and Safe Use of
Robots
 An intelligent industrial robot is
a remarkably useful
combination of a manipulator,
sensors and controls.
 The use of these machines in
factory automation can
improve productivity, increase
product quality and improve
competitiveness.
 Robots have been created to
perform a wide variety of tasks
spanning from educational
robots in classrooms, to arc
welding robots in the
automobile industry, to
teleoperated robot arms and
mobile robots in space.
10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 5
Objective
 Provide an overview of
the proven applications
of industrial robotics
 At the end of the
presentation the
students should be able
to describe the major
robot applications

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 6

What is a robot?
 Definition - The Robot
Industries Association (RIA)
has defined an industrial
robot as "a
reprogrammable, multi-
functional manipulator
designed to move material,
parts, tools or specialized
devices through variable
programmed motions for
the performance of a variety
of tasks."

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 7

Benefits of robots
 Introducing robot technology into factories
improved plant productivity, quality, and
flexibility above what could be realized on the
basis of hard or fixed automation structures.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 8

Applications
 Robots are now being used in many
applications including: welding, sealing, and
painting; material handling, assembly, and
inspection; and in non-automotive industries
such as electronics, consumer products,
pharmaceutical, and service [Weil, 1994].

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 9

Market
$1,300

13000
$1,200

12000
$1,100

11000
$1,000

10000
$900

9000
$800

8000
Units_ordered

$700

$US_(Million)
7000
$600

6000
$500

5000
$400

4000
$300

3000
$200

2000
$100

1000
$0

Year 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997
Units_ordered 3,800 4,000 4,500 5,000 4,488 4,561 5,942 7,634 10,198 9,709 12,459
$US_(Million) $300 $325 $510 $510 $470 $456 $559 $688 $887 $934 $1,104

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 10

500,000 robots in the world
 Record breaking shipments from US manufacturers
in 1997 totaled 12,459 robots, valued at $1.1
billion. This represents a 172% increase in robotic
systems, and a 136% increase in revenues since
1992. According to new statistics released by the
Robotic Industries Association, the world’s
population of installed robots at the end of 1997
exceeded 500,000. The country that has the largest
population of industrial robots is Japan (400,000),
followed by the USA (80,000), and the other
Western European nations (120,000).

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 11

Applications by use
Application Percent

welding 53.0

material handling 24.0

assembly 10.0

spray coating 8.5

inspection 1.0

other 3.5

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 12

Robot Characteristics
 1. Manipulator - The mechanical structure that performs the
actual work of the robot, consisting of links and joints with
actuators.
 2. Feedback devices - Transducers that sense the position of
various linkages and/or joints that transmit this information to the
controller.
 3. Controller - Computer used to generate signals for the drive
system in order to reduce response error in positioning and
applying force during robot assignments.
 4. Power source - Electric, pneumatic, and hydraulic power
systems used to provide and regulate the energy needed for the
manipulator's actuators.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 13

Manipulator configuration
 There are six basic motion degrees of
freedom to arbitrarily position and orient an
object in a three-dimensional space (three
arm and body motions and three wrist
movements).

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 14

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.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 15

Redundant DOF’s
 Robots with more than six axes of motion are
called redundant degree of freedom robots.
The redundant axes are used when greater
flexibility is required, such as obstacle
avoidance in the workplace, parts assembly
and machining applications.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 16

R-P joints
 Typical joints are either revolute (R) joints,
which provide rotational motion about an
axis, or prismatic (P) joints, which provide
sliding (linear) motion along an axis. Using
the R-P notation, a robot with three revolute
joints would be abbreviated as RRR, while
one with two revolute joints followed by one
prismatic joint would be denoted RRP.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 17

Major mechanism designs
 There are five major mechanical
configurations commonly used for robots:
Cartesian, cylindrical, spherical, articulated,
and SCARA (Selective Compliance
Articulated Robot for Assembly). Workplace
coverage, particular reach and collision
avoidance, are important considerations in
the selection of a robot for an application.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 18

Configurations fit applications
 Cartesian
 Application – assembly and
machine loading
 Configuration – PPP
 Percentage – 18
 Advantage – equal
resolution, simple
kinematics
 Disadvantage – Poor space
utilization, slow speed

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 19

Cylindrical
 Application – assembly
and machine loading
 Configuration – RPP
 Percentage - 15
 Advantage – good
reach, simple
kinematics
 Disadvantage –
variable resolution

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 20

Spherical

Application - automotive
manufacturing
Configuration – RRP
Percentage - 10
Advantages - excellent
reach; very powerful w/
hydraulic drive
Disadvantages - complex
kinematics; variable
resolution
10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 21
Articulated

Application - spray
coating
Configuration – RRR
Percentage - 42
Advantages - maximum
flexibility; large work
envelope; high speed
Disadvantages - complex
kinematics; rigid
structure; difficult to
control
10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 22
SCARA*

Application - assembly & insertion

Configuration – RRP
Percentage - 15
Advantages - horizontal compliance;
high speed; no gravity effect
Disadvantage - complex kinematics;
variable resolution; limited vertical
motion

* Selective Compliance Articulated

Robot for Assembly
(Source for the percent of use: V.D.
Hunt, Robotics Sourcebook, New
York: Elsevier, 1988.)

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 23

Common configurations

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 24

New designs
 While all of the above
configurations are rigid
serial links, a parallel
robot configuration,
known as Steward
platform, also exists.
There are also
lightweight, flexible
robot arms for faster
speed and lower
energy consumption.
 Humanoid robots
10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 25
Direct drive
 Industrial robots can be direct-driven arms
(DDArm) and indirect driven arms. Most
industrial robots used today are indirect-
drive-geared mechanisms. However, this
drive mechanism may suffer from poor
dynamic response under heavy mechanical
load and gear friction, and backlash.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 26

Robot Control Strategies
 Robot manipulators typically perform a task
repeatedly with high accuracy. Yoshikawa
[1990] defines the fundamental elements of
tasks performed by robots as:
 1. Gross manipulation: to move the end-
effector, with or without a load, along a
desired path (position control).
 2. Fine manipulation: to exert a desired
force on an object when in contact with it
(force control).
10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 27
Motion trajectory problem
 One of the major objectives of a robot is to
position its tool from one point to another
along a planned trajectory. This is called
controlled path motion, or the motion
trajectory problem.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 28

Non-linear system
 Describing the motion of an industrial robot
generates a set of highly nonlinear differential
equations.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 29

Complex torque functions
For an end-effector to move in a particular
trajectory at a particular velocity, a complex
set of torque functions must be applied by the
joint actuators. Instantaneous feedback
information on position, velocity, acceleration,
and other physical variables can greatly
enhance the performance of the robot.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 30

Basic control block diagram

Link parameters Loading condition

Yd
 Y
Desirred joint position Actual joint position,
Joint torques
velocity & cceleration velocity & cceleration

Trajectory
Controller Robot Environment
Planning

Sensors

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 31

Motion control
 With increasing demands for faster, more
accurate, and more reliable robots, the field
of robotics has faced the challenge of
reducing the required on-line processor
power, calibration time, and engineering cost
while developing new robot controllers.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 32

Robust control
 If the robot is to be controlled in real time, the
algorithms used must be efficient and robust;
otherwise we will have to compromise the
robot control strategies.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 33

Kinematics and dynamics
 The robot arm position control is a complex
kinematic and dynamic problem that has
received attention for many years. During the
last several years, most research on robot
control has resulted in algorithms that are
adaptive to non-linearities and structural
uncertainties but require a great deal of
processing resources.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 34

Two link manipulator

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 35

Torque 1 equation
2
m 2 a 1 m 2 a 2 2 m 2 a 1 a 2 cos q 2 d
2 2
 1.1 m1 q1
dt 2

2
m 2 a 2 m 2 a 1 a 2 cos q 2 d
2
 1.2  1.1 q2
dt 2

2
m 2 a 1 a 2  2  q 1  q 2 sin q
d d d
 1.3  1.2 q2 2
dt dt dt

 1  1.3 m1 m 2 g a 1 cos q 1 m 2 g a 2 cos q 1 q2

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 36

Torque 2 equation

And for the second torque

2 2
m 2 a 2 m 2 a 1 a 2 cos q 2 d m 2 a 2
2 2 d
 2.1 q1 q2
d t2 d t2

2
m 2 a 1 a 2  m 2 g a 2 cos q 1
d
 2  2.1 q1 sin q 2 q2
dt

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 37

Sample torque 1

200

100

 1( t ) 0

100

200
0 5 10
t

Note that the maximum value of about 200 Nm would let one size the motor correctly.
Also, the shape appears quite simple.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 38

Sample torque 2

50
31.320317

 21( t )  22( t ) 0

27.887245 50
0 5 10
0 t 10

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 39

Today
 Today, most robots have joint controllers that
are based on traditional linear controllers and
are ineffective in dealing with the nonlinear
terms such as friction and backlash.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 40

Computed torque control
 One popular robot control scheme is
computed-torque control or inverse-dynamics
control. Most robot control schemes found in
robust, adaptive, or learning control
strategies can be considered special cases of
computed-torque control. This techniques
involve the decomposition of the control
design problem into two parts [Koivo, 1989]:

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 41

Primary controller
 1. A primary controller, a feedforward (inner-
loop) design to track the desired trajectory
under ideal conditions.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 42

Outer loop control
 2. A secondary controller, a feedback (outer-
loop) design to compensate for undesirable
deviations (disturbances) of the motion from
the desired trajectory based on a linearized
model.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 43

Concept of high level
controller

Primary
Yd controller +  Y
Robot
+ Secondary +
- controller

Sensors

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 44

Artificial Neural Networks

 Potential for major improvement in flexibility

and learning capability of both stationary and
mobile robots.

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 45

Any questions?

10/14/2015 (C) 2001, Ernest L. Hall, University of Cincinnati 46

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