Industrial robots in modern production

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Industrial robots in modern production

Industrial robots are now widely used in human production activities. They serve as one of the most effective means of mechanization and automation of transport and loading operations, as well as many technological processes.

The positive effect of the introduction of industrial robots is usually noticeable from several sides at the same time: increasing productivity, improving the quality of the final product, reducing production costs, improving working conditions for people, and finally, the transition of the enterprise from one type of product to another is much easier.

Industrial robots in modern production

However, to achieve such a vast and multi-faceted positive effect of the introduction of industrial robots working hand-made, you need to calculate the planned costs of the implementation, the cost of the robot, as well as to weigh adequately, if at all, the complexity of your production and technological process of the modernization plan by installing industrial robots.

After all, sometimes production is so simplified initially that the installation of robots is simply impractical and even harmful. In addition, for setting up, maintenance, programming robots -- you will need qualified personnel, and in the process -- auxiliary devices, etc.it is important to take this into account in advance.

One way or another, robotic unmanned solutions in production are becoming increasingly relevant today, if only because the harmful impact on human health is minimized. We add here the understanding that the full cycle of processing and installation is carried out faster, without breaks for a smoke break and without the errors inherent in any production where a live person acts instead of a robot. The human factor, after setting up the robots and starting the technological process, is almost eliminated.

To date, manual labor in most cases is replaced by the work of the robot manipulator: tool capture, tool fixation, holding the workpiece, feeding it to the work area. Restrictions are imposed only: load capacity, limited working area, pre-programmed movements.

An industrial robot can, however, provide:

- high performance thanks to fast and accurate positioning

- better efficiency, since you do not need to pay a salary to the people it replaces, just one operator

- high quality-accuracy of the order of 0.05 mm, low probability of marriage

- safety for human health, for example, due to the fact that when painting now contact people with paint materials is excluded

- finally, the working area of the robot is strictly limited, and it requires minimal maintenance, even if the working environment is chemically aggressive, the robot material will withstand this impact.

Industrial robots in modern production

Historically, the first industrial robot manufactured under a patent was released in 1961 by Unimation Inc for the General Motors plant in new Jersey. The robot's sequence of actions was recorded as a code on a magnetic drum and performed in generalized coordinates. The robot used power steering to perform its actions. This technology was then transferred to Japanese Kawasaki Heavy Industries and English Guest, Keen and Nettlefolds. So the production of robots from Unimation Inc has expanded somewhat.

By 1970, Stanford University had developed the first robot resembling a human hand with 6 degrees of freedom, which was controlled from a computer, and had electric drives. At the same time, the development is led by the Japanese Nachi. German KUKA Robotics in 1973 will demonstrate a six-axis robot Famulus, and Swiss ABB Robotics will already start selling a robot ASEA - also six-axis and Electromechanical drive.

In 1974, the Japanese company Fanuc established its own production. In 1977, the First YASKAWA robot was released. With the development of computer technology, robots are increasingly being introduced into the automotive industry: in the early 80's, General Motors invests forty billion dollars in the formation of its own factory automation system.

In 1984, domestic AVTOVAZ will acquire a license KUKA Robotics and will produce robots for its own production lines. Almost 70% of all robots in the world, as of 1995, will be in Japan, its domestic market. So industrial robots will finally strengthen in the field of car production.

How will automotive production do without welding? No way. So it turns out that all automobile production in the world are equipped with hundreds of robotic welding systems. Every fifth industrial robot is engaged in welding. Next in demand is the robot loader, but argon-arc and spot welding-in the first place.

Industrial robot welder

No manual welding can match the quality of the seam and the degree of control over the process with a specialized robot. What can we say about laser welding, where from a distance of up to 2 meters with a focused laser, the technological process is carried out with an accuracy of 0.2 mm -- this is simply irreplaceable in the aircraft industry and medicine. Add in integration with CAD / CAM digital systems.

The robot welder has three main operating nodes: the working body, the computer controlling the working body and memory. The working body is equipped with a grip similar to the hand. The organ has the freedom to move along three axes (X, Y, Z), and the grip itself is able to rotate around these axes. The robot itself can shuffle along the guides.

No modern production can do without unloading and loading, regardless of the size and weight of products. The robot will independently install the workpiece in the machine, and then-unload and lay. One robot can interact with several machines at once. Of course, it is impossible not to mention in this context the loading of Luggage at the airport.

Industrial robots for automatic loading and unloading of products

Robots already allow you to minimize the cost of maintaining staff. It is not only about such simple functions as working with a stamp or operating a furnace. Robots are able to lift more weight, in much heavier conditions, without getting tired and spending significantly less time than it would take a living person.

In the foundry and blacksmithing industries, for example, conditions are traditionally very difficult for people. This kind of production is in third place after unloading-loading in terms of robotics. Not for nothing, almost all European foundries are already equipped with automated systems with industrial robots. The cost of implementing a robot costs the company a hundred thousand dollars, but there is a very flexible complex that pays off with a vengeance.

Robotic laser and plasma cutting can improve traditional lines with plasma torches. Three-dimensional cutting and cutting of corners and I-beams, preparation for further processing, welding, drilling. In the automotive industry, this technology is simply irreplaceable, because the edges of products must be accurately and quickly cut after stamping and molding.

Industrial robots for laser and plasma cutting

One such robot can combine both welding and cutting. Performance is enhanced by the introduction of waterjet cutting, eliminating unnecessary thermal effects on the material. Thus, in two and a half minutes, all the small holes are cut in the metal of the Renault Espace bodies at the Renault robotic plant in France.

In the production of furniture, cars and other products, robotic bending of pipes with the participation of the working head is useful, when the pipe is positioned by the robot and bends very quickly. Such a pipe can already be equipped with various elements, which will not interfere with the process of non-core bending by the robot.

Industrial robots for bending pipes

Processing edges, drilling holes, and milling -- which can be easier for a robot, whether it's metal, wood, or plastic. Accurate and durable manipulators cope with these tasks with a Bang. The working area is not limited, it is enough to install a long axis, or several controlled axes, which will give excellent flexibility plus high speed. A man can't do that.

Industrial robots for drilling products

The rotation speeds of the milling tool reach tens of thousands of revolutions per minute, and the grinding of the seams turns into a series of simple repetitive movements. But before grinding and abrasive surface treatment was considered something dirty and heavy, and also very harmful. Now the paste is fed automatically during processing with a felt circle after passing the abrasive belt. Fast and harmless to the operator.

The robot, its purpose

A robot is a mechanical system with manipulative devices, a control system, a complex of sensitive elements and means of movement in space. It is intended for replacement of the person at performance of the main and auxiliary operations in production processes.

The robot is a multi-purpose machine and differs from a conventional machine in the flexibility and versatility of performing various operations.

The term "industrial robot" usually refers to manipulators with automatic or combined control.

Robots implement the idea of functional modeling of production workers engaged in various technological operations of the production process.

An industrial robot is a reprogrammable manipulator that can automatically perform a set of actions provided by the program.

At the same time, an important social task is solved - the liberation of a person from work related to health hazards or heavy physical labor, as well as from simple monotonous operations that do not require high qualifications. Flexible automated production, created on the basis of industrial robots, allow you to solve automation problems in enterprises with a wide range of products in small-scale and piece production.

In General, an industrial robot includes the following basic elements: manipulation devices, control system, sensitive elements and means of transportation.

The robot's sensitive elements give the necessary signals to the control system about the approach of the hand to objects, about touch, and so on. These elements allow the robot to Orient itself in the right way to achieve certain goals in the environment where it functions.

Industrial robots in modern production

Manipulation system

industrial robot modern production

Robot manipulation devices - Executive organs that mimic the action of human hands on a natural scale, with any increase or decrease, as well as power effort.

Manipulator - this is a mechanism for controlling the spatial position of tools and objects of labor.

Manipulators include two types of movable links:

- links that provide translational movement

- links that provide angular movement

The combination and mutual arrangement of the links determines the degree of mobility, as well as the scope of the robot's manipulation system.

Electric, hydraulic or pneumatic drives can be used to provide movement in the links.

Part of the manipulators (although optional) are gripping devices. The most universal gripping devices are similar to the human hand-the grip is carried out using mechanical "fingers". Gripping devices with a pneumatic suction Cup are used to grip flat objects. To capture the same set of similar parts (which usually happens when using robots in industry) use specialized designs.

Instead of gripping devices, the manipulator can be equipped with a working tool. It can be a spray gun, welding head, screwdriver, etc.

System of transportation

The robot's means of transportation can be anything depending on its purpose: walking mechanisms; devices on wheels; devices on tracks; a combination of all three methods

Indoors, industrial facilities use movement along monorails, floor track, etc.

To move on an inclined, vertical planes, using a system similar to the "walking beam" designs, but with pneumatic suction cups.

Control system

The control system (with or without a computer) can have several levels, similar to the various stages of the human nervous system and brain.

There are several types of management.

Software control - the simplest type of control system used to control manipulators in industrial facilities. In such robots, there is no sensory part, all actions are rigidly fixed and regularly repeated. For programming such robots, programming environments such as VxWorks/Eclipse or programming languages such as Forth, Oberon, Component Pascal, C can be used. As hardware, industrial computers are usually used in the mobile version of PC/104, less often MicroPC. This can be done using a PC or a programmable logic controller.

Adaptive control - robots with an adaptive control system are equipped with a touch part. The signals transmitted by the sensors are analyzed and, depending on the results, a decision is made about further actions, moving to the next stage of actions, etc.

Based on artificial intelligence techniques.

Human control (for example, remote control).

Modern robots function on the basis of the principles of feedback, subordinate control and hierarchy of the robot control system.

The hierarchy of the robot implies the division of the control system of horizontal layers that control the overall behavior of the robot, calculating the necessary trajectory of the manipulator, the behavior of individual actuators, and the layers directly involved in motor control drives.

Human control (for example, remote control).

Modern robots function on the basis of the principles of feedback, subordinate control and hierarchy of the robot control system.

The hierarchy of the robot implies the division of the control system of horizontal layers that control the overall behavior of the robot, calculating the necessary trajectory of the manipulator, the behavior of individual actuators, and the layers directly involved in motor control drives.

Subordinate control.

Subordinate control is used to build the drive control system. If it is necessary to build a drive control system by position (for example, by the angle of rotation of the manipulator link), the control system is closed by position feedback, and within the control system by position, the speed control system operates with its speed feedback, within which there is a current control loop with its feedback.

1-feedback sensor; 2-gripping device; 3-brush; 4- the manipulator hand; 5-column; 6-supporting structure (base); 7- hand of drive; 8-control unit with remote control.

The modern robot is equipped not only with feedback on the position, speed and acceleration of the links. When capturing parts, the robot must know whether it has successfully captured the part. If the part is fragile or its surface has a high degree of purity, complex systems are built with force feedback, allowing the robot to grasp the part without damaging its surface or destroying it.

The robot can be controlled by both a human operator and an industrial enterprise management system (ERP system), which coordinate the robot's actions with the readiness of workpieces and machines with numerical control to perform technological operations.

The prospects for industrial robotics are huge, because robots can be implemented in principle in almost any production processes, and in unlimited quantities. The quality of automatic work is sometimes so high that it is simply unattainable for human hands. There are entire large industries where errors and errors are unacceptable: aircraft manufacturing, precision medical equipment, ultra-precise weapons, etc. Not to mention the increase in the competitiveness of individual enterprises and the positive effect on their economy.

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