CH 4 Automation is the technology by desired level, parameters and variables are usually programmable machine possessing certain anthropomorphic

c and stop anywhere in the work envelop, it is possible to which a process or procedure is accomplished continous, similar to operation of a feedback control system. characteristics. A joint of an industrial robot is similar to a control speed, acceleration and deceleration and jerk for without human assistance. It is implemented using a Most continuous industrial processes have multiple feedback joint in the human body: it provides relative motion between various axes, it requires large memory capacity to provide program of instructions combined with a control loops. Examples of continuous processes; control of the two parts of the body. Degree of freedom is associated with a smooth motion, it can be programmed for point to point, system that executes the instructions.Three basic output of a chemical reaction that depends on temperature, joint. Robots are classified according to the total number of straight line and continuous path operations, joint actuators elements of an automated system:Power to accomplish pressure control of the position of a cutting tool relative to degrees of freedom they possess. There are five types of are either hydraulic or electric servomotor, programming is the process and operate the system.A program of work part in CNC machine tool. Types of continuous robots: LINEAR joint(L) - the relative movement between the done in teach mode or offline, it is possible to program each instructions to direct the processA control system to actuate the instructions. Power for the process:To drive process control: regulatory control, feedforward control, input link and the output link is a translational sliding axis to move to any point along the axis which provide great the process itself. To load and unload the work unit. steady-state optimization, adaptive control, on-line search motion, with the axes of the two links being parallel; programming flexibility, it possible to permit branching Material transport between operations. Power to strategies, other specialized techniques: expert systems and ORTHOGONAL joint(O) - translational sliding motion, but the operations whereby alternative actions are taken by the automation: Controller unit, Power to actuate the control neutral networks. Regulatory control objective- maintain input and output links are perpendicular to each other manipulator based on data obtained form sensors, more signals, Data acquisition and information processing of process performance at a certain level or within a given during the move; ROTATIONAL joint(R) provides rotational expensive and reliable than non servo controlled devices. instructions: set of commands that specify the sequence tolerance band of that level, appropriate when performance relative motion, with the axes of rotation perpendicular to POINT TO POINT SERVO used in moving parts, and of steps in the work cycle and the details of each step. Work cycle program: typical sequence of steps is: Load relates to a quality measure. Performance measure is the axes of the input and output links; TWISTING joint(T) handling tools, palletizing and de-palletizing, only initial and the part into the production machine, Perform the sometimes computed based on several output variables; involves rotary motion, but the axis of rotational is parallel to final points need to be programmed, high work volume and process, Unload the part. Process parameter: are inputs to performance measure is called the Index of Performance the axes of the two links; REVOLVING joint(V) the axis of load carrying capacity, common use in operation such as spot the process, such as temperature setting of a furnace. (IP). Problem with regulatory control is that an error must the input link is parallel to the axis of rotation of the joint, welding. CONTINUOUS PATH SERVO CONTROLED ROBOT Decision making in the programmed work cycle: exist in order to initiate control action. Feedforward and the axis of the output link is perpendicular to the axis of can perform complex paths and high speeds, used in spray Operation interaction: the controller unit may require control: objective - anticipate the effect of disturbances that rotation. Robot divided into two section body arm painting, arc welding, polishing, grinding. , load carrying input data from a human operator in order to function. will upset the process by sensing and compensating for them assembly and a wrist assembly. There are five configurations capacity is not an issue, the path is taught using special Different part or product styles processed by the system: the automated system is programmed to perform different before they affect the process. Complete compensation for are: POLAR configuration(LTR) - this configuration consists device to sample points at a proper rate through the path, work cycles on different part or product styles. Variations the disturbance is difficult due to variations, imperfections in of a sliding arm(L) actuated relative to the body, that can the robot can be programmed offline using robot simulation in the starting work units: in many manufacturing the mathematical model and imperfections in the control rotate about both a vertical axis(T) and a horizontal packages such as ROBCAD and I-Grip. ROBOT MOBILITY can operations the starting work units are not consistent. actions usually combined with regulatory control. Regulatory axis(R).CYLINDRICAL configuration(TLO) consists of a be classified - stationary and mobile robots. Features of work cycle program: No. of steps in the work control and feedforward control are more closely associated vertical column, relative to which an arm assembly is moved STATIONARY(fixed position bases- floor, overhead, wall cycle, Manual participation on the work cycle, Process with process industries. Steady-state optimization- class of up or down. The arm can be moved in and out relative to the mounted), MOBILE(track mounted robot, free moving parameters, Operation interaction, Variations in part or optimization techniques in which the process exhibits the axis of the column. CARTESIAN coordinate robot(LOO) wheels, multiple leg devices). LOAD CARRYING CAPACITY(it product styles, Variations in starting work units. Control system: controls in an automated system can be either following characteristics: 1. Well-defined index of rectilinear robot and xyz robot. Composed of three sliding is the net weight that a robot can manipulate on its work closed loop or open loop. Closed loop control system: it performance (IP)2- known relationship between process joints, two of which are orthogonal. JOINT ARM robot(TRR) volume)CARRYING CAPACITY = Gross weight weight of is also known as feedback control system. One in which variables an IP 3- system parameter values that optimize IP has the general configuration of a human arm. Consists of end effector. load carrying capacity should be specified the output variable is compared with an input parameter, can be determined mathematically. Open-loop system, vertical column that swivels about the base using a T joint. when the robot arm is in the weakest position. Precision is and any difference between the two is used to drive the optimization techniques include differential calculus, SCARA(selective compliance assembly robot arm)(VRO) is defined as function of (spatial resolution, accuracy, output into agreement with the input. It consists of six mathematical programming Adaptive control- because similar to the jointed arm robot except that the shoulder and repeatability). SPATIAL RESOLUTION: it is defined as the basic elements: Input parameter, Process, Actuator, Output variable, Feedback sensor, Controller. Input stady-state optimization is open-loop, it cannot compensate elbow rotational axes are vertical, which means that the arm smallest increment into which the robot can define its work parameter: often referred to as the set point, represents for disturbances. Adaptive control is a self-correcting from of is very rigid in the vertical direction, but complaint in the volume. Function of:(system control resolution, robot the desired value of the output. Process: is the operation oprimal control that includes feedback control. Measures the horizontal direction. WRIST configuration: three joints are mechanical inaccuracies). CONTROL RESOLUTION:it is or function being controlled. Output variables: that is relevant process variables during operation (feedback defined as: ROLL using a T joint to accomplish rotation defined as the ability of the controller to divide the total being controlled in the loop. Feedback sensors: is used to control), uses a control algorithm that attempts to optimize about the robots arm axis; PITCH which involves up and range of movement for a particular joint indivisual elements measure the output variable and close the loop between some index of performance (optimal control). Adaptive down rotation, typically using a R joint; YAW - which that can be addresses by the controller. Increment are called input and output. It performs with the input and makes control operates in a time- varying environment: the involves right and left rotation, also accomplished by means addressable point. It is determined by:(robot positioning the required adjustment in the process to reduce the difference between them. Actuator: the hardware device environment changes over time and the changes have a of an R joint. JOINT DRIVE SYSTEM: PNEUMATIC control system, feedback measurement system) (formula that physically carryout the control actions, such as an potential effect on system performance, example: supersonic DRIVE(advantages relatively inexpensive, high speed, they next page). MECHANICAL INACCURACIES-(causes: elastic electric motor or a flow value. Controller: compares the aircraft operates differently in subsonic flight than in do not pollute the workspace with fluid, can be used in deformation, gear backlash, leakage in hydraulic system, output with the input and makes the required adjustment supersonic flight. If the control algorithm is fixed, the system laboratory work)(disadvantage the compressibility of air other imperfections). SPATIAL RESOLUTION(SR = CR+6 in the process to reduce the difference between may perform quite differently in one environment than in limits their accuracy, noise pollution, air leakage is a major sigma).( ACCURACY = 0.5 SR). FACTORS affecting ROBOT them.Open loop control system: operates without the another. An adaptive control system is designed to concern, additional filtering system are needed, increased ACCURACY:(location within work volume, motion cycle, feedback loop. This system are appropriate when the compensate for its changing environment by altering some maintenance and construction requirements). HYDRAULIC load). Repeatability repeatability refers to the robot ability following conditions apply: The actions performed by the control system are simple, The actuating function in very aspect of its control algorithm to achieve optimal DRIVE (advantage large lift capacity, moderate speed, oil is to return to the programmed point when commanded to do reliable, Any reaction forces opposing the actuation are performance. Three functions in adaptive control:1incompressible; thus provide accurate joint positions, offers so. It concerns with the ability of the robot to position its small enough to have no effect on the actuationAdvanced IDENTIFICATION FUNCTION - current of IP is determined accurate control)(disadvantages hydraulic systems are wrist or end effector attached to its wrist at a point in space automation function: Safety monitoring: two reasons based on measurements of process variables. 2- DECISION expensive, pollute workspace with noise and fluid, not that had previously been taught to the robot.(repeatability = for providing an automated system with a safety FUNCTION- decide what changes should be made to improve suitable for high speed cycles). ELECTRIC DRIVES +- 3 sigma). END EFFECTORS (GRIPPER mechanical monitoring capability: To protect workers form a system performance, change one or more input parameters, (advantage they provide better accuracy than hydraulic grippers: consists of two or more fingers that can be hazardous working environment. To protect the equipment associated with the system. Possible response after some internal function of the controller.3motors, small in size, thus can be used with any robot size actuated by the robot controller to open and close to grasp to hazards:Complete stoppage or the system,Sounding an MODIFICATION FUNCTION- implement the decision function, and provide high maneuvering, fast and accurate, possible to the workpart. Vacuum gripper: in which suction cups are alarm,Reducing operating speed of process, Taking considered with physical changes. Discrete control apply sophisticated control techniques, easily available and used to hold objects. Magnetized devices: holding ferrous corrective action to recover from the safety violation. systems- process parameters and variables are dZiscrete the relatively inexpensive, simple to use)(disadvantage require parts, adhesive devices: adhesive substance is used to hold Maintenance and repair diagonostics: refers to the changes are defined in advance by the program of power transmission systems such as gear trains, gear a flexible material such as a fabric, simple mechanical capabilities of an automated system to assist in the instructions. The changes are executed for either of two backlash limits precision, electrical arcing might be a devices: hooks and scoops. SENSORS IN ROBOTICS: typesidentification of the source of potential or actual reasons: 1- the state of the system has changed ( eventproblem, limited power for large robots. ELECTRIC TACTILE SENSORS used to determine whether contact is malfunctions and failures of the system. Three modes of operation are typical of a modern maintenance and repair driven changes) 2- a certain amount of time has elapsed9 ACTUATORS easy to control, can provide smooth torque made between the sensor and another objects. TOUCH diagnostics: Status monitoring: the diagnostic subsystem time driven changes). Even- driven changes - executed by even at low speeds for excellent positioning accuracy, can SENSORS indicate simple the contact. FORCE SENSOR - are monitors and records the status of key sensors and the controller in response to some event that has altered the provide high repeatability for robot arm, can provide high used to indicate the magnitude of the force with the object. parameters during system operation.Failure diagnostics: state of the system. Ex: a robot loads a workpart into a acceleration rate and rapid reversing of motion of robot arm PROXIMITY SENSORS indicate when the object is close to invoked when a malfunction or failure occurs. Its purpose fixture, and the part is sensed by limit switch in the fixture. at high speed. CONTROL UNIT brain of the robot. (function the sensor. OPTICAL SENSOR photocells can be utilized to is to interpret the current values of the monitored Time driven events executed by the controller either at a initiate and terminate the motion of individual components detect the presence or absence of objects and are often used variables and to analyze recorded values so the cause of specific point in time or after a certain time lapse. Eg: the of the manipulator, store data for points and sequence of for proximity detection. MACHINE VISION used in robotics the malfunction can be identified. Recommendation of repair procedure: provides recommended procedure for factory shop clock sounds a bell at specific times to indicate operations, facilitate interface with other units in robot for inspection, parts indentification, guidance and other uses. the repair crew to effect repairs. Error detection and start of shift, break start and stop times and end of shift. Two workcell). (control unit capabilities perform necessary INDUSTRIAL ROBOT APPLICATIONS: hazardous work recovery:Use the systems available sensors to determine types of discrete control : combinational logic control arithmetic computation for determining manipulator path, environment for humans, repetitive work cycle, difficult when a deviation or malfunction has occurred, Correctly controls the execution of event driven changes, also known speed and position,, send signals to the joint actuating handling for humans, multishift operation, infrequent interpret the sensor signal, Classify the error. Error as logic control. Sequential control controls the execution of devices and utilize sensors information, permit changeovers, part position and orientation are established in recovery possible strategies: Make adjustments at end time driven changes, uses internal timing devices to communication between peripheral devices and the work cell. of work cycle, Make adjustments during current work cycle, Stop the process to invoke corrective action, Stop determine when to initiate changes in output variables. Two manipulators). FOUR CLASSES OF CONTROL METHODS FOR the process and call for help. basic requirements for real time process control: Process- ROBOTS: NON-SERVO CONTROLLED ROBOT simplest, CH- 25 Steps in developing a process plan:step CH 5 Industrial control defined as the initiated interrupts (Controller must respond to incoming referred to as limited sequence robots, or end point robot or automatic regulation of unit operations and their associated signals from the process (event-driven changes), Depending pick and place or bang bang robots, axed are controlled by 1: interpretation of the design data to accomplish; equipment as well as the integration and coordination of the on relative priority, controller may have to interrupt current limit switches, therefore, the axes stay on motion until the understand the functions, clarifying the relative assembly position and mutual functions. Step 2: designing the stock. unit operations into the larger production system. Unit program to respond). Timer-initiated actions - Controller limits of the travel, each axes has two positions only, operation usually refers to a manufacturing operation and must be able to execute certain actions at specified points in programmed by setting a desired motion and adjusting the Step 3: selection of machining processes specification of the datum surfaces for fixturing; developing several plans and can also apply to material handling or other equipment. time (time driven changes). Examples: (1) scanning sensor position of the end stops, power provided by electrical selecting optimal process plan. Step4: selection of machine Process industries vs discrete mfg industries: process values, (2) turning switches on and off, (3) re-computing motors, or pneumatic or hydraulic motors.(refers to as open tools. Step 5: selection of tools, fixtures, and inspection industries: production operations are performed on amounts optimal parameter values. Capabilities of computer lop control, relatively small and have high speeds, low cost, equipment. Step 6: determining the machining conditions of materials like liquids, gases, powdersdiscrete control: POLLING, INTERLOCKS, INTERRUPT SYSTEM, easy to operate and reliable, limited flexibility with respect and manufacturing times. Traditional Approach: evaluate the manufacturing industries production operations are EXCEPTION HANDLING. POLLING periodic sampling of to positioning and programming). Eg: mechanical and part information; manually search for process plans for performed on quantities of materials parts, product units. data to indicate status of process. Issues: polling frequency, pneumatic robots. Controller for non servo: controller is a similar parts; modify process plans manually to meet current Variable and parameters: variables- outputs of the process. polling order, polling format. INTERLOCKS safeguard motor driven rotary device similar to a timer motor, it Parameters- inputs to the process. Continuous variables and mechanisms for coordinating the activities of two or more employs a series of jumper plugs to be enabled in the desired part requirements. Work book approach: develop a workbook containing process plans for parts classified by parameters are uninterrupted as time proceeds. Also devices and preventing one device from interfering with the sequence to actuate the corresponding axis actuator, considered to be analog and can take on any value within a others.(input interlocks- signal from an external device sent programming is accomplished by setting desired sequence of workpiece types; store process plans in groups for ease of retrieval. certain range. They are not restricted to a discrete set of to the controller. Output interlocks signal sent from moves and adjusting the end stop of each axis accordingly. values. Discrete variables and parameters can take on only controller to external device. INTERRUPT SYSTEM Each axis, one actuated, continues on until the program end certain values within a given range. Discrete variable and computer control feature that permits the execution of the stop is reached. The information is then used to cause the parameters categories: binary- they can take on either of current program to be suspended in order to execute sequencer to index to the next step in the program.(typical two possible values, ON or OFF, 1 or 0. Discrete other than another program in response to an incoming signal program for non servo move robot to start position, grasp binary- they can take on more than two possible values but indicating a higher priority event.(internal interrupt part, remove the part from machine, move to second less an infinite number of possible values. Pulse data- a train generated by the computer itself. External interrupts position, insert the part on another machine, prepare to start of pulses that can be counted. Types of control: continuous generated external to the computer.)EXCEPTIONAL another cycle). SERVO CONTROLED ROBOT two classes control- variables and parameters are continuous and HANDLING an exception is an event that is outside the continuous path, and point to point. Axes are controlled analog. Discrete control-variables and parameters are normal or desired operation of the process control system. and continuously monitored and a fed back is associated discrete, mostly binary discrete. Continuous control- usual Exception handling is a form of error detection and recovery. with each joint. Use closed loop control systems, the use of objective is to maintain the value of an output variable at a CH 8: A industrial robot is a general purpose closed loop permits programming individual axes, to move