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Industrial Robots

INTRODUCTION:
The word robot always refers to an automated multifunctional manipulator that works by energy, to perform a variety of tasks.
The first man to use the word robotics was the science fiction writer Isaac Asimov. He wanted to describe the robot technology in his work by this word. He had put three main laws that everybody considered them the most important principles in the use of robotics.

Two main old invented robots are in use today:

There are two main important types of robots that were used long ago and they were developed to be used nowadays.

The first one is called
MANIPULATOR.The second robot is called TELEOPERATOR.They are still in use today specially in the U.S.A .

Motivating factors:
For robotics systems to be introduced to the industrial world they must have positive factors that would make a difference in using them.
The motivating factors can be categorized as:

1. Technical factors.
2. Economic factors.
3. Social factors.



1. Technical factors:

Robots can do different incomparable tasks that humans can't do. It is generally considered that humans can't match the speed, quality, reliability and the endurance of robotic system. In that they offer:
a) High flexibility of product type and variation.
b) Lower preparation time than hard automation.
c) Better quality of products.
d) Fewer rejects and less waste than labour intensive production.








2. Economic factors:

a) The needs to increase production rates to remain competitive.
b) Pressure from the market place to improve quality.
c) Increasing costs.
d) Shortage of skilled labour.

3. Social factors:

Some people think that the usage of robotizied systems increase the unemployment of workers and prevent many people from a main income.
But the usage of robots cause a reduction of labour on workers and and prevent dangerous physically harms as robots are used in hazardous areas such as in automobile industries.

TYPES OF ROBOTS:
1. Cartesian coordinate system (axes or dimensions are 3 intersecting straight lines(x-y-z))
This makes the human task of programming easier and reduces the amount of computer power required.


2. Cylindrical coordinate system (one angular dimensions and 2 linear dimensions(r-0-z))
The rigid structure of this system offers them the capability to lift heavy loads through a large working envelope.


3. Spherical coordinate system (2 dimensions are angles, the third is a linear distance from point of origin(r-0-o))
This design is used where a small number of vertical actions are adequate . The loading and unloading of a punch press is a typical application.


4. Jointed arm coordinate system (whose manipulator arm degrees of freedom resemble that of a human arm).
This is the most common used arm configuration because of its flexibility in reaching any part in the working envelope. This flexibility allows such complex applications as spray painting and weld sealing to be done successfully.

ROBOT DRIVE MECHANISMS:
The movement of any axis of a robot can be either linear or rotary. Sometimes it can be a combination of both. But the rotation to be converted to the linear arm movement there must be mechanical drives to achieve the movement of a robot.

There are two types of mechanical devices:

Chain and linkage drives:
They are used to transfer rotary motion of an electric motor to a sprocket-driven
Joint situated at the end of the robot arm.
As an alternative to chain drives, ASEA robots have used linkage drives to transmit the motion generated by the electric motors mounted in the base or the shoulder.




GEAR DRIVES:
To transmit and change the velocity, direction and torque of the output shaft relative to the input.
Chain mechanical links or gears are used to drive bevel gears that form the wrist joined positioned at the end of the robot.
The main problem with using gears is that backlash in the gear train can cause positioning error.
If there is deficiency in the backlash between mating gears then the gears become overloaded. This cause excessive noise and overheating.
If there is too many backlash results in slip between the gears then it causes servo- mechanism instability and hence poor repeatability.



BELT DRIVES:
Tooth belts driven by pulleys are used to transmit energy over long distances.

HARMONIC DRIVES:

They used widely on robots to provide a high output torque from robot drive motors. It also reduces the rotational speed with virtually no backlash.
Its function also to provide a unit which has a very low vibration capability at low speeds . This is important for applications such as welding and adhesive applications.
Drive Systems
For any machine to function there must be a power that supplies this machine with energy that cause the movement .

IN ROBOTS THERE ARE THREE MEANS TO OPERATE ROBOTS:
1. HYDRAULIC DRIVES.
2. PNEUMATIC DRIVES.
3. ELECRICITY.


1.HYDRAULIC DRIVES.

Hydraulic drives are certain fluids (mostly oil) used in robots to function.
Before entering the fluid into the circulation ,it must first be filtered of any dirt or foreign particles . Also all air within the system must be removed because it may cause cavitation.
There are a number of conversion stages in order to achieve axis motion. First the hydraulic oil should be pressurized using an electric motor driving a hydraulic pump. The electric motor is called the prime mover since it is the first conversion process. Second, the fluid is then converted into mechanical power.
Hydraulic systems require a closed circuit and exhausted fluid must be directed back to the prime mover to be re-circulated.


2.PNEUMATIC DRIVES.

Compressed air is used in this power system as the main transmission medium.
Pneumatic drives don't give the same power application that is achieved by hydraulic drives.

Sensors

Being robots used in hazardous areas and industrial processes, therefore they were fitted with sensors to gather information about the nearby environment and objects around to come out with precise results of the work.


There are two types of sensors:
1. External these sensors are added to robots to perceive the world in which they operate and interact with the environment outside the robot.
2. Internal they are described as a variety of the encoders in robot joints used to measure the current position and velocity of the particular joint or link.
External sensors can be categorized as:
1. Contact: it is the ability of the robot to determine the shape, size, weight, or even the surface texture of an object by touching it. The contact sensors are situated in the design of the gripper of the robot to provide the robot with information about the forces in the wrist or the joint of the robot and also in the objects that are to be handled. It is very important for robots to determine these information specially in fettling and grinding operations and in assembly operations.

2.
Non-contact: these sensors are used to give the robot information about the process or the environment without the use of physical contact, They operate on the principles of electrical capacitive inductance sound waves as in ultrasonic , light, and laser beam techniques.

Capacitive sensors:

These sensors generate a symmentrical electric field in the surrounding air. When an object cuts this field, dielectric value gives rise to a change in the current which is measured using an electrode. And this change gives the robot the information of the interference of a strange object at a special distance.

Inductive sensors:

It uses the same method of the electric field.

Ultrasonic sensors:

It works by either sending a single sound pulse or emitting a continuous wave signal were the phase displacement is measured between the transmission and the return of the signal.


Light- Reflection sensors:

These types of sensor operate by using white light or infra-red light directed on to the object which is to be monitored or detected. the light beam is reflected and detected by a receiver.

Laser distance sensor:

It allows the exact non contact measurement of distances the the detection of component edges. The working distance and the measuring range essentially characterize it.

Internal sensors can be categorized as:

  • Potentiometer
  • Tachometer
  • Encoders

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