Design And Analysis Of Robot Manufacturing System For Automotive Industry.

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Penggunaan robot dalam industri automotif telah banyak berkembang atas kepentingannya dalam kilang(kilang automotif. Automasi robotik merupakan penyelesaian yang baik untuk pengeluaran kilang automotif ini kerana kebanyakan aktiviti industri pembuatan disifatkan sebagai berulang, berbahaya dan berat. Proses pengimpalan merupakan antara operasi pengeluaran kilang automotif yang banyak bergantung kepada penggunaan aplikasi robotik. Ini disebabkan proses pengimpalan memerlukan operasi yang berulangan dan berterusan. Selain itu, penggunaan robotik juga membantu dalam meningkatkan kualiti hasil kerja pengimpalan. Projek ini mengandungi dua tujuan. Pertamanya adalah untuk menganalisa

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I would like to express my gratitude to my supervisor, Dr. Zamberi bin Jamaludin for his support, encouragement, supervision and useful suggestions throughout this research work. His continuous guidance enabled me to complete my study successfully. I would also like to thank Mr. Muhammad Hafidz Fazli B. Md Fauadi, my ex(supervisor for his encouragements and enthusiastic helps in the first part of the study. I am truly grateful of their knowledge sharing and time spending in order to help me to complete the project.

Besides, I am ever, indebted to my parents for their love and support throughout my life. Although they did not contribute much in the information in the thesis, their moral supports are more than enough for me to overcome all the challenges I met during the study. I would also like to thank my brother for providing me a good computer for me to use the software related and to complete my thesis. Without him, my thesis could not be completed too.

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Abstract i

Abstrak ii

Dedication iii

Acknowledgement iv

Table of Content v

List of Tables ix

List of Figures x

List of Abbreviations xii

1.1 Background 1

1.2 Problem Statements 3

1.3 Objectives 4

1.4 Scope of Study 4

1.5 Summary 4

2.1 Introduction 5

2.2 History of Robot 6

2.2.1 What is Robot? 6

2.2.2 Robot Timeline 6

2.3 Classification of Robots 8

2.3.1 Cartesian Robot 8

2.3.2 Cylindrical Robot 9

vii Components to be Weld

viii

Programming of Robots Behaviour Spot Weld Gun Class Module Gripper Class Module

Kinematics Analysis

Forward Kinematics of Spot Welding Robot Forward Kinematics of Assisting Robot Path Planning

Future Work and Recommendations

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2.1 Timelines of Robots 7

2.2 Four Arm Parameters 27

3.1 Gantt Chart of PSM I 39

3.2 Gantt Chart of PSM II 40

5.1 Arm Parameters of Spot Welding Robot 63

5.2 Arm Parameters for Assisting Robot 67

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1.1 Spot welding of a car body in an assembly line 2

1.2 Spot welding 3

2.1 Cartesian robot 9

2.2 Cylindrical robot 9

2.3 Spherical robot 10

2.4 Articulate robot 11

2.5 The PTP motion 15

2.6 The continuous path motion 16

2.7 Welding application 18

2.8 Robot spot welding car body 18

2.9 Spray painting 19

2.10 Palletizing 20

2.11 Material Handling 20

2.12 Assembly process of a car 21

2.13 Relationship of forward and inverse kinematics 21

2.14(a) Roll 22

2.14(b) Pitch 22

2.14(c) Yaw 23

2.15 A transformation that consists rotation and translation 24

2.16 The four values (θ, d, a, α) identified relating one joint to the next 26

2.17 Polynomial trajectories with via points 30

2.18 Spot welding 30

2.19 Process to determine robotic work space simulation 34

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3.1 Methodology of the complete study 41

4.1 Arrangement of components in the workstation 48

4.2 Spot welding robot (ABB 6400 series) 49

4.3 End(effector of spot welding robot (C spot weld gun) 49

4.4 Assisting robot (ABB 6400 series) 50

4.5 Robot tool for pick and place 50

4.6 Car body 51

4.7 Roof of the car 51

4.8 Roof transferred by assisting robot while spot welding robots 52 ready in position

4.9 Welding route of both spot weld robots 53

4.10 Spot welding process ongoing while assisting robot holding the roof 53 4.11 Process flow of the spot welding process of car roof 54

Assisting robot grasping the roof

Assisting robot holding roof while spot welding robots move to first welding position

Spot welding robots welding at the second path

Spot welding completed and parts transferred to next station Coding for spot weld gun

Coding for gripper

Graph of distance versus time Graph of speed versus time Graph of acceleration versus time

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Path planning for robots system

Working envelopes for spot welding robots Working envelope for assisting robot Working envelope for all three robots Space for future allocation of new robot

xii CAD ( Computer Aided Design D(H ( Denavit – Hartenberg DoF ( Degree of Freedom GP ( Geometry Points

ISO ( International Organization for Standardization PC ( Personal Computer

PTP ( Point to Point

RMS ( Robot Manufacturing System RUR ( Rossum’s Universal Robots

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CHAPTER 2

LITERATURE REVIEW

2.1 Introduction

In this chapter, sources from journals, case studies and articles related are

summarized. All the information obtained will act as a guideline or references for

this study field. Analysis and detail research are done from these information

obtained to compile in this report for better exposure and understandings.

Robots are capable of performing many different tasks and operations precisely and

do not require common safety and comfort elements need. However, it takes much

effort and many resources to take a robot function properly. Hence, various types of

research and studies need to be done from various reading materials and the global

search engine on all the related information required in this study field.

When it comes to robots, reality still lags science fiction. But, just because robots

have not lived up to their promise in past decades does not mean that they will not

arrive sooner or later. Indeed, the confluence of several advanced technologies is

bringing the age of robotics ever nearer; smaller, cheaper, more practical and cost&

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2.2 History of Robot

2.2.1 What is Robot?

The Robot Institute of America (1979) defined a robot as a re&programmable, multi&

function manipulator designed to move material, parts or specialized devices through

variable programmed motions for performance of a variety of tasks. However, there

are many other definitions for robots where the encyclopedia defines a robot as a

stand – alone hybrid computer system that performs physical and computational

activities. In addition, robots are capable of performing many different tasks as it is a

multiple&motion device with one or more arms and joints.

Another definition given by the International Organization for Standardization (ISO)

in ISO 8373 states that robot is an automatically controlled, reprogrammable,

multipurpose, manipulator programmable in three or more axes, which may be either

fixed in place or mobile for use in industrial automation applications.

The acclaimed Czech playwright Karel Capek (1890&1938) made the first use of the

word ‘robot’. The word robot is originated from the Czech word which means

slave laborer. The use of the word robot was introduced into his play R.U.R

(Rossum's Universal Robots) which opened in Prague in January 1921.

There are no an exact definition of robot which can satisfy everyone and many

people have their own definitions. However, it can be generally concluded that from

the above mentioned definitions, the programmable and re&programmable multi&

functions are the most important features of a robot system.

2.2.2 Robot Timeline

Table 2.1 shows that robot has been evolved greatly since it has been from the first

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Table 2.1 : Timelines of Robots (http://en.wikipedia.org, 2008)

Year Significance Robot Name Inventor

1206 First programmable humanoid robots

Boat with four robotic musicians

Al&Jazari

1495 Designs for a humanoid robot Mechanical

knight Leonardo da Vinci

1738 Mechanical duck that was able to eat, flap its

wings, and excrete Digesting Duck

Jacques de Vaucanson

1800s Japanese mechanical toys that served tea, fired

arrows, and painted toys Hisashige Tanaka

1921 First fictional automatons called "robots" appear in the play

Rossum's Universal Robots

Karel Čapek

1930s Humanoid robot exhibited at the 1939 and 1940

World's Fairs Elektro

Westinghouse Electric Corporation

1948 Simple robots exhibiting biological behaviors Elsie and Elmer William Grey Walter

1956

First commercial robot, from the Unimation company founded by George Devol and Joseph Engelberger, based on Devol's patents

Unimate George Devol

1961 First installed industrial robot Unimate George Devol

1963 First palletizing robot Palletizer Fuji Yusoki Kogyo

1973 First robot with six electromechanically driven

axes Famulus

KUKA Robot Group

1975 Programmable universal manipulation arm, a Unimation product

PUMA Victor Scheinman

At year 1989, the first biped walking robot which was able to walk on a terrain

stabilized by trunk motion was developed by Kato which is named, WL12RIII

(Jaeger, 2004). It could walk at a rate of 2.6 seconds, up and down stairs. Then robots

revolved to another form where Honda creates P2, the first major step in creating

their ASIMO in year 1996. P2 is the first self&regulating, bipedal humanoid robot

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At year 2002, Honda creates the Advanced Step in Innovative Mobility (ASIMO). It

is intended to be a personal assistant. It recognizes its owner's face, voice, and name.

ASIMO can read email and is capable of streaming video from its camera to a PC.

While at year 2005, The Korean Institute of Science and Technology (KIST), creates

HUBO, and claims it is the smartest robot in the world. This robot is linked to a

computer via a high&speed wireless connection; the computer does all of the thinking

for the robot (Jaeger, 2004).

2.3 Classification of Robots

Industrial robots are categorized by the first three joint types which are the

prismatic/translational (linear) joint and rotational joints. These two types of joint is

the most current used in industrial robots. There are four different types of robot

configurations which are :

a) Cartesian

b) Cylindrical

c) Spherical

d) Articulated

2.3.1 Cartesian Robot

This type of robot has the first three joints corresponding to the major axes which are

all prismatic (PPP) as shown in Figure 2.1. This type of robot is commonly used for

positioning tools such as dispensers, cutters, drivers and routers (Parker, 2008). The

primary applications of this robot are in material handling, machine loading and

printer board construction. The advantages of Cartesian robot are that the

configuration and design are simple, motion control in Cartesian space can be easily

carried out and large work envelop. The robot will be easier to visualize and have

better inherent accuracy than most other types besides easier to be program offline.

On the other hand, the limitations of this type of robot are that it is not space efficient