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Introduction to Robotics in Cim Systems

by: Rehg, James A.

Introduction to Robotics in Cim Systems

by: Rehg, James A.

ISBN 13:
9780139012082
ISBN 10:
0139012087
Edition: 4th
Format: Hardcover
Copyright: 10/01/1999
Publisher: Pearson College Div
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Summary

For courses in two- and four-year colleges in Introduction to Robotics, Manufacturing Automation, or Production Design. This text addresses the use of robots for flexible automation from a manufacturing systems viewpoint. It begins with what industrial robots were and how they were integrated into an automated manufacturing system. Emphasis is placed on the hardware and software that support the implementation of automated work cells and manufacturing systems.

1 Introduction to Industrial Robots

(43)

1-1 Introduction

(1)

1-2 History of the Industry

(2)

1-3 Forty-Year-Old Industry

(2)

1-4 Integrated Systems--Meeting the External and Internal Challenges

(11)

External Challenges

(2)

Internal Challenge

(1)

Meeting the Internal Challenge

(7)

1-5 The Problem and a Solution

(1)

1-6 Definition of Robotics and Computer-Integrated Manufacturing

(2)

1-7 Manufacturing System Classification

(3)

Project

(1)

Job Shop

(1)

Repetitive

(2)

Line

(1)

Continuous

(1)

1-8 Robot Systems

(8)

Basic System

(1)

Mechanical Arm

(1)

Production Tooling

(1)

External Power Source

(1)

Robot Controller

(1)

Teach Stations

(1)

ABB Controller Interface

(2)

1-9 Some Basic Terms

(9)

1-10 Robot Standards

(1)

R15 Standards

(1)

A15 Standards

(1)

1-11 Summary

(1)

Questions

(1)

Problems

(1)

Projects

(1)

2 Robot Classification

(66)

2-1 Introduction

(1)

2-2 Robot Arm Geometry

(8)

Cartesian Geometry

(2)

Cylindrical Geometry

(2)

Spherical Geometry

(1)

Articulated Geometry

(2)

Selective Compliance Articulated Robot Arm (SCARA)

(1)

Horizontally Base-Jointed Arm

(1)

2-3 Power Sources

(6)

Hydraulic Power

(2)

Pneumatic Power

(3)

Electric Power

(1)

2-4 Drive Systems

(17)

Torque

(5)

Belts

(3)

Chains

(1)

Gear Drives

(4)

Gear Error

(1)

Ball Screw Drives

(2)

Harmonic Drives

(2)

2-5 Application Areas

(2)

Assembly

(1)

Nonassembly

(2)

2-6 Control Techniques

(16)

Closed-loop Systems

(12)

Open-loop Systems

(4)

2-7 Path Control

(7)

Stop-to-stop Path Control

(1)

Point-to-point Control

(3)

Controlled Path

(1)

Continuous Path

(2)

2-8 Design Guidelines

100

(2)

Robot Selection Criteria

100

(1)

Robot Survey

101

(1)

2-9 Classification by the International Standards Organization (ISO)

102

(1)

Sequenced

102

(1)

Trajectory

103

(1)

Adaptive

103

(1)

Teleoperated

103

(1)

2-10 Summary

103

(1)

Questions

104

(1)

Problems

105

(2)

Projects and Case Study Problems

107

(3)

3 Automated Work Cells and CIM Systems

110

(25)

3-1 Introduction

110

(1)

3-2 The CIM Implementation Process

111

(8)

Step 1: Assessment of Enterprise Technology, Human Resources, and Systems

111

(2)

Step 2: Simplification--Elimination of Waste

113

(2)

Step 3: Implementation with Performance Measures

115

(4)

3-3 Making the CIM Process Work

119

(1)

3-4 Automated Production

120

(1)

3-5 Flexible Automation

120

(7)

3-6 Fixed Automation

127

(1)

In-Line Fixed Automation

127

(1)

Rotary-Type Fixed Automation

127

(1)

3-7 Work-Cell Design Checklist

128

(1)

3-8 Implementing Automated Work Cells

129

(2)

New Versus Existing Production Machines

129

(1)

Fixed Versus Flexible Automation

130

(1)

3-9 Summary

131

(1)

Questions

132

(1)

Problems

133

(1)

Projects and Case Study Problems

133

(2)

4 End-of-Arm Tooling

135

(40)

4-1 Introduction

135

(1)

4-2 Standard Grippers

136

(8)

Gripping Force

140

(2)

Minimum Gripper Force

142

(2)

4-3 Vacuum Grippers

144

(6)

Lifting Capacity

145

(2)

System Components

147

(1)

Vacuum Surfaces

148

(2)

Vacuum Suckers

150

(1)

4-4 Magnetic Grippers

150

(1)

4-5 Air-Pressure Grippers

150

(5)

Gripping Force

152

(3)

4-6 Special-Purpose Grippers

155

(1)

4-7 Gripper Selection and System Intelligence

155

(1)

4-8 Special-Purpose Tools

156

(1)

4-9 Robot Assembly

157

(1)

4-10 Compliance

158

(6)

Active Compliance

159

(1)

Active Compliance Applications

159

(1)

Passive Compliance

160

(4)

4-11 Multiple End-Effector Systems

164

(3)

Wrist Interface

165

(1)

Multiple-Gripper Systems

165

(2)

4-12 Collision Systems

167

(3)

Breakable Link Devices

169

(1)

Spring and Pneumatic Collision Devices

169

(1)

4-13 Summary

170

(1)

Questions

171

(1)

Problems

171

(3)

Projects and Case Study Problems

174

(1)

5 Automation Sensors

175

(40)

5-1 Introduction

175

(2)

Discrete Sensors

176

(1)

Analog Sensors

177

(1)

5-2 Contact Sensors

177

(10)

Discrete Devices

177

(4)

Dogs

181

(3)

Artificial Skin

184

(3)

5-3 Noncontact Sensors

187

(20)

Proximity Sensors

187

(2)

Inductive Sensor Operation

189

(9)

Capacitive Sensors

198

(2)

Photoelectric Sensors

200

(7)

5-4 Sensor Selection Checklist

207

(1)

5-5 Smart Sensor Systems

207

(2)

DeviceNet Network

209

(1)

5-6 Process Sensors

209

(2)

5-7 Summary

211

(1)

Questions

211

(1)

Problems

212

(1)

Projects and Case Study Problems

213

(2)

6 Work-Cell Support Systems

215

(23)

6-1 Introduction

215

(1)

6-2 Machine Vision Systems

215

(7)

Vision Standards

216

(1)

Vision System Components

216

(2)

Image Measurement

218

(2)

Image Analysis

220

(1)

Image Recognition

221

(1)

6-3 Lighting for Machine Vision

222

(3)

Selection of the Light Source

223

(1)

Lighting Techniques

223

(2)

Illumination Sources

225

(1)

6-4 Material Handling

225

(5)

Automated Transfer Systems

226

(3)

Automatic Storage and Retrieval Systems

229

(1)

6-5 Part Feeding

230

(3)

Gravity Feeders

230

(1)

Tape Feeders

231

(1)

Waffle-Tray Feeders

232

(1)

Vibratory Feeders

232

(1)

6-6 Inspection

233

(1)

6-7 Automatic Tracking

233

(3)

6-8 Summary

236

(1)

Questions

237

(1)

Projects and Case Study Problems

238

(1)

7 Robot and System Integration

238

(26)

7-1 Introduction

239

(2)

7-2 System Overview

241

(1)

Hardware Overview

241

(1)

Software Overview

242

(1)

7-3 Work-Cell Architecture

242

(3)

Cell Controllers

242

(1)

Cell Control Software Structure

243

(1)

Work-Cell Management Software

244

(1)

7-4 Programmable Logic Controllers

245

(3)

PLC System Components

245

(1)

Basic PLC System Operation

246

(2)

7-5 Computer Numerical Control

248

(1)

7-6 Controller Architecture

249

(5)

Nonservo Robot Controllers

249

(2)

Servo Robot Controllers

251

(3)

7-7 Interfaces

254

(4)

Simple Sensor Interface

254

(3)

Complex Sensor Interface

257

(1)

Enterprise Data Interface

258

(1)

7-8 An Integrated System

258

(3)

Machining Cell

260

(1)

Assembly Cell

260

(1)

Signal Types

260

(1)

Work-Cell Controller

261

(1)

Programmable Logic Controller

261

(1)

7-9 Summary

261

(1)

Questions

262

(1)

Projects and Case Study Problems

263

(1)

8 Work-Cell Programming

264

(29)

8-1 Introduction

264

(1)

8-2 Work-Cell Controller Programming

265

(2)

Software Developed In-House

265

(1)

Enabler Software

266

(1)

OSI Solution

266

(1)

8-3 Programming Sequential Cell Activity

267

(3)

PLC Programming

268

(2)

Other Sequential Programming Options

270

(1)

8-4 Robot Language Development

270

(1)

8-5 Language Classification

271

(3)

Joint-Control Languages

271

(1)

Primitive Motion Languages

272

(1)

Structured Programming Languages

273

(1)

Task-Oriented Languages

274

(1)

8-6 Robot Program Fundamentals

274

(3)

8-7 Translation or Position Points for Servo Robots

277

(7)

Reference Frames

277

(4)

Programming Servo Robot Translation Points

281

(3)

Programming Nonservo Robot Translation Points

284

(1)

8-8 Program Statements for Servo Robots

284

(5)

Basic Program Structure--Step 1

284

(1)

Process Analysis--Step 2

285

(1)

Tasks and Subtasks--Step 3

285

(1)

Task Point Graph--Step 4

286

(1)

On-Line and Off-Line Programming

286

(3)

Translation Points and System Variables--Step 5

289

(1)

System Variables--Step 6

289

(1)

8-9 Summary

289

(2)

Questions

291

(1)

Problems

292

(1)

Projects and Case Study Problems

292

(1)

9 Justification and Applications of Work Cells

293

(24)

9-1 Introduction

293

(1)

9-2 Capital Equipment Justification

294

(3)

Return on Investment Method

295

(1)

Cash Flow Method

295

(1)

Time Value of Money

295

(1)

Justifying Robotics Applications

296

(1)

Justification Spreadsheet

296

(1)

9-3 Automation Applications

297

(17)

Material Handling

297

(4)

Machine Tending

301

(1)

Assembly

301

(5)

Process

306

(1)

Welding

306

(3)

Paint Spraying

309

(5)

9-4 Summary

314

(1)

Questions

314

(1)

Problems

314

(2)

Projects and Case Study Problems

316

(1)

10 Safety

317

(38)

10-1 Introduction

317

(1)

10-2 Safety Standards

318

(2)

Robot Systems and Integrated Work Cells

319

(1)

Corporate Standards

319

(1)

Governmental and Other Organizations

319

(1)

10-3 Occupational Safety and Health Administration (OSHA)

320

(1)

10-4 American National Standards Institute/Robotic Industries Association Standard for Robot Safety

321

(1)

10-5 Safeguarding a Work Cell

321

(2)

Safeguarding Devices

321

(1)

Safety Hardware

322

(1)

10-6 Presence Sensing Devices

323

(8)

Proximity Sensing Devices

323

(1)

Light Curtain Introduction

324

(1)

Light Curtain Operation

325

(1)

Light Curtain Applications

326

(1)

Calculating Safe Curtain Distance

327

(3)

Presence Sensing Mats

330

(1)

Sensing Mat Operation

330

(1)

10-7 Interlock Devices

331

(8)

Interlock Switch Operation

331

(1)

Interlock Positive Mode Operation

331

(1)

Forms of Interlock Devices

332

(1)

Power Interlocking

332

(1)

Control Interlocking

332

(1)

Calculating Safe Guard Distance

333

(1)

Mechanical Interlock Devices

334

(2)

Non-Contact Interlock Devices

336

(1)

Interlock Switches with Guard Locking

337

(1)

Unconditional Guard Unlocking

338

(1)

Conditional Guard Unlocking

338

(1)

10-8 Safeguarding the Operator

339

(1)

10-9 Safeguarding the Programmer

339

(1)

10-10 Safeguarding Maintenance and Repair Personnel

339

(1)

10-11 Developing a Safety Strategy

340

(7)

Risk Assessment-Three Steps

343

(2)

Final Assessment Rating

345

(1)

Hazard Reduction

346

(1)

Personnel Protection Equipment

347

(1)

10-12 Design Guidelines

347

(1)

10-13 Safety Justification

348

(1)

10-14 Summary

349

(1)

Questions

350

(1)

Problems

351

(2)

Projects and Case Study Problems

353

(2)

11 Human Interface: Operator Training, Acceptance, and Problems

355

(9)

11-1 Introduction

355

(1)

11-2 General Training

356

(1)

General Training Program

356

(1)

11-3 Operator Training

357

(1)

11-4 Maintenance Training

357

(1)

11-5 Team-Based Manufacturing

358

(2)

Description of a Self-Directed Work Team

359

(1)

Making Work Teams Work

359

(1)

11-6 Resistance

360

(1)

11-7 Organized Labor

361

(1)

11-8 Summary

361

(1)

Questions

362

(1)

Projects and Case Study Problems

363

(1)

12 Work-Cell Design Case Study

364

(50)

12-1 Introduction

364

(1)

12-2 Company Profile

364

(1)

12-3 Introduction to CIM Automation at West-Electric

365

(3)

West-Electric Automation Team

366

(1)

The First Meeting

366

(2)

12-4 Turbine Blade Production

368

(9)

Step 1: Raw Material Inspection

370

(1)

Step 2: Production of Slugs

370

(1)

Step 3: Slug Lubrication

371

(1)

Step 4: Extrusion

371

(2)

Step 5: Upset Forging

373

(1)

Step 6: Block Forge

373

(1)

Step 7: Final Forge and Trim

374

(1)

Step 8: Alternate Process for Small Airfoils

374

(1)

Step 9: Deburring

375

(1)

Step 10: Heat-Treating

375

(1)

Step 11: Measuring Airfoil Cross-Section

375

(1)

Step 12: Chemical Milling

376

(1)

Step 13: Machining Base

376

(1)

Additional Data on the Blade Production Line

376

(1)

12-5 CDM Improvement Process

377

(2)

Five-Step Design Process

378

(1)

12-6 The Automation Plan

379

(3)

12-7 Selection Criteria

382

(5)

Work-Cell Technical Design Checklist

383

(1)

Robot Selection Checklist

384

(3)

12-8 Performance Measures

387

(2)

12-9 Technical Issues

389

(4)

Performance Requirements

389

(1)

Layout Requirements

389

(1)

Production Characteristics

390

(1)

Equipment Modifications

390

(1)

Process Modifications

390

(3)

Robot Specifications

393

(1)

Oven Modifications

393

(1)

Work-Cell Simulation

393

(1)

12-10 Automation Cell Integration

393

(6)

12-11 Work-Cell Control

399

(1)

12-12 Cell Programming

399

(3)

12-13 Cost Justification

402

(1)

12-14 Safety Plan

403

(5)

Operational Overview

403

(2)

Work-Cell Safety

405

(3)

12-15 Final Performance Measures

408

(6)

Case Study Problems

409

(1)

Sections 12-1 to 12-4

409

(1)

Sections 12-5 to 12-8

409

(1)

Sections 12-8 to 12-9

410

(1)

Section 12-10

410

(1)

Section 12-11

411

(1)

Section 12-12

411

(1)

Section 12-13

412

(1)

Sections 12-14 to 12-15

412

(2)

Appendix A Robot Specifications

414

(9)

Appendix B Internet Resources

423

(3)

Thomas Register

424

(1)

Web Search Engines

424

(1)

Standard Organizations

424

(1)

Robot Vendors

424

(1)

Automation Sensors

424

(1)

Automation Support Components

424

(1)

Programmable Logic Controllers

425

(1)

Work-Cell Control Software

425

(1)

Material Handling Systems

425

(1)

Appendix C Justification Program

426

(6)

Index

432

Amazon no longer offers textbook rentals. We do!

Introduction to Robotics in Cim Systems

Introduction to Robotics in Cim Systems

9780139012082

0139012087

Summary

Table of Contents

Supplemental Materials

Write a Review

Amazon no longer offers textbook rentals. We do!

Introduction to Robotics in Cim Systems

Introduction to Robotics in Cim Systems

9780139012082

0139012087

Summary

Table of Contents

Supplemental Materials

Write a Review

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