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manufacturing_advanced edit Flashcards

1
Q

How does a harmonic drive work?

A
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2
Q

How does a lead screw work?

A
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3
Q

What are the equations for a rack and pinion systems?

A
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4
Q

What are the different acuator controls?

A
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5
Q

Electric motors bascis

A
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6
Q

Series wound DC motors

A
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7
Q

Shunt wound DC motors

A
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8
Q

Compound wound DC motors

A
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9
Q

Permant magnet DC motors

A

Built in tachometer for velocity feedback

Flux remains constant at all motor speeds so speed torque curve is linear

Avaliable in fractional and low horsepower designs

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10
Q

Advantages of permant magnet motors over conventional DC motors

A
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11
Q

What are AVG guidance systems?

A

Wire-guided: • An energized wire is rooted along the guide path. • The antenna of the AGV follows the rooted wire.

Optical: • Colourless florescent particles are painted on the concrete/tiled floor. • Photo-sensors are used to track these particles.

Inertial: • The guide path is programmed on a microprocessor which is fixed on the AGV • Sonar system is incorporated for finding obstacles.

Infrared: • Infrared light transmitters are used to detect the position of the vehicle. • Reflectors are affixed on the top of vehicle to reflect the light.

Laser: • Laser beam is used to scan wall-mounted bar-coded reflectors. • Accurate positioning can be obtained.

Teaching type: • AGV learns the guide path by moving the required route. • Sends the information to the host computer.

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12
Q

What is an AVG?

A

Driverless Vehicle

Electric motors, battery powered

Programming capabilities

Destination

Path selection

Positioning

Collision avoidance

• System Discipline

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13
Q

AGVs as assembley line opperators.

A

• Applications include assembly lines where the production rate is relatively low (e.g. 4 to 10 minutes per station), and variety of different models are made on the production line.

  • Between workstations components are placed on the vehicle for the assembly operations on the partially completed product at the next workstation.
  • Workstations are generally configured in parallel configurations to allow flexibility to the line.
  • Unit load carriers and light load vehicles are used in this system.
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14
Q

AGVs in flexiable manufactuing systems

A

• Components are transferred from storage area to various work stations as part of FMS environment.

Once parts are processed (e.g. machined, etc.) at each station, they are transported to the next station for further manufacturing processing.

• AGVs provide added flexibility to the entire FMS.

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15
Q

What are some of the good things about guidance systems for AGVs?

A
  • One of the major advantage of AGV is ease in modification given by the guidance system for changing the guide path at low cost compare to conveyors, chains, etc.
  • Another benefit is: guide path is flexible which means intersection of path is possible.
  • Generally, guide path does not obstruct another systems.
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16
Q

What is AGV routing?

A

• A routing system is used to select the vehicle which is positioned with the optimum path. • A network controller gives the destination, while the onboard controller navigates the vehicle.

Frequency select Method • At the junction of more than one paths (decision point), the vehicle reads a code on the floor in the form of metal plate, or coded device. • The vehicle selects one of the frequencies as per the direction required. • The frequencies are always active. • A continuous wire is used to loop the frequencies.

Path-Switch Select Method • Path is divided into segments. • One frequency is used. • Segments are switched On/Off by separate floor controls according to the path to be followed. • Less preferred over Frequency select method.

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17
Q

What is the definition of AS/RS?

A

Automatics storage and retrieval system

Combination of equipment and controls which, Handles, Stores and Retrieves materials with Precision Accuracy and Speed with a defined degree of automation

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18
Q

Function of AS/RS

A
  • Automatic removal of items from a storage location.
  • Transportation of items to a specific processing or interface point.
  • Automatic storage of items in a predetermined location.
  • Automatic reception and processing of items from a processing or interface point.
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19
Q

Advantages of AS/RS

A

 High space efficiency

 Improved inventory management and control

 Reduction in labor costs

 Better security

 Flexibility in design to accommodate various loads

 Increased productivity when interfaced with other manufacturing systems

 Helps JIT implementation

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20
Q

Unit load AS/RS

A
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21
Q

Mini load AS/RS

A
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22
Q

Person on Board AS/RS

A

Allows storage of items in less than load quantities

Person performs tasks of selection and picking

Flexibility and time reduction

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23
Q

Definition of a robot

A
  1. Must be produced by manufacturing not by biology.
  2. Able to move physical objects or be mobile itself.
  3. Capable of some sustained actions without intervention by an external agent – programmable, multi-functional.
  4. Be possible to modify its behavior in response to its environmental changes (sensor equipped).

An industrial robot is a reprogrammable device to both manipulate and transport parts, tools or specialized manufacturing implementation through variable programmed motions for the performance of specific manufacturing tasks

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24
Q

Why are robots used?

A

Do not tire or grumble – no health claims (except some maintenance).

Higher quality (consistency).

Repeatable performance.

Stronger, faster, more accurate.

More productive.

Work 24 hours each day.

Immune to dangerous environment .

Reduction of labor cost.

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25
Q

Why are humans still used?

A

• Adaptable to problems and environments. • Wide range of sensory inputs, with pattern recognition. • Make decisions, set priorities and define goals. • Investigate new techniques. • Easy to reprogram.

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26
Q

Typical uses of robots in industry

A
  • Spot welding
  • Arc welding,
  • Gluing for auto body panel or car window
  • Inspection
  • Finishing
  • Polishing
  • Deburring
  • Material handling
  • Cleaning of casting, grinding off
  • Sorting
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27
Q

Bits of robots

A

• Links: rigid bodies that form the robot manipulator.

Joints: connect neighboring links allowing either rotary (revolute) or translating relative motion (prismatic).

End effectors: the tip of the manipulator. Gripper, welding torch, electromagnetic, suction cups, etc.

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28
Q

Degrees of freedom

A

equal to number of joints

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29
Q

What are the dimensions of 6 dimentional space?

A

the 3 spartial dimensions and rotation about the 3 axises.

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30
Q

What is the work volume?

A

• Work space: the space reachable by a manipulator.

Work volume is the volume of the work space, i.e., the region within which the robot can position its endeffectors.

Robot configuration will decide the size of work volume of the industrial robot.

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31
Q

Cartesion robot configuration

A

• Simple control but can carry heavy loads

Strong rigidity, accuracy and repeatability.

Limited movements.

Assembly, pick-and-place, loading and unloading, palletizing (ex. insert components in a circuit board).

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32
Q

Cylindrical robot configuration

A
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33
Q

Spherical robot configuration

A
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34
Q

SCARA Configuration

A
  • Requires very sophisticated controller
  • Programming is more complex.
  • Assembly, Inspection and measurement, machine vision,

inspection, etc

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35
Q

Articulated robot Configuration

A
36
Q

Multilpe joint configuration

A
37
Q

How many degrees of freedom are needed to reach anypoint in 3D space?

A

6

38
Q

What are the different types of motions a robot arm can undertake?

A

Arm and body motions

Wrist motions.

39
Q

Give some examples of end effectors

A
40
Q

What should be considered with grippers?

A

Grippers are used to hold workpiece using mechanical open-close mechanism. Should consider the followings:

  1. Large mass at the end of robot arm requires a considerable amount of force to halt the movement.
  2. Changing direction of movement is difficult at high speeds with heavy loads.
  3. The workpiece should remain secured in the gripper even when the power of the grips is removed (safety reason).
41
Q

What is the tool centre point? (TCP?)

A

TCP is the origin of the coordinate system or the point of action of the tool attached to the robot arm.

Using forward kinematics, we could relate the coordinate system in the base to the coordinate system attached on the tool-mounting plate of the arm. All movements of the manipulator are referenced from this location in space.

If an end-effector is added to the mounting plate, the origin of coordinate system moves to a new location, which is called the TCP.

42
Q

Pneumatic Drives

A
  • Compressible air is used – position control problem.
  • Usually used in relatively low-cost with low-carrying capacity.
  • Mechanical stops are usually used to control the actuator position – simple stop-to-stop motions, Example: pick and place application.
  • Simple control – ideal for gripper

Disadvantages:

  1. Usually more sophisticated valve required to reduce the error (limited accuracy).
  2. Noise pollution from exhausts.
  3. Low efficiency especially at reduced loads.
  4. Low stiffness.

Advantages:

  1. High speed and relatively high power to weight ratio
  2. Very low cost
  3. No contamination of work space (no oil leak)
  4. Light weight.
43
Q

Advantages of hydraulid drives

A

Using compressible fluid - mechanically relatively simple (familiar to maintenance personnel)

High strength and high speed for relatively small size (high power to weight ratio) – ideal for moving moderate to high loads at reasonable speeds and moderate noise level.

Stiffer than electrical motors, resulting greater accuracy and better frequency response.

Smoother response in low speed.

44
Q

Hydrualic drives: disadvantages.

A

 Expensive for small or medium sized robot with limited accuracy.

 Required additional energy storage unit including pumps and accumulators.

 Susceptible for oil leaks – frequent cleaning and maintenance required.

 Highly nonlinear movement.

 Digital encoder and highly capable feedback control system can provide better accuracy and repeatability compared to electrical drives but required very sophisticated control.

45
Q

How does a non-servo controller work?

A
46
Q

How does a servo controller work?

A

Closed-loop system.

Detect and correct errors.

The desired position and the actual position to be compared and the difference to be reduced by control action.

Servo-controlled controllers also consider the rate of changes from tachometers.

47
Q

What is slew motion?

A

Simplest type of motion.

The robot is to travel from one point to another where each axis of the manipulator travels as quickly as possible (feasible top speed) from its initial position to the required final position.

All axis begin moving at the same time.

It usually results in unnecessary wear on the joints and often leads to unanticipated results in the path taken by the manipulator.

48
Q

Joint motion

A

Simplest type of motion.

The robot is to travel from one point to another where each axis of the manipulator travels as quickly as possible (feasible top speed) from its initial position to the required final position.

All axis begin moving at the same time.

It usually results in unnecessary wear on the joints and often leads to unanticipated results in the path taken by the manipulator.

49
Q

Linear interpolation motion

A

The tool of the robot travels in a straight line between the start and the end points.

  • This can be difficult, and lead to rather erratic motions when the boundaries of the workspace are approached.
  • Cycle time is slower than a joint move since the controller must compute the axis movements.
  • Very useful in the applications such as arc welding, insert pins into holes, or laying materials along a straight path, etc
50
Q

Circular interpolation motion

A

Controller defines the points of a circle on a minimum of three specified position, start, end, and intermediate points.

  • This usually consists of short straightline segments.
  • Basically moves along a linear approximation of circle.
  • Cycle time is slower than a joint motion since the controller must compute the axis movements.
51
Q

How does stop-to-stop motion work?

A

Open loop control – No servo-control to indicate relative position of the joints.

Position and velocity unknown for controller.

Instead limit switches or mechanical or electrical constraints are used to limit the movements of joints.

The individual joints can only be moved to their extreme limits of travel.

Each axis is normally limited to two end points, pick-and-place applications.

Simple and reliable system, easy to maintain.

Not flexible.

52
Q

Point-to-point motion

A

Fastest motion and most common.

No attention is payed to the route the end effector goes to get to where its going.

Controler changes axises at the maximum rate and more than one at a time.

Reliable, but difficult to do straight lines.

Used for spot welding, loading and unloading, hole drilling.

53
Q

Controlled linear path

A

 Point-to-point path with added capability, i.e., the start and the end coordinates and the path definition are required for control.

 the path between points is straight line.

 Controlled-path is used when the manipulator must move in a perfect path motion.

 Operation requires accurate path control

 Example: Arc welding.

54
Q

Continuous path motion

A

Number of program points is large.

While the operator is moving the robot through its motion during programming, the positions are stored at a constant rate until the destination point reached.

The memory and control requirements are greater.

Very high level of control required.

Applications : Spraying paint, grasping objects moving along the conveyor belt.

55
Q

Dynamic properties of robots

A

The capacity of a robot to position and orient the end of its wrist with accuracy and repeatability is an important control attribute for most Industrial robots.

  1. Stability
  2. Control resolution
  3. Spatial resolution
  4. Accuracy
  5. Repeatability
  6. Compliance
56
Q

Dynamics Properties: Stability

A

Stability is associated with the oscillations in the motion of the robot end-effector.

The fewer oscillations presents, the more stable the operations of the robot.

It could cause additional wear and a collision with some objects in the system because of overshoot.

Regardless of conditions imposed on the robot, the servos should operate properly according to the specifications.

57
Q

Dynamics Properties: Control Resolution

A

 Control resolution specifies the smallest increment of motion by which the robot system can divide its working space.

 It may be the function of the smallest increment in position the control system can command (robot control system) and/or

 the smallest incremental change in position that the control system can measure (robot’s feedback measurement system).

 These increments are referred to as addressable points.

 Control resolution can be given by the total motion range divided by the number of increments.

 In a robot with several DOF, each axis’s resolution is to be added vectorically to obtain the total control resolution.

 Adjacent manipulator positions: two manipulator positions that differ by only one increment of a single joint.

58
Q

In regards to control resolution, how do you find the number of increments along a particular axis?

A

The number of increments for a particular axis is given by 2n, where n is the number of bits in the control memory.

59
Q

A sliding joint has a full range of 1.0m. Robot memory has 12 bits capacity. Calculate control resolution.

A

The control resolution = 1.0m/(212) = 0.000244m or 0.244mm.

60
Q

Dynamic Properties: Spatial Resolution

A

Spatial resolution is control resolution with mechanical inaccuracy.

Defined as the smallest increment of movement that a manipulator can be commanded to move.

It is basically the control resolution degraded by the mechanical inaccuracy in the joints.

Mechanical inaccuracy comes from elastic deflection, gear backlash, stretching of pulley cords, leakage of hydraulic fluid, etc.

61
Q

Dynamic Properties: Accuracy

A

Defined as the robot’s ability to position and orient the end of its wrist at a desired target point within the work volume – how closely it can move to the target point.

Depends on its ability to divide its joint movements into small increment (Spatial Resolution)

It is affected by mechanical inaccuracies.

It is half the distance between two adjacent spatial resolution points.

62
Q

Dynamic Properties: Repeatability

A

Defined as the robot’s ability to re-position itself at the same point during successive trials.

Mechanical wear, environmental changes (such as temperature changes) would affect the repeatability.

Repeatability is generally larger than accuracy.

63
Q

Difference between accuracy and repeatability

A
64
Q

Robot Precision Problem

A

Robot precisions are usually referred to spatial resolution, accuracy and repeatability.

The main causes of the precision problem are:

  1. Environmental factor: temperature, humidity or electrical noise, etc.
  2. Kinematics parameters: robot link lengths, joints.
  3. Dynamic parameters: frictions.
  4. Measurement factors: encoder resolution limit.
  5. Computational factors: steady-state control errors.
  6. Application factors: installation errors.

Calibration and on-line or off-line monitoring can improve the precision.

65
Q

Dynamic Properties: Compliance

A

 Defined as a quality that gives a manipulator of a robot the ability to tolerate misalignment of mating parts.

 It prevents jamming, wedging, etc. of the parts.

 High compliance means that the tool moves a lot in response to a small force, and the manipulator is then said to be spongy or springy.

 If it moves very little, the compliance is low and the manipulator is said to be stiff.

66
Q

What are sensors and transducers?

A

Transducer: a device to convert one type of physical variable (ex. Force, pressure, etc) into another form (e.g. voltage) which is usable.

Sensor: a transducer used to make a measurement of a physical variable of interest.

In robotics world: a sensor is a device that detects information about the robot and its environment and transmits it to the robot controller to provide a measurement for the operation control.

67
Q

What are robot sensors used for?

A

ØDetect position and orientation of parts.

ØInspect the final part.

ØDiscover variations of shape and dimensions of parts.

ØAdjust the robot control for environment.

ØDetect and prevent failures.

ØDetect and avoid collisions.

ØMonitor the environmental changes (temperature, position of obstacles, etc.)

ØMonitor the interaction with the environment – ex. Welding, paint spraying, etc.

68
Q

What are the features we want of sensors?

A
  1. Accuracy: no systematic positive or negative errors in the measurement.
  2. Precision: no random variability in the measurement.
  3. Operating range: the entire operating range is accurate and precise.
  4. Speed of response: it should be capable of responding in minimum time.
  5. Calibration: it should be easily calibrated. No drift (tendency for sensor to lose accuracy over time).
  6. Reliability: High reliability with no failure.
  7. Cost and ease of operation: Cost to purchase, install, maintain and operate should be as low as possible.
69
Q

Internal state sensors

A

Internal Sensors - used to monitor position, motion, force and mass for the control of robot and usually installed inside the robot mechanism:

ØLimit switches,

ØEncoders,

ØLoad cells,

ØLinear Variable Differential Transformers (LVDT)

ØTachometers,

ØPotentiometers,

ØAccelerometers, etc

70
Q

How does the potentiometer work?

A

Basically it will convert the voltage signal into the position of the wiper using the linear variation in resistance.

Can be used to measure rectilinear or rotational motion.

Steady supply of voltage is crucial for the accurate measurement.

Commonly used to set the initial position of robot – home position.

71
Q

Optical encoders

A

Encoders are either angular or linear devices which determine the position of part of a machine. Angular encoders determine shaft position, while linear encoders determine linear position.

There are three general types of angular-position encoders using digital outputs: tachometer, incremental encoders and absolute encoders.

Generally installed in each robot joint.

72
Q

Incremental encoders

A

The incremental encoder emits pulses which determine how far the device has rotated. In other words, it tells how far the shaft rotated from its previous position, but not where it is started or finished

However, if the initial position is known, we can find the final position.

Basically it works as a pulse counter from a home reference position.

The direction of rotation can also be determined.

More widely used than absolute encoders because they are cheaper.

One fundamental problem – in the case of power failure, it will lose the information of the reference point. So the robot must not be turned off without permission.

73
Q

Linear Variable Differential
Transformer (LVDT)

A

Capable of accurate position measurement

The electromechanical configuration consists of a coil and a rod (One can move relative to the other)

The output voltage is proportional to the displacement of moveable member relative to fixed member

74
Q

Absolute encoders

A

It uses an array of Light Emitted Diodes LEDs and light sensors and with combination of unique patterns on the disc, it can provide a binary number which describes the angular position of the disc.

An absolute encoder must transmit its information over multiple parallel output lines. Thus, to get a resolution of 1 part in 1024, the absolute encoder requires 10 output lines (or bits).

75
Q

Tachometers

A
76
Q

Load cells

A

A load cell is a transducer which converts force into a measurable electrical output so we can measure the magnitude of force.

Those based on the strain gauge are the most commonly used type.

A load cell can be used as a limit switch.

  • Within the limit of measurements, all forces applied to load cells cause elastic deformation only.
  • Any plastic deformation would destroy the load cell and cut-off the power - Hence acts as a safety limit switch.
  • So it can be used as an internal and external sensor.
77
Q

What are extenal sensors?

A

External sensors – to measure the interaction between the robot and its working environment:

Micro switches, Proximity sensors,

Simple tactile/touch sensors

Photoelectric devices

Pressure transducers

Vision sensors,

Sonar, Ultra sonic sensors,

Infra-red sensors, Laser sensors, etc

78
Q

Proximity sensors

A

Proximity sensors are non-contact and linear position sensors that can be used as limit switches.

Several types of proximity sensors;

  • Inductive proximity sensors,
  • Capacity proximity sensors,
  • Ultrasonic proximity sensors,
  • Magnetic proximity sensors, etc.
79
Q

Inductive Proximity Sensors

A

The sensor incorporates an electromagnetic coil which is used to detect the presence of a conductive metal object.

When the target enters the electromagnetic field, the amplitude of the field will be decreased. The reduction of the amplitude of the field will trigger the detection mechanism of the sensor.

80
Q

Capacitive Proximity Sensors

A

It obtains the switching signal based on the air gap between the sensor and non-conductive materials.

When an object nears the sensing surface, it enters the electrostatic field of the electrodes and changes the capacitance of the sensor which triggers the changes of the states of the switch.

81
Q

Photoelectric Sensors

A

Photoelectric sensors are non-contact position-sensing device which use a modulated light beam that is either broken or reflected by the target.

It usually consists of an emitter, a receiver and other electronics.

Types:

  • Thru-beam type
  • Retro reflector
  • Diffuse scanner
  • Reflect scanner
82
Q

Tactile sensors

A

Two types: touch sensors and force sensors

Touch sensors provide a binary output signal (0 or 1) that indicates whether or not a contact has been made with other objects. Based on limit switch design, it can detect obstacles to avoid collisions – avoiding is better than detecting.

Force sensors (sometimes called stress sensors) indicate not only that a contact has been made with the object but also the magnitude of the contact force between two objects.

83
Q

Ultrasonic sensors

A

Ultrasonic sensors use a transducer to send and receive high frequency sound signals.

When the work piece enters the beam the sound is reflected back to the switch, causing it to energise and de-energise the output switches.

Usually used to detect the presence of object or to measure the distance.

Propagation speed (340m/sec) is slower than optical ones (laser sensor) - simpler circuits will do the job.

Travel distance = speed of sound (c) x time delay between emitting the pulse and receiving echo (t/2).

Low accuracy, easily affected by environments (temperature, moisture, dust…), but it is simple and cheap – widely used in industry.

84
Q

Sonar

A

Sound Navigation and Ranging (Sonar) sensors use acoustic or sound signals.

Used to determine the position, velocity and orientation of the objects in the underwater world.

Sonar sensors are usually installed by locating sonar units at uniform angular intervals especially in mobile robot applications.

85
Q

Laser sensors

A

Use laser optical signal (Laser-light amplification by stimulated emission of radiation).

The propagation speed is too fast – need a good hardware support.

Very accurate.

Usually used to measure the distance and position.

86
Q

Four major uses of Sensors

A

Safety monitoring: the protection of human workers and other equipment (limit switches, light curtains, etc.)

Control interlocking: coordination with other equipment in the work cell and verification before proceeding with the next sequence of operations.

Quality control inspection: determination of a variety of part quality characteristics.

Positions and related information: Positions and/or orientations of various parts in work cells, such as workpieces, fixtures, people, equipments, etc.

87
Q

How to choose a Sensor

A

There are four main factors to consider in choosing a sensor.

Cost: sensors can be expensive, especially in bulk.

Environment: there are many sensors that work well and predictably inside, but that choke and die outdoors.

Range: Most sensors work best over a certain range of distances. If something comes too close, they bottom out, and if something is too far, they cannot detect it. Choose a sensor that will detect targets in the range you need.

Field of View: depending upon what you are doing, you may want sensors that have a wider area of detection. A wider “field of view” will cause more objects to be detected per sensor, but it also will give less information about where exactly an object is.

Manufacturing systems (3 decks)

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