Mark Tyson, ABB Technology Show, May 2013 …Introduction+to+Robot… · ABB Robots will share starring roles in the fourth of the highly popular Terminator film franchise. “We

© ABB Group

May 13, 2013 | Slide 1

Robotics 101 Mark Tyson, ABB Technology Show, May 2013

© ABB Group May 13, 2013 | Slide 2

The visibility of ABB Robots reached an entirely new level on

May 21, 2009 when Warner Brothers Studios released the new

Terminator Salvation movie to North American audiences. In

addition to Christian Bale and the army of rival Terminators, 18

ABB Robots will share starring roles in the fourth of the highly

popular Terminator film franchise.

“We looked at a variety of different robot manufacturers, but

were most struck by the presence of ABB’s robots, especially

the larger units,” said Zolfo. “They had the right lines and they

provided the feel that they could actually be making

Terminators.”

“What the ABB programming system was able to get the

robots to do was better than we ever expected. The robots are

very visible and instrumental in the final, climactic scene of the

movie.”

”The robots were really an evolutionary

character,” said Zolfo. “Like an interim step

between the humans and the Terminators.”

ABB Robots featured in “Terminator Salvation” movie – 2009


http://www.google.co.za/imgres?imgurl=http://dclips.fundraw.com/400dir/traffic_light_dan_gerhar_01.gif&imgrefurl=http://www.fundraw.com/clipart/clip-art/00002527/Traffic-Light/&h=400&w=400&sz=48&tbnid=5xtwX3c4NlnXJM:&tbnh=124&tbnw=124&prev=/images%3Fq%3Dtraffic%2Blight&hl=en&usg=__zEYh2jktgs0KWvgkPPH2nBIXrQQ=&ei=W0rlSpu8DMXP-Qav65zJCQ&sa=X&oi=image_result&resnum=1&ct=image&ved=0CBAQ9QEwAA

http://dclips.fundraw.com/400dir/traffic_light_dan_gerhar_01.gif


17th century

Robot History The world’s first robot?


The human machine

Barbarossa with his

creator 1900

Automaton =

self-operating machine

Robot History The world’s first robot?


The term “Robot”

The term robot comes from the Czech

word robota, generally translated as

"forced labor.“

The Czech playwright Karel Capek

originated the term robot in his 1920 play

"R.U.R.“ (Rossum’s Universal Robots) In

the play, machine workers overthrow

their human creators when a scientist

gives them emotions.

Source: www.howstuffworks.com


Human Beings

On the most basic level, human beings are made up of five major components:

A body structure.

A muscle system to move the body structure.

A sensory system that receives information about the body and the surrounding environment.

A power source to activate the muscles and sensors.

A brain system that processes sensory information and tells the muscles what to do



Robots

A robot is made up of the very same components.

A typical robot has a movable physical structure, a motor of

some sort.

A sensor system.

A power source (supply)

A computer "brain" that controls all of these elements.

Essentially, robots are man-made versions of animal life --

they are machines that replicate human and animal behavior.



Robots versus machines versus computers

Most roboticists (people who build robots) use a more precise definition. They specify that robots have a reprogrammable brain (a computer) that moves a body.

Robots are distinct from other movable machines, such as cars, because of their computer element. Many new cars do have an onboard computer, but it's only there to make small adjustments. You control most elements in the car directly by way of various mechanical devices.

Robots are distinct from ordinary computers in their physical nature -- normal computers don't have a physical body attached to them.



Types of Robots?

Cartesian robot / Gantry robot: Used for pick and place work, application of sealant,

assembly operations, handling machine tools and arc welding. It's a robot whose arm

has three prismatic joints, whose axes are coincident with a Cartesian coordinator.

Cylindrical robot: Used for assembly operations, handling at machine tools, spot welding,

and handling at die-casting machines. It's a robot whose axes form a cylindrical

coordinate system.

Spherical/Polar robot: Used for handling at machine tools, spot welding, die-casting,

fettling machines, gas welding and arc welding. It's a robot whose axes form a polar

coordinate system.

SCARA robot: Used for pick and place work, application of sealant, assembly operations

and handling machine tools. It's a robot which has two parallel rotary joints to provide

compliance in a plane.

Articulated robot: Used for assembly operations, die-casting, fettling machines, gas

welding, arc welding and spray painting. It's a robot whose arm has at least three rotary

joints.

Parallel robot: One use is a mobile platform handling cockpit flight simulators. It's a robot

whose arms have concurrent prismatic or rotary joints.


http://prime.jsc.nasa.gov/ROV/images/cartesian.GIF

http://prime.jsc.nasa.gov/ROV/images/gantry.gif

http://prime.jsc.nasa.gov/ROV/images/cylindrical2.GIF

http://prime.jsc.nasa.gov/ROV/images/sphericalpolar.GIF

http://prime.jsc.nasa.gov/ROV/images/SCARA.GIF

http://prime.jsc.nasa.gov/ROV/images/articulated.jpg

http://prime.jsc.nasa.gov/ROV/images/parallel.jpg


Types of Robots?



Types of Robots?

Cartesian robot /Gantry robot: Used for pick and place work, application of sealant,





coordinate system.



coordinate system.






joints.












Types of Robots?


http://users.aber.ac.uk/jnw/CS364/cylindrical.jpg


Types of Robots?






coordinate system.



coordinate system.






joints.












Types of Robots?


http://users.aber.ac.uk/jnw/CS364/polar.jpg


Types of Robots?






coordinate system.



coordinate system.






joints.












Types of Robots?

SCARA Robots

The SCARA acronym stands for Selective Compliant Assembly Robot Arm and is one that is hard to remember. It's also sometimes referred to as: Selective Compliant Articulated Robot Arm.



Types of Robots?






coordinate system.



coordinate system.






joints.












Human Arm, Robot Arm

An industrial robot with six joints closely resembles a human arm

-- it has the equivalent of a shoulder, an elbow and a wrist.

Typically, the shoulder is mounted to a stationary base structure

rather than to a movable body. This type of robot has six

degrees of freedom, meaning it can pivot in six different ways.

A human arm, by comparison, has seven degrees of freedom.

DOF 1

DOF 2

DOF 3 DOF 4

DOF 5

DOF 6


Types of Robots?



Types of Robots?






coordinate system.



coordinate system.





welding, arc welding and spray painting.

Parallel robot: One use is as a high speed Pick & Place. The use of lightweight but

strong arms allows for high acceleration and deceleration.












Types of Robots?


http://www.google.co.za/imgres?imgurl=http://www.generation5.org/content/2005/images/FlexPicker.png&imgrefurl=http://www.generation5.org/content/2005/sim2005.asp&h=377&w=380&sz=39&tbnid=G9x92FX-dtBEKM:&tbnh=122&tbnw=123&prev=/images%3Fq%3Dflexpicker&hl=en&usg=__aMYgFvpY5JhRWYCJ9bobxEPf7YY=&ei=gkXlSt-HJpGL-QaQuoHJCQ&sa=X&oi=image_result&resnum=9&ct=image&ved=0CCIQ9QEwCA

http://www.google.co.za/imgres?imgurl=http://www.generation5.org/content/2005/images/FlexPicker.png&imgrefurl=http://www.generation5.org/content/2005/sim2005.asp&h=377&w=380&sz=39&tbnid=G9x92FX-dtBEKM:&tbnh=122&tbnw=123&prev=/images%3Fq%3Dflexpicker&hl=en&usg=__aMYgFvpY5JhRWYCJ9bobxEPf7YY=&ei=gkXlSt-HJpGL-QaQuoHJCQ&sa=X&oi=image_result&resnum=9&ct=image&ved=0CCIQ9QEwCA


History of Real-World Robots:

One of the first robots was the water clock, which was made

in 1500 B.C. One of the oldest water clocks was found in the

tomb of Amenhotep I, buried around 1500 B.C.

From The University of Birmingham



One of the first robots was the or water clock, which was made in 250

B.C. It was created by Ctesibius of Alexandria, a Greek physicist and

inventor.

The earliest remote control vehicles were built by Nikola Tesla in the

1890's. Tesla is best known as the inventor of AC electric power,

radio (before Marconi), induction motors, Tesla coils, and other

electrical devices.

Other early robots (1940's - 50's) were Grey Walter's "Elsie the

tortoise" ("Machina speculatrix") and the Johns Hopkins "beast."

"Elsie the tortoise"


http://www.apc.net/bturner/tesla.htm

http://www.epub.org.br/cm/n09/historia/documentos_i.htm

http://www.epub.org.br/cm/n09/historia/documentos_i.htm



"Shakey" was a small unstable box on wheels that used

memory and logical reasoning to solve problems and navigate

in its environment. It was developed by the Stanford Research

Institute (SRI) in Palo Alto, California in the 1960s.




The General Electric Walking Truck was a large four legged

robot that could walk up to four miles a hour. The walking truck

was the first legged vehicle with a computer-brain, developed

by Ralph Moser at General Electric Corp. in the 1960s.




The first modern industrial robots were probably the Unimates.

created by George Devol and Joe Engleberger in the 1950's and

60's. Engleberger started the first robotics company, called

"Unimation", and has been called the "father of robotics."

Isaac Asimov and

Joe Engleberger



Industrial Robot

An industrial robot is officially defined by ISO[1] as an automatically controlled, reprogrammable, multipurpose manipulator programmable in three or more axes.

An Industrial Robot is a reprogrammable device designed to

both manipulate and transport parts, tools, or specialized manufacturing implements through programmed motions for the performance of specific manufacturing tasks.

The most widely accepted definition of an industrial robot is one developed by the Robotic Industries Association:

An industrial robot is a reprogrammable, multifunctional manipulator designed to move materials, parts, tools, or specialized devices through variable programmed motions for the performance of a variety of tasks.

http://en.wikipedia.org/wiki/International_Organization_for_Standardization


The Robotic Arm

The most common manufacturing robot is the robotic arm.

A typical robotic arm is made up of seven metal segments, joined by six joints.

The computer controls the robot by rotating individual step motors connected to each joint (step motors move in exact increments).

This allows the computer to move the arm very precisely, repeating exactly the same movement over and over again.

The robot uses motion sensors to make sure it moves just the right amount.



Human Arm, Robot Arm

DOF 1

DOF 2

DOF 3

DOF 4

DOF 5

DOF 6

Shoulder

Elbow

Forearm

Wrist


But what about the hand?

The hand on a robot is the “end effector” or End Of Arm Tool

(EOAT).

Vacuum Gripper

Suction Cups

Source: emiplastics.com

http://emiplastics.com/eoat_eng_design.htm


Some less common applications

Ten years ago, who would have thought that robots would be

used to…..

Milk cows

Put books away in a library

Put icing on cookies for the holidays

The medical and surgical field such as grinding of hip

replacements

The accurate positioning of humans for medical treatment

and testing

The filleting of fish,

The cutting of meat


What are robots used for today?

Common Uses

Standard manufacturing systems for Manufacturing

In Automotive body shops - Welding

Paint shops

Assembly

Material handling

Arc welding

Palletizing applications

Picking, Packaging and Palletizing applications in the Food

industry

Robotic cells, stations and systems to produce parts for small sub-

assemblies to larger systems for framing on the main assembly.

Variety of applications performing dispensing


From Here to…..


To NOW

C:/../Data/My Videos/RealPlayer Downloads/ABB Robotics - Packing Sausages.flv


The 10 good reasons to invest in robots

Based on research carried out by the International Federation of Robotics (IFR)

Published in World Robotics 2005

1. Reduce operating costs

2. Improve product quality & consistency

3. Improve quality of work for employees

4. Increase production output rates

5. Increase product manufacturing flexibility

6. Reduce material waste and increase yield

7. Comply with safety rules and improve workplace health &

safety

8. Reduce labour turnover and difficulty of recruiting workers

9. Reduce capital costs (inventory, work in progress)

10. Save space in high value manufacturing areas


Reason 1 – Reduce operating costs

Robots can help you to reduce both your direct costs and your overhead costs

Robots eliminate the costs associated with manual workers - in terms of wages, training, health and safety, holidays and employee administration

Energy Efficiency. With no requirement for minimum lighting or heating levels, robots offer a great opportunity to reduce your energy bills

Current estimates point to a potential saving of 8% for every 1°C reduction in heating levels, while savings of up to 20% can be achieved by turning off unnecessary lighting


Client AFC Stamping and Production, Inc

Dayton, Ohio

Application – Welding Source of finished manufacturing for power

sports frame components, automotive tubular

components, and automotive stampings with

weld components

System installed by ABB US

Key Drivers & Benefits Achieve quick change tooling & handling

Eliminated customer rejections for missing,

incomplete or non-compliant welds

Labour cost reduction in the first year

$64,000

Savings expected to be maintained over the

next two and a half years

“The low cost of the

U2 cell was easily

justified with the cost

savings we were able

to achieve.”

Jon Lambert, AFC

Reason 1 – Reduce operating costs


Reason 2 – Improve product quality & consistency

Robots can help ensure consistently high quality output of

products and control of manufacturing processes

No risk of errors caused by human factors such as tiredness,

distraction or the effects of repetitive and tedious tasks

Process control can be integrated with the robot

Inherent accuracy and repeatability means a high quality finish

for every product produced


Client Dolphin Casting (Subsidiary of Karsten Mfg)

Phoenix, Arizona

Application – Casting Provides investment castings for the sporting

goods industry, specifically casting putter and

iron heads for PING products System installed by Vulcan Engineering

Key Drivers & Benefits

Improved output quality

Significantly reduced waste and cycle

times

Improved work flow

Limited the production variation

Improved ergonomic demands on employees

Allowed company to stay ahead of the global

marketplace competition

“Robots have

improved the quality

of life for our work

force, while producing

reasonable production

processes.”

Pete Poleon, Dolphin

Casting

Reason 2 – Improve product quality & consistency


Reason 3 – Improve quality of work for employees

Robots can help you improve staff working conditions

Can take over tasks in dusty, hot or hazardous

environments

Staff motivation can also be improved by retraining staff

to use robots – provides chance to learn valuable

programming skills and do work that is more stimulating

Client Franklin Bronze and Alloy Inc.

Franklin, Pennsylvania

Application – Materials Handling Investment casting of precision parts in

brass, bronze, aluminium, stainless steel and

nickel-based alloys System installed by ABB USA

Key Drivers & Benefits Reduction of man-hours from 56 to 32 per

day

Mould production up 60%

Improvement of shell quality

Return on investment in 2.5 years

Cleaner environment for employees &

reduction in physical stress

“We’re increasing our

moulds by 30% to

40% with the same

amount of people,

and there is still a lot

of capacity left.”

Kevin Weaver, Franklin

Bronze and Alloy Movie available on abb.com/robotics

Reason 3 – Improve quality of work for employees


Reason 4 – Increase production output rates

Robots can be left running long shifts, overnight and during

weekends with little supervision

Enables true 24 hour production to increase output levels and

meet client order deadlines

No disruptions to production from breaks, sickness, lapse of

concentration or human error

Performs routine functions to fine tolerances reducing rejects &

scrap rates

New products can be introduced faster & production begin

earlier

Programming of new products can be done off-line without

disrupting production


Client NECCO

Revere, Massachusetts

Application - Packaging Boxing Sweethearts Valentine

Conversation Hearts System installed by JLS Automation

Key Drivers & Benefits Increase in production, doubled or

quadrupled

Labour costs significantly reduced

Created a continuous process for

packaging

Introduction of new product made

seamless

Ability to handle varied packaging

configurations

“The ABB robots

have increased

throughput,

reduced costs and

we have been able

to automate the

entire process.”

Maribel Caban,

NECCO

Reason 4 – Increase production output rates


Reason 5 – Increase product manufacturing flexibility

Robots can provide flexibility to your production line

Once the processes you require are programmed into the

robot controller, you can easily switch from one process to

another

Enables you to maximize your investment by using robotics

equipment to accommodate many product variants or for

more than one process

Ability to respond to fast changing customer demands &

peak load requirements

Vision guidance technologies can accommodate variations

in products, processes & work place


Client Chrysler

Belvidere, IL

Application – Body Shop Switch between the assembly of cars

and small SUVs with minimal

interference to production System installed by ABB Robotics US

Key Drivers & Benefits Shortened installation time

Increased line utilization

One line, three model, high volume

flexible facility

Flexible system thanks to inexpensive

model changeovers or separate lines for

each vehicle

“Belvidere is a true

one line, high

volume, flexible

facility.”

Frank Ewasyshyn,

Chrysler

Reason 5 – Increase product manufacturing flexibility


Reason 6 – Reduce material waste and increased yield

Improved accuracy from using robots means you can

have more products finished first time to the quality

standard demanded by your customers

Also reduces the amount of waste produced as a result

of poor-quality or inconsistent handling or finishing

With products being produced to consistently high

quality levels - rejects & scrap are eliminated and yields

increased


Client Chabot Carrosserie

Montmagny, Quebec, Canada

Application – Paint Painting of plastics components for

recreational vehicles System installed by Prodevco Industries

Key Drivers & Benefits 50% reduction on material waste

Material savings of 35%

45% reduction in paint and finishing

personnel combined

Line speed from 3.5 feet per minute

expected to go to 4.5 feet per minute after

optimization

29% gain in productivity

“The installation

of these robots

were key to our

survival.”

Stephane Poliquin,

Chabot Carrosserie

Reason 6 – Reduce material waste and increased yield


Reason 7 - Comply with safety rules & improve H&S

Robots can take over unpleasant, arduous or health-

threatening tasks currently undertaken by people

Robots can decrease the likelihood of accidents

caused by contact with machine tools or other

potentially hazardous production machinery or

processes

Can also help to eliminate ailments associated with

repetitive or intensive processes, e.g. repetitive strain

injuries (RSI) and vibration white finger


Client The Great Canadian Bean Company

London, Ontario, Canada

Application – Palletizing Placing 25-50kg sacks of dry beans onto a

pallet in order to ship to the international

market System installed by Automation Project group

Key Drivers & Benefits Increased productivity – delivers more

products in a shorter amount of time

The number of workplace injuries has

been reduced to zero

Easy to program and operate robot

Reduced labor costs

“Prior to using the robot,

the employees were very

skeptical that it could do

the job. Now, they can’t

imagine how they ever

loaded all the pallets

without it.”

Bill MacLean, The Great

Canadian Bean Company

Reason 7 - Comply with safety rules & improve H&S


Reason 8 - Reduce labour turnover

Highly skilled manual workers are becoming harder to find

and more expensive to employ

Robots can provide an ideal alternative. Once

programmed, they can begin work with none of the costs

associated with recruitment, induction or ongoing training

Robots often come with hard to find process skills “built in”

Also offer greater flexibility, both in terms of work patterns

and ability to adapt to different production tasks

Robots love the jobs that people hate to do. Their

“motivation” levels are always high


Key Drivers & Benefits Productivity of packaging line increased

significantly

Reduced the number of training

sessions, making the staff more

productive

Work conditions for employees have

improved without loss of jobs

Client White Castle

Louisville, KY

Application – Packaging Switch from labour intensive manual

packaging to using robots programmed to

package two 3-packs or club packs. System installed by ABB US

“The FlexPicker is a

fantastic, high-

quality product and

exactly what we

have been looking

for to help us.”

Tony McGraw, White

Castle Movie available on abb.com/robotics

Reason 8 - Reduce labour turnover


Reason 9 - Reduce capital costs

With robots you can reduce the cost of consumables used

and reduce wastage

Less manual labour can also mean fewer costs relating to

sickness, accidents and insurance


Client Injection Technology Corporation

Arden, North Carolina

Application - Plastics Custom moulder for precision plastic parts

such as electric meter cover, dental appliance

cases and spools System installed by ACS

Key Drivers & Benefits Reduced man hours by 45%

Reduced cycle time by 23%

Added capacity to mould other products on

same machine

Return on investment in less than 8 months

compared to the usual 2 years

“It makes our

customers’ jobs easier.

We can meet their

demands, and we can

maintain prices on our

products in a time of

rising material prices.”

Van Durham, Itech

Reason 9 - Reduce capital costs


Reason 10 - Space savings

Robots can be mounted on walls floors, shelves & ceilings

– resulting in space saving cell design

Can also be programmed to work in confined spaces so

you don’t lose valuable floor space


Client Azimuth Three Enterprises (AZ3)

Brampton, Ontario, Canada

Application – Custom Steel Fabrication

Value added treatment of beams,

including cutting holes in beams and

then cutting the beams themselves System installed by Burlington Automation

Key Drivers & Benefits Reduces material-handling shop space

and simplifies shop layout

Increases speed and accuracy

Reduces both capital and maintenance

costs

Cleaner shop that is more agreeable to

work in

Boosts shop productivity

“The more steel you

pump out of here, the

more money you

make, the more you

cut your overhead.”

Jean G. Diab, AZ3

Reason 10 - Space savings


Summary - The 10 good reasons to invest in robots

Based on research carried out by the International Federation of Robotics (IFR) Published in

World Robotics 2005

1. Reduce operating costs

2. Improve product quality & consistency

3. Improve quality of work for employees

4. Increase production output rate

5. Increase product manufacturing flexibility

6. Reduce material waste and increase yield

7. Comply with safety rules and improve workplace health &

safety

8. Reduce labour turnover and difficulty of recruiting workers

9. Reduce capital costs

10. Save space in high value manufacturing areas

For more information and the name of your local ABB contact visit www.abb.com/robotics


Documents

Mark Tyson, ABB Technology Show, May 2013 …Introduction+to+Robot… · ABB Robots will share starring roles in the fourth of the highly popular Terminator film franchise. “We