AutomationAutomation
Year 2 – Lecture 1
Dr Linda Newnes
MethodsMethods
Start at 3.15 p.m. finish at 4.05 p.m.All videos / slides examinable1 question in exam from this work.Questions at the beginning of each lecture
from previous lecture notes. Please read before the lecture!
Groover and Zimmer, CAD/CAM, library shortloan.
Course contentsCourse contents
Manufacturing AutomationAutomation Building BlocksHard & Flexible AutomationRoboticsManual Systems vs. Automated Systems
Typical areas of automationTypical areas of automation
Automotive IndustryBomb DisposalSurgeryAerospaceFoodPharmaceutical
Automation and Robotics in the Automotive Industry
• Brief History and overview.
• Applications
• Case studies
• The future?
• Limitations
Brief History
~ 1910.
•Cars built in small workshops
• Skilled workers.
• No automation.
•High cost. Low volume. Up to 10 days per car.
1913.
• Mass production techniques introduced.
• Large moving assembly line.
• One task per worker
• Standardised parts.
1910 1913
1920 - 1940
1920- 40
•Automatic transfer machines integrated into assembly lines.
1945 - ‘Automation’ coined by Ford employee.
1957
1954
• First highly automated factories
•Ford reduces work force from 117 to 40
1954
1962
• First industrial robot saw service
• Stacking metal from die-casting m/c
1962 Present
1970
• First integrated manufacturing system
• First spot welding of auto bodies.
1970s
• Microprocessors
• Mini-computer control industrial robots
1957
• First commercially available NC machines
1970
1980-1990s
• Sensor based machines
• Integrated manufacturing systems
• Unattended cells
• AI
1980s 1990s
19761976
• First spray painting robots
Present
• Huge & highly competitive industry. Drive for higher production rates, low cost & high quality. Typically 200-300,000 cars per year per line.
• Industry uses over 50% of all industrial robots globally – 60% of these for spot welding.
Applications in the automotive industry
PositionersGeneral CNCWeldingSpray paintingAssemblyOther
Limitations
• Difficulty of getting information into a robot without human intervention.
• The level of dexterity required for some operations is too high for current systems
• The cost of some robots is prohibitive.
• People are more flexible for production lines which change operations frequently.
Automation in the Bomb Disposal Industry
Introduction
Bomb technicians wear protective suits that reduce the effect of a blast but do not provide protection in all cases.
Bomb disposal units are increasing relying on robots.
Robots reduce or eliminate the technicians time-on-target.
A robot takes the risk out of potentially deadly scenarios.
Enables technician to focus fully on the bomb rather than the immediate danger.
Figure 1. Example of a bomb disposal robot.
History Even before WWII a “rope and hook” procedure was used
to move packages to less dangerous locations.
During the early 1970’s remotely operated systems began to emerge to handle bomb threats.
The death of several bomb technicians over a short period of time in N.Ireland prompted development.
A remotely controlled electric wheelchair was developed. Fitted to carry several items of bomb disposal equipment.
Development First robot was a battery operated wheelbarrow. Used to tow away
suspect vehicles to safer areas. Improved to have the ability to drop explosive charges into cars. Further development with an improved chassis and four wheel drive. Addition of closed circuit television camera for remotely viewing
objects. Wheels were replaced with tracks. More improvements to tracks and manipulator arm had been
produced.
A modified electric wheelbarrow had evolved to a tracked vehicle able to fire a disrupter, conduct surveillance and perform a number of other tasks.
Common Design ComponentsManipulator
•2-3 joints
•Large coverage area
•Electrically powered
•Replaceable
End-Effector
•Usually 2-fingered gripper
•2 degrees of freedom
•Integrated vision system
Manuverability Unit
•Extremely versatile
•Robust
•Adaptive to terrain
•Drive vision system
Features•Modular construction•Radio controlled•Multi-robot capable control systems
BRATVision
B&W drive cameras with halogen spotlights Colour zoom camera with spotlights for manipulator arm.
Manoeuvrability chassis Wheeled or tracked module Adjustable front tracks for stair climbing/ obstacle crossing Electric power pack
End effector/arm Interchangeable manipulator arm/disrupter deployment module Manipulator arm has 5 degrees of freedom, including a rotating turret.
Package Small and lightweight Number of optional add-ons High speed and robust
Future Developments• Increasing use of Explosive ordinance disposal robots:
Mine ClearanceSurveillance and ReconnaissanceHostage Rescue Observation & SupportNuclear, Biological, and Chemical Detection systems
• Incorporation of leading edge technologies, e.g.. Virtual reality head set control equipment
• Robots becoming more compact and versatile with development.
• Artificial Intelligence? Virtual reality equipment
Automation in the Electronics
Industry
<Insert Picture>
Traditional Electronic Production
Reasons for Automation: Accuracy
– Handling small components– Pick and Place
Repeatability– Consistent Processing – Minimise Human Error
Processing Speed Assembly in Clean Environment Harsh Environment
– Hot solder– Acid Dip tanks
RSI - (Repetitive Strain Injury)
< pictures of people soldering / assemble>
Applications - Positioning of Components
Pick and place of components onto the circuit board
Robot configuration: – Cartesian – SCARA
Gripper: – Mechanical (jaws)– Suction cup
Types of Drive– Electric– Pneumatic
Applications - Soldering of Components
Conventional components / surface mount
Robot configuration: Polar Coordinate
End Effector : soldering iron with continuous solder feed
Electrically driven
Sensoring - Vision System
The Outlook - Micro Robots
Used for component assembly on PCBs– Pick and place of components– Soldering components
Control from central computer Advantages:
– Simultaneous use of multiple robots – Robot paths can cross over– Robots can work in a team - communicate & co-operate
Aerospace Industry
Aerospace IndustryTypes of robot End effectorsCommon uses and applications
The Aerospace Industry
Aerospace Companies generally have: Very small production quantities. A large quantity of active part numbers for both current
and out of date models. Very high tooling start-up costs. High Labour content, with manually operated and
manipulated tools. Minimal opportunity to design for mechanism. Highly developed use of CAD/CAM techniques.
Manufacture and Assembly
Final Assembly
- Low Volume
- Static Build
Component Manufacture
- Higher Volume
- High Automation
Component Manufacture
High Volumes
Highly Automated Electronic circuits/wiring Seating Small ‘bought in’ parts
Consistent Accuracy
Highly Automated Composite fibre lay-up Parts with complex geometry
Aircraft Assembly
Dimensional / quality inspection Airframe skin attachment Painting Jigless assembly Refurbishment Modifications Cleaning
In General Across Aerospace
Companies Interested In Processing Capabilities As Opposed To Parts Handling– e.g.. Spray Painting etc.
Development towards Fully Integrated CAD / CAM Cells– Removing Human Link In Programming Robot– Hence Removing Error
Types of Robot Used
Articulated robotic arms (e.g. welding, inspection)
Types of Robot Used
Cartesian gantry (e.g. drilling holes for an aeroplane trail)
Types of Robot UsedSelective Compliance Automatic Robot
Arms (e.g. sub assemblies, pick and place)
Aerospace Robotic End Effectors
• CNC Aerodrill
• Drill and fill
• Fastner installation tool
• Aerorouter
• Fastner removal
• Stem Shaver
• Air router
• Aeroquick change
• Measurement tools
Common Uses and Applications
Industrial use focuses on process handling such as complex positioning and assembly
Drill and routing of aluminium sheet metal, also mating parts together and feeding the piece through an automatic riveter
Accurate finishing processes on engine parts e.g. turbine blades
Conclusion + Future
Aerospace Industry IncreasingCompetition in Air TravelLean ManufactureHigher Level of Automation
Robotics in Surgery
The robots fit into one of two categories: Passive or Active.
Passive devices rely on an external operator to move them.
Active devices move solely under computer control.
The Acrobot
This procedure requires high accuracy.
Acrobot is an active device but it is positioned by a passive one.
It uses the Active Constraint Principal.
Co-operates with surgeons by allowing them to work under force and spatial constraints.
The Bloodbot
The procedure is to take blood samples from the forearm.
Needle overshoot often occurs with the manual procedure.
Robot prevents overshoot.
Open-heart Surgery
Traditional High patient trauma High infection risk Long recovery
Robot assisted Ribs intact, far less trauma Reduced infection risk Increased precision
Neurophysiological Monitoring
Use of robotics Electrodes inserted into
brain for monitoring Using robotics electrons
can be positioned with accuracy of 50 microns
Electrons can be advanced through brain in steps of 1 micron
Laparoscopic Surgery
Robot assisted routine Used for gall-bladder,gynecological,chest and abdomen
pin-hole surgery Robot “hands” manipulate fibre-optic light and camera
while surgeon carries out surgery Voice controlled robot can hold tools steadier and longer
than a human equivalent
Advantages of Robotic in Surgery
Reduced costs after initial set-up
Less chance of complications
Eliminates surgeon fatigue and tremor
Robot training using sensorised glove
Future Advancements
Increase Autonomy, walking away from the master-slave approach.
Decrease operating times even further.
Expand the use of the technology into more hospitals.
Future Advancements
Increased dexterity. Reduce size of the
technology. Future work involves the
development of new technologies for producing powerful autonomous microrobots capable of moving within the human body.
The Use of Robots in Space
Space robots originally pictured as ‘Humanoid’ or ‘Mechanical Men’
Nowadays applied to any device that works automatically, or by remote control.
Particularly devices programmed to perform tasks normally done by people
In space, robots perform tasks that are too dull, dirty, delicate or dangerous for people.
Space Robots
Space Robots - How they work?
Similar in design to terrestrial robots. Each has controller, sensors, actuators, radio communications
and power supply.
Differences between space and earth robots:– Weightlessness. No need to support any weight, only required to apply
accelerating / decelerating force, so can be much lighter.– Reliability. On-site repairs are costly and difficult. Robots have Orbital
Replacement Units (ORU) to allow modular repairs– End effectors. Must have a hard contact point and a solid connection to
prevent the target drifting away.
Exploration & Reconnaissance.
Space Robots – Different types
Space probes such as Galileo and Cassini fully merit the name of robots.
They perform programmed tasks over long periods without direct human supervision.
They operate in the vacuum of space withstanding exposure to radiation and extremes of temperature, where humans cannot explore.
Exploration & Reconnaissance.
Space Robots – Different types
Roving vehicles such as the Mars Sojourner explore planet surfaces autonomously, receiving periodic updates & instructions.
Control module based on insect behaviour.
Modules are organised into a ‘pecking order’ to avoid conflicts.
Astronaut Assistance.
Space Robots – Different types
Robot Arm such as the Shuttle Remote Manipulator System.
Deploys payloads and captures free floating or stationary objects for maintenance & repair.
All systems are designed to be maintained by humans.
The robots make use of the existing tools, spare parts & handholds.
Consequently, space robots are designed to mimic human design & movement.
Space Robots – Different types
Astronaut Assistance. Free Flying Television Camera. Used for remote inspections of the
exterior of space stations & spacecraft. Contains 2 TV cameras & a floodlight. Steered by 12 nitrogen thrusters. Can operate continuously for 7 hours.
The Space Station Remote Manipulator System (SSRMS) at the International
Space Station (ISS).
Properties of the SSRMS.
Multi-purpose manipulator arm.17m long.Handling capacity of 100,000 kg due to the
use of Servo Power Amplifiers at the joints.3 segments and 7 joints combined with the
ability to move along the Space Station give all over access for the primary use of servicing.
End Effector for the SSRMS.
Equipped with: Vision and force sensors. Control systems for
astronauts performing space walks.
Mobile Serving System (MSS)
Special Purpose Dexterous Manipulator (SPDM)
•15 degree’s of freedom.
•600 kg mass handling capacity.
•3.5 m long.
•1662 kg.
•Can attach to either the MBS or the SSRMS.
Orbital Replacement Unit/Tool Changeout Mechanism (OTCM)
•Keyed parallel jaws.
•Retractable nut drive unit.
•An offset camera and light.
In Summary
Various Applications.Relevant and crucial to all industrial / other
sectors.In the next few weeks we will cover the
building blocks.Learn the correct vocabulary.