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.