Project in CAM and Robotics

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Guide line for the Course project in CAM and Robotics ( You have an additional material which is already posted on Canvas - modeling of a Fanuc LR mate Li robot)

Part I Modeling of the Robot

1. Draw out the kinematic diagram and assign joint, frame and link numbers. This task is an essential task and you need to carefully consider the actual configuration of the robot and draw the kinematic diagram. You must know the type of the motion and how each joint move the next link. Use the standard notations for the joints, frames and the links.

2. Assign the Joint axes

It robot kinematic analysis it is preferred to use the Denavit Hartenberg (DH) notations, hence assign the joint axes by carefully following the DH rules. If you have assigned your axes correctly, then the rest of the kinematic modeling would be easier for you. Otherwise you may get incorrect results, hence check whether you have assigned the joint axes a number of times.

3. Knowing about the end effector type, position and orientation The goal of calculating the Forward Kinematics is to be able to calculate the end effector position and orientation from the position of the joints.

4. Fill the DH parameter table and calculate the parameters The DH parameters break down each joint of the robot into four parameters, each taken with reference to the previous joint. They are calculated in reference to the "common normal" described above. Note that if the previous z-axis intersects the current z-axis, which is often the case, the common normal has a length of zero.

d - the distance between the previous x-axis and the current x-axis, along the common normal

θ - the angle around the z-axis between the previous x-axis and current x-axis.

a (or r) - the length of the common normal

α - the angle around the common normal to between the previous z-axis and current z-axis.

Link ai αi di θi 1

Once you have filled the DH table you can combine all transformations, from the first joint (base) to the next until we get to the last joint, to get the robot’s total transformation matrix

nn AAAT ........... 21 0 =

ixaixdzzi RTTRA ii aq ,,,,=

ú ú ú ú

ê ê ê ê

é -

1000 0 i

dcs sascccs casscsc

iiiiii

qaqaqq

5. Modeling the forward and inverse kinematics

Once you had formulated the Forward and inverse kinematic equations. The next step simplifying the calculations using computer programs. There are lots of kinematic software libraries (available for use – search for a kinematics software written in a software of your choice) and many of them do

far more than just calculate Forward Kinematics. Most of them include Inverse Kinematic solvers, dynamics, and etc. These libraries will transform your DH parameters into matrices, which are then multiplied together to calculate the relationship between joint positions and end effector position. You can also use your favorite programming language and write a program to do the same. My recommendation is that you use MATLAB. Part II Using the selected robot to solve a particular manufacturing problem. 1. Think where the robot which you had selected may be used and using the

robot selection criteria (Lecture 8), justify the selected robot 2. Economic justification of the selected robots (Lecture 8). Conduct an

economic justification of the selected robots (Lecture 8) 3. Show the integration of the robot with the selected manufacturing, in order

to solve specific manufacturing functions. 4. If additional computer operated equipment, or CNC or other automation

units are needed explain about each of the existing units and how they function.

Some application of robotics for different manufacturing solutions from AGT robotics

( Refer the following site for further information http://agtrobotics.com/custom-solutions/)

Robotic Welding Cell on Gantry:

This robotic welding system on Gantry has been developed to weld parts on metal panels. The cell includes a robot equipped with smart detect system to automatically detect when to stop welding and an auto adjust unit which modifies the robot movement to adjust the plate deformation.

Robotic Welding for the Fabrication of Large Panels

The system is used to automate the welding tasks on panels. Thus, the operators can concentrate on the assembly of the parts to improve production capacity. The system is equipped with a laser touch sensing package. This system will allow fast and accurate seam finding for all joints.

Cross – Frames Robotic welding system – steel Bridge manufacturing

The goal is to automate the welding tasks of a bridge cross-frame. Thus, the operators can concentrate on

the assembly of the parts to improve production capacity. It is not possible to have a mass production of

cross frames as they might be all the same but slightly different in sizes. That is the reason why a

parametric programming system was needed for this system. The system is equipped with a laser touch

sensing package. This system will allow fast and accurate seam finding for all joints.

Robotic Painting Cell Self Learning Technology (SLT),

Using a patented Self Learning Technology (SLT), a highly flexible robotic solution to automate Low-

volume / High-mix Painting Applications. Without any knowledge of the shape and size of the parts

that are placed on a conveyor, the system automatically, scans the part in 3D (up to 48 inches wide) and

generates and executes a custom-made painting path for each part

Robotic Laser Cladding Cell

Robotic equipment for projection of metal particles used fused with a laser, for parts cladding. To increase surface hardness, wear resistance and useful life of the parts, allows repair of valuable parts, allows preheating of parts, superior cladding pace.

Robotic Cutting & Grinding Cell for Elbows

Fully automatic plasma cutting and grinding system for elbow manufacturers. The project consists of installing an automated production cell to cut (in an optimised fashion) the elbow forgings (halves). This equipment automatically scans pairs of elbow forgings, generates and runs an optimised plasma cutting path, grinds cut edges, and removes excess material from elbow section ends (pre-cut)

Generic Welding Robotic Cell, with parts positioner

Standard robotic cell with tilting and rotating axis for steel arc welding. Industrial Welding Robot, Tilting and rotating table with 500 kg capacity, Complete security equipment. Automated operations, No need for highly-trained personnel, Flexible cell that can accommodate many parts.

Robotic Cell for Welding & Plasma Cutting

Customized robotic cell with tilting and rotating axis for steel arc welding and 3D plasma cutting. Industrial cutting and welding robot, with one tilting and rotating table of a capacity of 500 kg. Automated operations, no need for highly-trained personnel, flexible cell that can accomodate many parts.