PowerPoint Presentation

Design ReviewRobotic Work Cell

Problem StatementHundreds of nut plate assemblies are built everyday using human labor. This work is monotonous and physically taxing for the workers involved, often resulting in injury due to repetitive motions. In addition to causing workplace injury, the repetitive nature of these tasks result in an accumulation of process errors. The goal of this project is to create an automated work cell centered on an industrial robot which can tirelessly and consistently perform these assembly tasks which are ill-suited for human workers.

Design Goals and DeliverablesSafety remove humans from the manufacturing task, create a process that adheres to safety requirements where humans may interact with robot.Create a proof of concept for a process that may be adapted for production.Create thorough documentation for future students and design teams, including robot operation and programming tutorials.

SpecificationsCan be adapted to various nut plate assembly tasksDepth of rivets must be meet tolerance requirement of -0/+0.010 inchesMinimum distance of two rivet head diameters between rivets and part edgeNut plates must be clocked within 2 degrees of drawing specificationsNut plates must be within 0.030 inches of drawing specificationsAssembly requires minimal manual operations

Robotic Work Cell CapabilitiesDenso RobotVS-6577GM-B Six-axis articulated robotHigh speed and repeatability7 kg maximum payloadWINCAPS III softwareAllows programming of robot motions without operating the robotProvides a 3D simulation environment 3D objects from CAD may be imported for a more accurate simulationReal time robot movement can be monitored

Robotic Work Cell CapabilitiesUniversity of Idaho safety enclosureConstructed from 80/20 framing system and polycarbonate sheetseGard system Modular safety device which regulates external control and safety featuresEmergency stop with key lockSolenoid locking actuatorExternal program controlStep stopStartOperating lightProgram selector

Changes to Proposed ProcessPrimary goal is to move nut plate positioning and rivet setting process to the robot end effector.Uses an air hammer and bucking bar to set the rivets instead of a c-squeeze.Part will be placed in a fixture, which includes a stationary anvil and rivet feeding system.Robot picks and places nut plates, as well as setting the rivets.Expands the range of parts to which the process may be adapted.Simplified version of a two robot solution where the second robot can position and advance the bucking bar/rivet feed operation.

SetupUsing a robot to locate and drill holes is a well understood operation so our process will focus on the nut plate installation process. Since adding the capability to perform tool changes will add too much scope to the project, we will be performing the drilling operation outside of the work cell using our nut plate drill. Once the holes are drilled the part will be placed in a fixture that includes the combination rivet feed/bucking bar. Hole alignment will be performed manually. This fixture will be adjustable in order to demonstrate the process in non-horizontal orientations.

Proposed Process

Proposed ProcessOperator places partOperator opens the work cell door and places the part in the clamp.Operator makes sure that the part is in the correct orientation.Operator closes door for safety and to allow robot to function.Rivet feed and bucking bar

Proposed ProcessNut plate placement and rivet hammering

Operator moves part to new location

Rivet Feed AnvilRivets are pneumatically fedPlate slides to act as bucking bar for air hammerThickness of plate matches length of rivet so one rivet slides within the plate

Robot End Effector

Impact hammer is a place holder until final impact hammer is selected

Mounts will be modified once final impact hammer dimensions are obtained

Nut Plate GrabberSimulation of the interference fit between the grabber and the nut plate to confirm that the grabber design should not fail during normal operation

Nut Plate Dispenser

Gravity fedRails keep nut plates from over lappingAllows nut plate grabber to precisely seat nut plate by pushing it against the back wall

Part Frame

Operator manually clamps part into placeAble to adjust the angle of the part

Complete Work Cell

Complete Work Cell

Pneumatic SystemThe robot includes air lines for pneumatic control of the end effector, but we will require additional pneumatics to operate the rivet feed and actuate the anvil.Future teams will likely require additional actuation.

Robot DocumentationDocumentation package for future teams to get up to speed on robot operation and programming. There is a huge volume of documentation for the Denso robot, and it would be helpful to have a basic manual that includes all information necessary to start working with the robot.The documentation will have the following components:A quick start guide that runs through the process of starting up the robot and walks through the basics of manually operating the robot.A beginners programming guide with example code that breaks down syntax for clarity.A reference guide that can point future teams to the most important/useful section of the various robot documentation.

Project Timeline (Spring 2016)DeadlineEvent/MilestoneAdditional Deliverables2/1CAD Drawings of Work Cell/ComponentsMock part design, models, drafts completed2/19Logbook Due2/22Detailed Design Review3/8WINCAPS Program of Robot MotionsRobot motions coded based on current design. Major adjustments anticipated. 3/8Prototypes of Work Cell ComponentsFirst functional prototypes of work cell steps built and ready to test on individual basis3/8Design Revisions To Prototype ComponentsResults of prototype testing evaluated, prototype revisions considered and3/8Snapshot Day3/29Wiki Page Review4/10WINCAPS Programming CompleteAll robot motions completely coded. Further adjustments should be minor.4/10Final Work Cell BuiltAll work cell components installed, Final process may be evaluated4/20Evaluation of Process (Results of Testing)4/29Design Expo5/6Course Deliverables DueFinal hardware/software, Design Report/Project Portfolio, Wikipage, Project Poster, Work Area Checkout

DiscussionAre you satisfied with the solution we have presented?Are the process steps selected for our proof of concept appropriate?Air hammer/nut plate grabber end effector.Nut plate feed device.Anvil/rivet feeder. Are there any obvious pitfalls that you would like to point out?Thank you for your time.