industrial robotics - uniroma1.itdeluca/rob1_en/01_industrialrobots.pdf · world robotics 2017...
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Robotics 1
Industrial Robotics
Prof. Alessandro De Luca
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What is a robot?n industrial definition (RIA = Robotic Institute of America)
re-programmable multi-functional manipulatordesigned to move materials, parts, tools, or specialized devices through variable programmed motions for the performance of a variety of tasks,
which also acquire information from the environmentand move intelligently in response
n ISO 8373:2012 definitionan automatically controlled, reprogrammable, multipurpose manipulator
programmable in three or more axes, which may be either fixed in place or mobile for use in industrial automation applications
n more “visionary” definitionintelligent connection between perception and action
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Robots !!
Waseda WAM-8 (1984)
Comau H4 (1995)
Spirit Rover(2002)
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A bit of history
n Robota (= “work” in slavic languages) are artificial human-like creatures built for being inexpensive workers in the theater play Rossum’s Universal Robots (R.U.R.) writtenby Karel Capek in 1920
n Laws of Robotics by Isaac Asimov in I, Robot (1950)1. A robot may not injure a human being or, through inaction, allow a
human being to come to harm2. A robot must obey orders given to it by human beings, except
where such orders would conflict with the First Law3. A robot must protect its own existence as long as such protection
does not conflict with the First or Second Law
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Evolution toward industrial robots
n with respect to the ancestorsn flexibility of usen adaptability to a priori unknown conditionsn accuracy in positioningn repeatability of operation
computer numerically controlled
(CNC) machines
mechanicaltelemanipulators
1950
robotmanipulators
1970Unimation PUMA
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The first industrial robot
G. Devol and J. Engelberger (Unimation)
US Patent General Motor plant, 1961
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Historical pictures and clips
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bimanual remote manipulation at Oak Ridge Nat’l Labs Unimate 6-dof robots
video
video
Robot manipulators
ASEA IRB-6(1973)
first robotall-electric-drives
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Hirata AR-300(1978)
first SCARArobot
CincinnatiMilacron T3
(1974)first micro-computer controlled
robot
UnimationPUMA 560
(1979)6R with
human-likedexterity
robots – a 50-year journeyrobotics research up to 2000
Video compiled for the IEEE ICRA 2000 conference, S. FranciscoRobotics 1 9
World Robotics 2020
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n total worldwide stock at end 2019: 2.7 million units of operational industrial robots (+12% w.r.t. 2018, +13% CAGR since 2014)
n new robot sales in 2019: ~373K (-12%, 3rd highest ever, +11% CAGR since 2014)n robot market value in 2019: $13.8 billion (without software and peripherals)n robotic systems market value: ~4 times as muchn China expanded further as the largest market since 2013, now with a 38% sharen 73% of new robot installations in 5 countries: China, Japan, USA, Korea, Germany
executive summary for 2020 statistics by IFR
issued yearly in late September(for back issues since 2007,
check course web site)
Compound Annual Growth Rate: CAGR = &'()&*'+,(
-//0123− 1
Technology & application trends in service robotics
Page 30 | 24 Sept 2020
Important markets to watch out:• Unbroken scale-up of logistic systems (AGV, AMR)• Mergers & acquisitions activities, e.g. in medical robotics• Heavy construction machinery become robotized allowing multi-machine operation by one
single person• Information interaction (telepresence, advisory); >30 new disinfection robot models in 2020• Covid-19 raised attention on healthcare robots Major Technology Accelerators • Cloud technologies and 5G: e.g., remote procedures using surgical robots and 5G in China• Business models like Robot-as-a-Service lower the entrance level, especially in new markets• Standardization & “platformization”: e.g. for peripherals (app store), sales platform, plug& play
Diffusionindustrial robots in operation worldwide
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(as reference, industrial robots in 1973 = 3K, 1983 = 66K, 1993 = 575K, 2003 = 800K) length of robot service life is estimated in 12-15 years
preview in 2020: ~3M robots in operation
Diffusionindustrial robots in operation by world area
Robotics 1 12preview in 2020: almost 1M robots operating in China!
Diffusionrobots in industrial sectors
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70% of robots are deployed in three main industries
Diffusionrobots by main applications
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almost 70% of robots are used for material handling or welding
Annual supplynew industrial robots worldwide
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year of highest everselling of new robots
stop of growth rate in 2019: automotive transition, trade & political headwindspreview in 2020: deferred investments, plummeted consumer demand, travel restrictions,
disrupted supply chains (due also to Covid-19)medium term preview: crisis will be a digitalization booster creating growth opportunities
for robotics industry worldwide
Annual supplynew robots by industrial sectors
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the two major industries struggled in 2019 (especially in Asia)
Annual supplynew installations in top markets (countries)
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China well ahead, with 5 markets accounting for 73% of total supply
Italy (2nd EU market): double as many new robots installed as in 2015
Density of robots
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number of robots per 10000 employeesin the manufacturing industry
almost doubled in last 5 years!
Collaborative robots
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a small but steady growing market in the industrial setting
Industrial & service robots
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Industrial robots§ automatically controlled, programmable, multipurpose, 3+ axes § for use in industrial automation applications § equipped with application-specific end-effectors Service robots§ perform tasks excluding industrial automation § usually application-specific design, often fewer than 3 axes § sometimes not fully autonomous but remote-controlled
different customers, pricing, machinery, distribution channels, suppliers
… but separationline is blurring:
same unit can actas both, dependingon the application
Personal/domestic service robotsdata (2018-19) and forecast*
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vacuuming and floor cleaning: true tasks for robotssteady growth of turnover expected
10 billions $ value*
1,9 billions $ value*
5,7 billions $ value (+20%)
Professional service robotsdata (2018-19) and forecast*
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robots (AGV, AMR) in logistics are still the growth driversEurope is the main supplier of service robots (with many young start-ups!)
Industrial robotand its auxiliary equipments
1. Comau SMART H robot 2. C3G Plus controller3. Welding control box4. Application software5. Air/water supply 6. SWIM Board 7. Integrated cables8. Welding gun9. Auxiliary devices in the
robotic cell(servo-controlled axes)
SWIM = Spot Welding Integrated Module
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ABB IRB 7600
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commercial video by ABB
Industrial applications• manipulation (pick-and-place, handling,
machine feeding)• assembly and packaging• spray painting and coating (nozzles)• arc welding or spot welding (with
pneumatic or servo-controlled guns)• laser cutting and welding• gluing and sealing• mechanical machining operations
(milling, drilling, deburring, grinding, …)
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video
A day in the life of an industrial robot• At BMW car production line with ABB robots
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videovideo
pick-and-placewith end-effectorto reorient part
pick-and-placewith support
to reorient part
A day in the life of an industrial robot
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videovideo
pick-and-placeheavy parts and
human intervention
metal cuttingon a supporting
machine with dofs(video speeded up
at some point)
A day in the life of an industrial robot
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videovideo
glue deposit(on fancy paths!)
cooperation ofmultiple robotsfor handling and inspecting/sealing
a car body
A day in the life of an industrial robot
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videovideo
coating partsfor rust and corrosion
protection
spray painting
A day in the life of an industrial robot
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videovideo
hood deburringwith a suspended tool
test measurementswith assembly on a AGV
What a robot should do and what cannot do
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video
spray paintingvery unhealthy
for human operators
assembly of flexibleor complex parts
(here a car dashboard)
videoyet
⇒ human-robot collaboration(co-bots or co-workers)
Plasma cutting
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video
small KUKA robot used for plasma cutting of a stainless steel toilet(courtesy of Engenious Solutions Pty)
electrode
nozzle
hot plasma
gaschamber
Robotized workcells
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3D simulation of robotic tasks
• analysis of operative cycle times• off-line programming and optimization• layout design and collision checking• 3D graphic simulation
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Welding - 1
• spot with servo-controlled gun • stud welding
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Welding - 2
• spot (discrete) or arc (continuous)
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Two cooperating robots in arc welding
ABB video at Laxa, Sweden
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Palletizing
pallet = a portable platform on which goods can be moved, stacked, and stored
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Palletizing of cheese forms
using Kawasaki robots (courtesy of Effedue Engineering)
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video
Folding
with loading of sheets under the press
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Deburring
• car windshields may have large manufacturing tolerances and a sharp contour profile
• the robot follows a given predefined Cartesian path
• the contact force between cutting blade and glass must be feedback controlled
• deburring robot head mounts a force load cell and is pneumatically actuated
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Deburring center
deburring center for steel partsusing Comau SMART NJ 110-3.0/foundry robot (courtesy of Adami srl)
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video
Off-line robot workstation
articulated robot in metal surface finishing operation
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Safety in robotic cells
commercial video from ABBSafeMove (2008) cell monitoring system: no fences!
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Robot manipulator kinematics
ComauSmart H4
closed kinematic chain
Kuka 150_2 S2000open kinematic chain(series of rigid bodies connected by joints)
FanucF-200iB
parallel kinematics
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SCARA-type robots
SCARA (Selective Compliant Arm for Robotic Assembly)
• 4 degrees of freedom (= joints): 3 revolute + 1 prismatic (vertical) axes • compliant in horizontal plane for micro-assembly and pick-and-place
Mitsubishi RP(repeatability 5 micron,
payload 5 kg)
Mitsubishi RH(workspace 850 mm,
velocity 5 m/s)Bosch Turbo
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Adept Cobra i600
fastest SCARA robot for pick-and-place tasks!
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video
Other types of robots
Comau Mastgantry robot
(payload up to 560 kg)
ABB Flexpicker(150 pick-and-place operations/minute)
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Chocolate packaging withlightweight parallel robots
test video withABB Flexpicker
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video withAdept Quatro s650
Distribution by robot type
for 59600 articulated robots installed back in 2004(90% of all robots installed in America, 74% in Europe, only 49% in Asia)
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of kinematic configuration
Robot data sheet
Fanuc R-2000i/165F
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Workspace
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Visualization of workspace and mobility
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kinematic simulation of a 6-dof Comau robot (all revolute joints)
video
Visualization of workspace and mobility
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V-REP simulation of the 7-dof KUKA LWR4+ robot (all revolute joints)
video
Robot end-effector sensors and tools
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Calibration of robot kinematics
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Man-machine interface
• teach-box pendant used as robot programminginterface
• cabinet with power electronicsfor robot supervision and control
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Programming and control environment
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control modulesand interfaces(Reis Robotics)
Motion programming and scaling
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commercial video from ABBTrueMove & QuickMove fast motion control performance
Mobile base robots in industry
• AGV (Automated Guidance Vehicles) for material and parts transferon the factory floor: wire- or laser-driven along predefined paths
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Lifting AGV for warehouses
video by Elettric80
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Kiva Systems
company acquired in 2012 for $775 million by Amazon (store automation)
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Intelligent AGV in factories
commercial video of ADAM mobile robot (RMT Robotics)
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What’s next in industrial robotics?
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changing nature of manufacturing and work
n shift from high volume/low mix to low volume/high mix is having a profound impact on manufacturing
n many industries are facing acute shortages of skilled laborn quicker return-of-investment (ROI) of automation and rising
wages are eventually discouraging labour arbitragen increased focus is being placed on workplace safety
Source: Steven Wyatt (IFR). “Today’s trends, tomorrow’s robots!” Frankfurt, 27 September 2017
What’s next in industrial robotics?
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addressing some real facts opens huge opportunities
answers to these challenges lie in Simplification, Digitalisation, and Collaboration
What’s next in industrial robotics?
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Simplification (critical for SME, but also for large global manufacturers)n robots easier to install, program (with open source) and operate will unlock entry
barriers to the large market of small and medium enterprises (SMEs)n trend towards having production closer to the end consumer is driving the
importance of standardisation & consistency across global brandsDigitalisation (Big Data allows taking better decisions on factory operations)n “Industry 4.0”, linking the real-life factory with a virtual/digital one, will play an
increasingly important role in global manufacturingn vision and sensing devices, coupled with analytics platforms, will pave the way
for new industry business modelsn IoT/AI/Machine Learning will drive many robotics developments in coming yearsCollaborationn collaborative robots are shifting the traditional limits of “what can be automated?” n collaborative robots increase manufacturing flexibility as ‘low-volume, high-mix’
becomes the main standardn collaboration is also about productivity with increased physical and cognitive
human/robot interaction
What’s next in industrial robotics?
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“connected” future of robotics
connected and collaborative robots will enable SMART Manufacturing for both SMEs & Global Enterprises
n robots doing the same task connect across all global locations so performance can be easily compared and improved
self-optimizing production
n robots automatically download what they need to get started from a cloud library and then optimize through “self-learning”
self-programming robots
Franka Emika robot
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... one possible example (dated 2016) video