ROBOTICS
A Brief Overview Report submitted by
Minkul Tekwani , Muzammil Shadab MSRIT,Bangalore
ABB Robotics
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ABB, formerly ASEA Brown Boveri, is a SwissSwedish multinational corporation headquartered in Zürich, Switzerland, operating mainly in the power and automation technology areas. ABB is one of the largest engineering companies as well as one of the largest conglomerate companies in the world. ABB has operations in around 100 countries, with approximately 115,000 employees (2008).
ABB can be broadly divided into 5 divisions • • • • •
Power Products Power Systems Automation Products Process Automation Robotics
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Robotics Division ABB has one of the world's largest installed bases of industrial robots also providing robot software, peripheral equipment and modular manufacturing cells. ABB's robots are provided for tasks such as thermal spraying (plasma, HVOF), welding, assembly, painting and finishing, picking, packing, palletizing and machine tending. Key markets include automotive, plastics, metal, foundry, packaging, material handling, and food & beverage industries. In 2006 ABB's global robotics headquarters moved to Shanghai, China and in 2007 ABB added a manufacturing unit for industrial robots in China serving the local market.
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Reasons to invest in robots
Reduce operating costs Improve product quality and consistency Improve quality of work for employees Increase production output rates Increase product manufacturing flexibility Reduce material waste and increase yield Comply with safety rules and improve workplace health & safety Reduce labour turnover and difficulty of recruiting workers Reduce capital costs (inventory, work in progress) Save space in high value manufacturing areas
Major Applications of ABB Industrial Robots Automotive Packaging & Palletizing Metal Fabrication Production of Plastics Foundry and Forging Welding(Arc, Spot,Laser) ABB Robotics
Drilling Riveting Fettling Machine Tending Pick and Place Material Handling Page 4
Painting Mechnical cutting Polishing
Measurement Filling Food Processing
Competitors of ABB Robots USA – IBM, General Electric, PUMA Axera European – BOSCH KUKA NOKIA Japanese – Fanuc, Nachi, Motoman ,Toshiba
Comparison between Robots and Humans
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Robot Terminology • • • • • • • • • • • •
Number of Axes, Degrees of freedom, Working Envelope, Kinematics, Carrying Capacity or Payload, Speed, Acceleration, Accuracy, Repeatability, Motion Control Power Source, Drive, Compliance,
Types Of Robots
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Cartesian or gantry robot : Cartesian robots have three linear joints that use the Cartesian coordinate system (X, Y, and Z). They also may have an attached wrist to allow for rotational movement. The three prismatic joints deliver a linear motion along the axis. Cylindrical robot : The robot has at least one rotary joint at the base and at least one prismatic joint to connect the links. The rotary joint uses a rotational motion along the joint axis, while the prismatic joint moves in a linear motion. Spherical Robot : The robot whose arm has two rotary joints and one prismatic joint and whose axes form a polar coordinate system
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SCARA: Commonly used in assembly application, this selectively compliant arm assembly is primarily cylindrical in design. It features two parallel joints that provide compliance in one selected plane. Articulate: All joints are revolute. Most industrial robots are of this type. Parallel Link: example Stewart’s platform, spider from Adept
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The main components of the Industrial Robot manufactured by ABB are • Manipulator • Micro Controller • ToolTip/End Effector/Gripper • Flex Pendant
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Major Components of Manipulator
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Shaft
Cut Through View of Tabular
Axes 1,2 and 3 are the main axes ABB Robotics
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Axes 4,5 and 6 are the wrist axes
Important Features 6 Axis Manipulator with 6 degrees of freedom Generally only 6 axes are present in Industrial Robots, this is because 6 axes manipulators are the most efficient and widely used all over the industry. ➢
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AC Servo Motors are used in the manipulators • Permanently magnetized AC servo motors • High voltage type (400-480V AC) from IRB 66X0/7600 • Low voltage type (262V AC) for small and medium sized robots • Higher voltage -> higher RPM for given current to get more power • If low voltage: larger drive units with higher currents
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➢
The tubular shaft doesn’t fall under its own weight. When the mains are switched off the brakes are actuated and this prevents the falling of manipulators and keeps them in a stable positon
Health and safety policy To provide a healthy and safe working environment at all sites and facilities and to take adequate steps to prevent accidents and injury to health arising from the course of work by minimizing, so far as is reasonably practicable, the causes of hazards inherent in the working environment. Eight health and safety "expectations" support the policy and comprise the framework of the health and safety culture we are pursuing in ABB. 1. Leadership and accountability - clearly defined responsibilities, resources, and accountability for managers. 2. Managing health and safety risks - at every stage of project, service or manufacturing life cycle, where meeting national and international standards is the minimum requirement. 3. Demonstrating health and safety competence so that all managers, employees, safety advisors and contractors know their responsibilities and have the training and experience to carry them out. 4. Ensuring safe contractors and business partners by selecting contractors and suppliers that perform to ABB’s health and safety requirements. 5. Ensuring health and safety is integrated into the processes for managing change, both globally and locally. ABB Robotics
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6. Ensuring a crisis and emergency management system is in place. 7. Ensuring accident analysis and prevention is in place. 8. Routine review of health and safety performance by managers, supported by a reporting process.
Future Of Robotics 2008: 6.5 million robots in operation world-wide Japan has the highest robot density In 2011 more than 18 million robots will populate the world At the end of 2008 about 1.5 million industrial robots and 5.5 million service robots were worldwide operating in factories, in dangerous or tedious environment, in hospitals, in private houses, in public buildings, underwater, underground, on fields, in the air, in the space – robots are everywhere! Up to the end of 2011 more than 17 million service robots and 1.2 million industrial robots will populate the world, reports the IFR Statistical Department in the new study “World Robotics 2008”, which was published on Wednesday in Frankfurt. Future of Industrial robots – technical trends and customer trends The main customer – the automotive industry – is changing. Significant growth in unit sales of cars can only be realised in the growing markets of India, Southeast Asia, Russia and other Eastern European countries. In these countries, demand is mainly for small and lowcost cars. In the mature car markets of Western Europe, North America, Japan and the Rep. of Korea, growth in value of turnover is only possible as a result of improvements in technology. Furthermore, demand for small, economical and low-cost cars as well as for environmentally-friendly cars is becoming increasingly important also in these markets. Alternative drive systems are gaining in importance given the rising price of fuel. Palletizing, packaging, picking and placing has gained rapidly in importance over the past three years in Europe. Automation in the food and beverage industry– the principal industry for this application – is very high in Europe. The Americas lag far behind with automation in this sector. Labour is still cheap in many regions in Asia, therefore the degree of automation is still not as high as in Europe. Installations of industrial robots continue to grow between 2008 – 2011 The world market for industrial robots is projected to increase by 4% from 114,365 units in 2007 to 118,900 in 2008. From 2009, it will rise by a yearly average of 4.1% to 134,100 in 2011. In 2008, Europe will be up by 6% to a new peak level. North America will be down slightly by 1%, while Brazil will continue to grow substantially. Total Americas will stagnate at a high level. Demand in China, India, ASEAN, Central/Eastern Europe and South America will again increase at an above-trend rate. Robot supplies will stagnate in Japan, while in the Republic of Korea growth of about 8% can be expected. Total Asia/Australia will grow by 6%. ABB Robotics
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Projections for the period 2008-2011: about 12.1 million units of service robots for personal use to be sold It is projected that sales of all types of domestic robots (vacuum cleaning, lawn-mowing, window cleaning and other types) could reach over 4.6 million units in the period 2008-2011, with an estimated value of US$3.3 billion. The size of the market for toy robots and hobby systems is forecast at about 4 million units, most of which, of course, are very low-priced. About 3.2 million robots for education and training are expected to be sold in the period 2008-2011. Sales of all types of entertainment and leisure robots are projected at well beyond 7.3 million units, with a value of about US$1.8billion.
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