References and bibliography

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1 References and bibliography ACARD (1979) Joining and Assembly: The Impact of Robots and Automation Her Majesty's Stationery Office, London. Aleksander, I.; Schlesinger, R.J. (1983) The International Robotics Yearbook Kogan Page, London. Atkinson, B.; Heywood, P. (1982) The Challenge of Vision British Robotic Systems Ltd, London. Ayres, R.U.; Miller, S.M. (1983) Robotics: Applications and Social Implications Ballinger, Cambridge, Massachusetts. Boothroyd, G.; Dewhurst, P. (1983) Design for Assembly: A Designer's Handbook University of Massachusetts. Coiffet, P. (series editor and consultant); Aleksander, I. (English language series consultant) ( ) Robot Technology (an eight-volume series plus index and bibliography) Kogan Page, London. Csakvary, T. (1981) Product Selection Procedure for Programmable Automatic Assembly Technique Proc. 2nd. Int. Conf. on Assembly Automation, Brighton, UK, pp Kehoe, E.J. (1984) Robotic workcell combines ultrasonic insertion and assembly operation, Robotics Today, pp 93-95, April. Kondoleon, A.S. (1976) Application of technology-economic model of assembly techniques and programmable assembly machine configurations. Master's thesis, Massachusetts Institute of Technology. Lundstrom, G.; Glemme, B.; Rooks, B.W. (1977) Industrial Robots-Gripper Review. IFS (Publications) Ltd, Kempston. Martensen, N.; Johansson, C. (1980) Subassembly of a Gearshaft by Industrial Robot, 10th Int. Symp. and 5th Int. Conf. on Industrial Robots, Milan, Italy, pp Naruki, K. (1981) How to Promote Automation in Japanese Industries Proc. 2nd Int. Conf. on Assembly Automation, Brighton, UK, pp Nevins, J.L.; Whitney, D.E. (1979) In Computer Vision and Sensor Based Robots (eds G.G.Todd and L.Rossell) pp , Plenum Press, New York. 199

2 Assembly with Robots Open University (UK) (1984) Three-volume Textbook for the Robotics Module of a Master Degree Course in Manufacturing Systems. Owen, A.E. (1982) Automated Assembly can Equate with Short Payback Periods. Proc. 3rd Int. Conf. on Assembly Automation, Stuttgart, West Germany, pp Owen, A.E. (1982) Chips in Industry. Economist Intelligence Unit, London. Owen, A.E. (1983) Designing for automated assembly, Engineering, June. Owen, A.E. (1984) Flexible Assembly Systems Plenum Press, New York. Owen, A.E. (1984) Guidelines to the selection of robots, The Industrial Robot I (II) pp PERA (1983) Robots: a further survey of robots and their current applications in industry, Report 377, Melton Mowbray, UK. Railbert, M.H.; Tanner, J.E. (1982) Design and implementation of a VLSI tactile sensing computer, The International Journal of Robotics Research Vol I No 3 pp Redford, A.; Swift, K. (1980) Salford University Industrial Centre Report, August. Rogers, P.F. (1978) A time and motion method for industrial robots, The Industrial Robot 5 (4) pp Scott, P.B. (1984) The Robotics Revolution Basil Blackwell, Oxford. Sutton, G.P. (1980) The many faces of productivity, Manufacturing Engineering 85 (6) pp UK Department of Industry (1977) Commitment for Terotechnology Life Cycle Costing in the Management of Assets: A Practical Guide. University of Nottingham (1982) Proceedings of one-day seminar on robot safety. 200

3 Appendix Assembly Robots Available in the USA and the UK (correct at time of printing) N Vendor Robot Basic Configuration Repeatability Programming Country of name cost style origin _- Adept Technology Inc Mountain View CA Adept One $40,000 (415) Meta Machines Ltd $49,650 Oxford OXI4 loy Adept One (priced in dollars) American Robot Corp Clinton PA Merlin $65,000 SCARA 0.05mm Offline USA l (412) Online Arm and elbow 0.025mm and USA Rediffusion Robot System offline Crawley RH 10 2PY Reflex 42, ASEA Inc Troy MI48084 IRb 1000 NIA (313) Novel Online gantry and O.IOmm (offline in Sweden ASEA Ltd pendulum future) Milton Keynes MKI3 9HA IRb ,

4 0 Vendor Robot Basic N Configuration Repeatability Programming Country of > name cost style origin '" 3 e:r Automatix Inc Billerica MA AID 600 $70,000 Cartesian 0.07mm Online and USA!. (617) offline :r Control Automation Inc CAR-2000 <:> e:r g Princeton NJ Mini- $40,000 Cartesian 0.02mm Online and USA '" (609) Sembler offline Fleximation Systems Corp Toshiba Burlingtun MA Tasman NIA (617) TSR 701H Evershed Robotics Ltd Toshiba Chertsey KTl6 8LJ Tasman c 20, TSR 70lH Online and SCARA 0.05mm offline Japan GCA Corp Industrial Naperville IL DKP200H $24,000 (312) DKP200V $30,000 Dainichi-Sykes Robotics Daros ( SCARA 0.05mm Online Japan Preston PR5 8AE PT200H N/A PT200V General Electric Company Bridgeport CT Model A12 NIA (203) ( Cartesian 0.025mm Online and Italy Fairey Automation Ltd DEA Varies on offline Swindon SN2 6HB Pragma number of arms A 3000 and grippers N

5 Vendor Robot Basic Configuration Repeatability Programming Country of name cost style origin GMF Robotics Corp Fanuc Troy MI48098 AOO NIA (313) AO NIA Al NIA 600 Fanuc Robotics Ltd Fanuc Colchester C02 8LE AOO 13, AO 18,400 Al 23,300 Hirata Corp of America $15,300 Indianapolis IND Armbase to (317) $21,300 Airstead Industrial AR-H250 17,500 Brighton BNI 4GH AR-H300 19, AR ,000 { Cylindrical 0.05mm Online Japan Online and SCARA 0.05mm offline Japan IBM Advanced Manufacturing 7535 NIA Systems 7540 NIA Boca Raton FL NIA / SCARA 0.05mm Online and Japan (305) NIA SCARA 0.05mm offline Japan SCARA 0.05mm Japan IBM UK Ltd ,000 Cartesian O.lOmm USA Croydon CR9 6HS , , ,000 > 'C 'C '" N 0 = w 5<'

6 0 Vendor Robot Basic Configuration Repeatability Programming Country of '".j:> name cost style origin.. '" r::1' Intelledex Inc 605S $48,000 I Corvallis OR T $48,000 (503) T $60,000 Approximate 0.025mm Online and USA "=' 0 r::1' Zehntel Ltd Intelledex Between arm and elbow offline Milton Keynes MK9 2NJ 605S 40, T and 705T 60,000 Machine Intelligence Corp Hitachi Sunnyvale CA A3020 NIA (408) GEC Robot Systems Ltd Hitachi Rugby CV21 IBU A3020 N/A SCARA 0.05mm Online Japan!. '" Micro Robotics Systems Lowell MA MR-Ol $40,000 (617) MR-03 $50,000 l Special 0.02mm Online Switzerland Concentric Production Microbro Cylindrical Sutton Cold field B72 1 RD MR-OI 25, MR-03 30,500 N

7 0 IV v. Vendor Robot Basic Configuration Repeatability Programming Country of name cost style origin Pental of America Ltd (see below for details of HR 26 and HR 63) Torrance CA HR26 $20,000 (213) HR63 $21,500 Sale Tilney Technology Pental Weybridge KTl5 2RH HR26 18,000 SCARA 0.05mm Online and HR 63 21,300 SCARA 0.05mm offline Japan Type 3 18,000 SCARA 0.05mm Type 4 21,300 SCARA 0.05mm Unimation Inc I Puma Shelter Rock CT NIA (203) $41, $41, $47, $60,000 Unimate Series 100 NIA Unimation (Europe) Ltd Puma Telford TF3 3AX ,750 Arm and elbow 0.05mm Online USA Arm and elbow 0.05mm and and Arm and elbow O.lOmm offline UK Arm and elbow O.lOmm Arm and elbow 0.20mm SCARA 0.025mm USA , , , ,000 Unimate Series 100 > "CI N/A "CI.. = Q. ;,'

8 '" Vendor Robot Basic Configuration Repeatability Programming Country of name cost style origin United States Robots King of Prussia PA Maker 100 $40,000 Arm and elbow 0.05mm Online and (215) offline USA British Olivetti Ltd Sigma Milton Keynes Series 3 N/A Gantry O.IOmm Online Italy John Brown Automation Wickman Coventry CV3 2NY W500 15,500 Cylindrical 0.05mm Online UK VS Remek Ltd Milton Keynes MK2 3HY PAM 2 15,000 Cartesian 0.05mm Online UK These robots are included for completeness only, to indicate the total Puma range. n Some manufacture and assembly of these robots is done in the UK. The amount of UK centered fundamental design work is unknown to the author. Please note that no inference is intended to be drawn from either inclusion or exclusion of robots or vendors in this appendix. The dynamics of the robotic market mean that both products and vendors are entering and leaving the scene at a rapid rate. Consequently, any list only represents a 'snapshot' in time of the members of the assembly robots' fraternity. Please note also that the italicized vendors are American. The UK vendors are shown beneath in normal type. ;I> '" '" 3 <:r 1; := Q <:r S. '" N 0

9 Index accuracy, specification of, 40, 42 active compliance, 61 adhesive grippers, 64 adhesives, 78, 83, 124 airjet sensors, 132, 133 alternative systems, Amprobe case study, 84 anthropomorphic hands, 63, 64, 184 appraisal of project, arm and elbow configuration, robot, 25,26,33, 188 array sensors, 136 ASEA, 73,189,191,193 assembly, base, classification, 89 definition, II fixed and flexible, 177 labour cost, II, 173, line balancing, 110 manual, 11, 88, 159, means of, II process, 78 et seq related tasks, 17, 24, robot, 12, sequence, 92 signature, 139 system, flexible, 145 integrated, 109 task analysis, tasks, 11, 14 techniques, 79 asymmetry, 100 audio sensor, 139 automated guided vehicles (AGVs), automatic inspection, automation, flexible, 16, 17 hard, 15-17, , 195 autoscrewdriver, 85, 86, 96, 119 axis limits, 30, 31 balancing multirobot system, base assembly, 89, 92 benefits of robotic assembly, 158, 174 bin picking, 137 bowl feeders, 73, 74, 97,104,108,117, 118, 133 caged robot, 150 Cam Gears case study, 70, 71 capacitance sensors, 132 cartesian configuration, robot, 24, 26, 30, 108, 188 case study - Amprobe, 84, 174, 175 Cam Gears, 70, 71 DEA, 121, 122 Hirata, Nippondenso, Toshiba, 72-5 census, problems with, 20, 23 clamping, magnetic, 63 mechanical, 62 vacuum, 63 collision sensor, 150 committing of assembly, 107 compliance, active, 61 remote centre (RCC), 61 component feeder, in situ manufacture, 123, 124 orientation, 106 placing of, 105 presentation, 17 rate of presentation, 102 specification, 96 symmetry of, 99, 100 variation in, 99 compressor valve case study, 121, 122 computer controlled gripper, 57-9 configuration of robot, construction of product, 89 modular, 89, 93 consumable materials, 124, 125 controlled shutdown, 149 conveyors, 125, 126 coordinate entry, 36,

10 Assembly with Robots cosmetic damage, 122 cost groups, fixed, 165 hidden, 153, 165, 166 labour, 159, 160, 180 of assembly, 102, 159, 170, 171 of gripper, 69, of multiple systems, 183 of robot, 33,180-83,194 costing, life cycle, 156, 157 cycle time, 34, 42-53, 71, 75, , 178, 179, 185 calculation of, intermediate method, 44-6 most exact method, simple method, 43 cylindrical configuration, robot, 24-6, 30,31, 189 damage, cosmetic, 122 functional, 138 DEA case study, 54, 122, 130 definition, robot, 15 design, criteria, 87, 88 for assembly, 12, for automation, 12 of gripper, 64-6 principles, diode array, 130, 136 double armed robot, 29, 37, 70, 72, 183 downstream element, 116 drive through programming, 35, 36 economic justification, economics of alternative systems, of grippers, of robot, of scale, 124 efficiency, human, 146 emergency stop, 149 end effector, error, geometric, 60 expansion/contraction gripper, 63 Fairey Automation, 70, 130 FAS layout, 107, 145, 146 fastener groups, fasteners, 78, 194 feeder problems, feeders, 74, 75, 96, automatic, 117 bowl, 73, 74, 97,104,108,117, 118, 133 gravity, 74, 120, 121 feeding, consumable materials, 124 delicate items, 121 fibre optic sensors, 55, 131, 133 financial equation, finger grippers, 55, 56, 63 fixed cost, 165 flexibility, 15, 16, constraints of, 17 flexible assembly systems, 145 flexible automation, 16, 17 flexible systems, 16 frame construction, 89, 90 functionability, 87, 138, 139 functional damage, 138 future of robot assembly, long-term, 195 short-term, 192 GADFLY, 191, 192 gantry configuration, robot, 24, 26, 27, 188 General Electric, 130 geometric error, 60 gravity feeders, 74, 120, 121 gripper, 17,39,54,77,129-31, 183-i action, 61-4 adhesive, 64 changes, time for, 56, 71, 75, 77, classification, 67, 69 computer controlled, 57-9 cost, design, 64 et seq discrete, 75 economics, 180 et seq expansion/contraction, 63 finger, 55, 56, 57, 63 intelligent, 12, 56, 57, 60, 66, 67, 129, 130 interchangeable, 76 multiple, 70, 71 et seq, 181 piercing, 63 reconfiguration of, 57 sensor control, 66, 67 sophisticated, 55 types of, 61-4 guided vehicles, automatic (AGVs), 126 half-task, 45 hand, anthropomorphic, 43, 63, 64, 184 hard automation, 15-17, , 195 hidden cost, 153, 165, 166 Hirata robot, IBM, 28, 54, 130, 190 idle time, 111, 113, 115 implementation, 116 indices, 161,

11 Index inductive sensors, 132 inspection, automatic, 138 at workstation, 138, 174 online, real-time, , 174 intangible factors, cost, 14, 166 integrated assembly system, 109 integrated circuits, 105 interaction, man-machine, 141 et seq interchangeable grippers, 75-7 interlocks, 109, 142, 150 jigging, 142, 144 justification, use of robots, kitting of parts, 123, 127 labour costs, 159, 160, 180 Lanco, laser welding, 83 layout of FAS, 107, 145, 146 lead through programming, 35 life cycle costing, 156, 157 product, 16 line balancing, lingua robotica, 168 maintenance, 18, 147, 148, 150 Maker robot, 84, 85 manipulator, primitive, 12 manpower savings, 142, 159 man-robot mix, 13, 27, 108, 109, 141-6, 159, 160 manual assembly, 11,88,159,161-4 manufacture in situ, 123, 124 market, for robots, 17-23, market dynamics, , 193, 194 material control, 127 feeders, 27, 73-7,182-6 material for gripper, 66 matrix sensors, 131, 132 Microbo, 28, 29, 36, 189, 195 minimization of items, 92, modular construction, 89, 93 multiarmed robot, 29, 70, 72, 183, 184 multigripper,71 multiple gripper, 70-77, multiple robot, 70, 71, 182, 184 multirobot, balancing system, nesting, 102, 104 Nippondenso case study, nonservoed robots, 30-33, 38, 39, 41, 72 offline programming, 34, 37, 39, 40, 142, 194 online programming, 35-7 online real-time inspection, , 174 optical sensors, 55, 131, 133 orientation of component, 106 outcome of assembly task, 60 output rate, 108, 146, 174 PAM, 28, 34, 188 parallel jaws, 62, 63 parts, kitting of, 123, 127 tree, passive compliance, 61, 62 payback period, 155 payload, 33, 34, 39 PCB populating by robot, 72 permanent fastener, 79, 81 pick and place robots, 30-33, 38, 39, 41,72 picking, bin, 137 piercing gripper, 62, 63 pixels, 136 pneumatic sensors, 131-3, 138 polar configuration, robot ',,, PRAGMA, 28, 33, 54, 70, 71 precedence diagram, 92, 114 prepackaged material control, 127, 128 price of robots, 15; 18, 180, 181, 189, 190, 194 prime cost, 153 primitive manipulator, 12 product, compatibility, 88 construction, 84 design, , 192 design rules, life cycle, 16 productivity indices, 161, 162 programming, 34-7, 39, 142, 143, 148, 194 drive through, 35, 36 offline, 34, 37, 39,40, 142, 192 online, 35-7 proposal, 167, 168 proximity sensors, 131,132 Prutec, 29, 37 pseudo intelligence, 12 psychological problems, 143, 144 PUMA, 26, 27, 32 quality, 15,98,146,152,153,174 cosmetic, 87, 122 vendor responsibility, 128 remote centre compliance (RCC), 61 robot arm, economics, 183 and automation, 15 availability, 17 capability,

12 Assembly with Robots configuration, choice of, 24 et seq polar coordinates, 20-23, 24 cost per hour, 159 customized, 16 cycle time, 43 et seq definition, 15 double armed, 29, 37, 70, 72, 183 economics, 180 et seq gantry configuration, 24, 26, 27, 188 line, balancing, 114 manipulator arm, 70 multiple, 70 nonservoed, 30-33, 38, 39, 41, 72 payload, 19, 20, 23 population, 39 programming, 34-9 reliability, 17 repeatability and accuracy, 40 specification, 39 et seq task time, 40 use, 21-2 viability, 18 safety, 13,87,108,109,113,141, devices, 149 procedures, 149 zone, 13, 149 salvage cost, 16 SCARA, 24, 26-9, 109, 133, 134 sealant dispensing by robot, 83, 84, 124 segmented cost, selective assembly, 98, 142 semi-permanent fasteners, 79, 81 sensing, 12, 54, 67, 68, , 194 sensor, airjet, 132, 133 array, 136 audio, 139 capacitance, 132 classification, 131 collision, 150 inductive, 132 matrix, 131, 132 optical, 55, 131, 133 pneumatic, 131-3, 138 proximity, 132 selection of, 137 tactile, 131 vision, 135 sensory control of gripper, 66-8, 129, 130 shingling, 104, 105 shutdown, controlled, 149 snap signature, 139 specification, robot, speed control in assembly, 115 stacked construction, 89, 91 stand-alone workstation, 108 stops, hard, multiple, 31 strategic justification, robot, 157, 158, 192 stud welding by robot, 84, 85 symmetry, need in components, 99 tactical justification, use of robot, 157, 158, 192 tactile sensors, 55, 131, 132 tangible factors, cost, 14, 166 tangling, 102, 103 task, 17,23,24, 78, 80, 138 assembly, 14 performance, 14 times, calculation, 40, 43, 53 technical parameter, 33 telescoping, 104 time of action, 33 Toshiba case study, 72-5 Tosman,72 transportation system, 125, 126, 128 tray, 128 two state sensors, 132 ultrasonic welding by robot, 84 unidirectional assembly, 105 Unimate, 12, 13 Unimation, 12, 13 upstream elements, line, 116 usage, manufacturing site of, 123 vacuum gripper, 12,62,63 variable cost, 165, 166 variation, minimization of, 99, 101 velocity, 32-4,41,48,49, 191, 193 vision, 129 et seq profile, 49 vision in gripper, 54, 55, 57, 58, 67, 68, 130 vision systems, 12, VS Engineering, 12 VS Remek, 28, 34, 188 welding, are, 83 gun, 83 laser, 83 stud, 84-5 ultrasonic, 84 work envelope, 17,27,148,149 ethics, 106 load, 50-3 plane, 26 workstation, 53,

13 Index cost, 182, 183 inspection, knowledge of, 130 layout in FMS, 145 stand-alone, 108 with feeders, 120, 121 YES-MAN, 29, 37,

Assembly. with Robots. Tony Owen. Kogan. Page

Assembly. with Robots. Tony Owen. Kogan. Page Assembly with Robots Assembly with Robots Tony Owen &\ Kogan Page First published in 1985 by Kogan Page Ltd 120 Pentonville Road, London NI 9JN Copyright 1985 Tony Owen Softcover reprint of the hardcover