Intro to Robotics 110

Transcription

1 Intro to Robotics 110 Wecome to the Tooing University. This course is designed to be used in conjunction with the onine version of this cass. The onine version can be found at We offer high quaity web -based e -earning that focuses on today's industria manufacturing training needs. We deiver superior training content over the Internet using text, photos, video, audio, and iustrations. Our courses contain "ro -up -your -seeves" content that offers rea -word soutions on subjects such as Meta Cutting, Workhoding, Materias, and CNC with much more to foow. Today's businesses face the chaenge of maintaining a trained workforce. Companies must ocate apprenticeship programs, cover trave and odging expenses, and disrupt operations to cover training needs. Our web -based training offers ow -cost, a -access courses and services to maximize your training initiatives. Cass Outine Objectives What Is a Robot? The History of Robotics The Industria Appications of Robots Basic Robot Components The Parts of a Robot s Body Arm-Shaped Robots Robot Coordinate Systems Robotic Arm Configuration Mobie Robots Robots and Artificia Inteigence Robot Teaching Methods Robot Safety Trends in Industria Robotics Copyrightin Robotics 2009 Tooing U, LLC. A Rights Reserved. Careers The Pros and Cons of Robots Summary

2 Cass Outine Objectives What Is a Robot? The History of Robotics The Industria Appications of Robots Basic Robot Components The Parts of a Robot s Body Arm-Shaped Robots Robot Coordinate Systems Robotic Arm Configuration Mobie Robots Robots and Artificia Inteigence Robot Teaching Methods Robot Safety Trends in Industria Robotics Careers in Robotics The Pros and Cons of Robots Summary Lesson: 1/17 Objectives Define a robot. Describe the history of industria robotics. Describe the industria appications of robots. Describe the basic components of a robot. Describe the different parts of a robot s body. Describe robotic arms. Describe the coordinate systems used to program a robot s movement. Distinguish between different robotic arm configurations. Describe mobie robots. Describe artificia inteigence for robots. Distinguish between different robot teaching methods. Describe safety precautions for working with robots. Describe present and future trends in industria robotics. Describe careers in robotics. List the advantages and disadvantages of using robots. Copyright 2009 Tooing U, LLC. A Rights Reserved. Figure 1. Robots can have different coordinates depending on the point of origin.

3 Lesson: 1/17 Objectives Define a robot. Describe the history of industria robotics. Describe the industria appications of robots. Describe the basic components of a robot. Describe the different parts of a robot s body. Describe robotic arms. Describe the coordinate systems used to program a robot s movement. Distinguish between different robotic arm configurations. Describe mobie robots. Describe artificia inteigence for robots. Distinguish between different robot teaching methods. Describe safety precautions for working with robots. Describe present and future trends in industria robotics. Describe careers in robotics. List the advantages and disadvantages of using robots. Figure 1. Robots can have different coordinates depending on the point of origin. Figure 2. In ead-through programming, the trainer uses a remote teach pendant to program the robot. Lesson: 2/17 What Is a Robot? Peope have been fascinated by the idea of automated machines for centuries. Devices propeed by water and steam were created as eary as 350 B.C.E. Throughout history scientists and inventors became increasingy interested in creating machines that coud dupicate human anatomy and movement. This eventuay gave rise to the modern industria robot. An industria robot is a programmabe mechanica device used in pace of a person to perform dangerous or repetitive tasks with a high degree of accuracy. Not a programmabe machines are robots, however. The aser weding machine in Figure 1 Copyright 2009a Tooing U, LLC. AVCR Rights Reserved. is a robot, but programmabe is not. A robot must be abe to move on its own, sense information about its environment, and use that information to accompish a programmed task. Robots can change their behavior in response to

4 Lesson: 2/17 What Is a Robot? Peope have been fascinated by the idea of automated machines for centuries. Devices propeed by water and steam were created as eary as 350 B.C.E. Throughout history scientists and inventors became increasingy interested in creating machines that coud dupicate human anatomy and movement. This eventuay gave rise to the modern industria robot. An industria robot is a programmabe mechanica device used in pace of a person to perform dangerous or repetitive tasks with a high degree of accuracy. Not a programmabe machines are robots, however. The aser weding machine in Figure 1 is a robot, but a programmabe VCR is not. A robot must be abe to move on its own, sense information about its environment, and use that information to accompish a programmed task. Robots can change their behavior in response to their environment whie automated machines simpy foow instructions. Robots can be arge or sma and they come in many shapes. They are capabe of ifting very heavy objects and performing repetitive tasks for ong periods of time without stopping. Figure 2 shows a machine tending robot. In this cass you wi earn the cassifications, characteristics, and functions of industria robots. You wi aso earn basic safety precautions for working with robots. Figure 1. This arc weding robot moves on its own and uses a vision sensor to accompish its task. [Courtesy of Kawasaki Robotics (USA), Inc.] Figure 2. This machine tending robot can work for many hours without getting bored or tired. [Courtesy of Kawasaki Robotics (USA), Inc.] Lesson: 3/17 The History of Robotics Industria robots were first used in the 1960s. U.S. companies were ooking for cheap abor, and robotics was a potentia soution. However, eary robots were buky, sow, and inefficient. The amount of human effort required to keep the robots running canceed out any cost advantage that the robots provided. In the end, manufacturers reaized that robots coud never fuy repace peope. Instead, robots simpy became another part of factory technoogy. The weding robots in Figure 1 are very good at their job, but they do not have the fexibiity and inteigence of a human worker. The use of industria robots increased significanty after stepper motors became smaer and stronger and AC servomotors became more affordabe. These deveopments, aong with the use of transistors and integrated circuits, improved the productivity of robots. Copyright 2009 Tooing U, LLC. A Rights Reserved. Today s robots are extremey smart and versatie. In the miitary, panes known as unmanned aeria vehices (UAVs) can fy without an onboard piot. Robots are aso Figure 1. Robots are an important part of factory technoogy, but they wi never fuy repace peope.

5 Lesson: 3/17 The History of Robotics Industria robots were first used in the 1960s. U.S. companies were ooking for cheap abor, and robotics was a potentia soution. However, eary robots were buky, sow, and inefficient. The amount of human effort required to keep the robots running canceed out any cost advantage that the robots provided. In the end, manufacturers reaized that robots coud never fuy repace peope. Instead, robots simpy became another part of factory technoogy. The weding robots in Figure 1 are very good at their job, but they do not have the fexibiity and inteigence of a human worker. The use of industria robots increased significanty after stepper motors became smaer and stronger and AC servomotors became more affordabe. These deveopments, aong with the use of transistors and integrated circuits, improved the productivity of robots. Today s robots are extremey smart and versatie. In the miitary, panes known as unmanned aeria vehices (UAVs) can fy without an onboard piot. Robots are aso used for exporation. NASA makes extensive use of sma robotic vehices, ike the rover in Figure 2, to expore other panets. Figure 1. Robots are an important part of factory technoogy, but they wi never fuy repace peope. Figure 2. NASA uses mobie robots ike this Mars rover to expore other panets. Lesson: 4/17 The Industria Appications of Robots In industry, robots perform a wide variety of tasks. They are often used to hande materias that are extremey hot or heavy. For exampe, robots are used to remove a waste product caed dross from moten meta baths. A skimmer fu of dross can weigh up to 33 bs (72.2 kg). In addition, meta baths can reach temperatures that exceed 800 F (426 C). For a human, skimming dross woud be a hot, exhausting, and potentiay dangerous job. But a robot can perform this work quicky and easiy without being harmed. One of the most common industria appications for robots is weding, shown in Figure 1. Robots are idea for weding because of their high speed, the uniform quaity of their and abiity toreserved. repeat tasks without wearing out. The Copyright 2009work, Tooing U, their LLC. A Rights automotive industry is one of the argest users of robotic weders. Spray painting, shown in Figure 2, is another common use for robots. The highy

6 Lesson: 4/17 The Industria Appications of Robots In industry, robots perform a wide variety of tasks. They are often used to hande materias that are extremey hot or heavy. For exampe, robots are used to remove a waste product caed dross from moten meta baths. A skimmer fu of dross can weigh up to 33 bs (72.2 kg). In addition, meta baths can reach temperatures that exceed 800 F (426 C). For a human, skimming dross woud be a hot, exhausting, and potentiay dangerous job. But a robot can perform this work quicky and easiy without being harmed. One of the most common industria appications for robots is weding, shown in Figure 1. Robots are idea for weding because of their high speed, the uniform quaity of their work, and their abiity to repeat tasks without wearing out. The automotive industry is one of the argest users of robotic weders. Spray painting, shown in Figure 2, is another common use for robots. The highy repetitive motions required in spray painting are we-suited to robots. Robots can paint quicky and efficienty with neary perfect quaity. Because of their speed and efficiency, robots aso use ess paint. Figure 1. Weding is a common industria robot appication. [Courtesy of Kawasaki Robotics (USA), Inc.] The newspaper industry makes extensive use of robots for a type of materias handing caed paetizing. The robots oad and unoad stacks of newspapers onto movabe patforms caed paets. Other industria uses for robots incude packaging, part transfer, pick and pace, machine oading, materia remova, and assemby. An assemby robot is shown in Figure 3. Robots are aso an idea resource for working with integrated circuits in a cean room. ICs are extremey sensitive to dust and dirt and other types of debris. Because robots have no skin, hair, or breath, they do not contaminate the cean room environment. Figure 2. This spray painting robot works quicky and efficienty with neary perfect quaity. [Courtesy of Kawasaki Robotics (USA), Inc.] Figure 3. An assemby robot. [Courtesy of Kawasaki Robotics (USA), Inc.] Copyright 2009 Tooing U, LLC. A Rights Reserved.

7 Lesson: 5/17 Basic Robot Components Figure 1 iustrates the basic components that make up an industria robot. These components are the power suppy, controer, teach pendant, axis contro modue, input/output modues, and mechanica body. The main power suppy to the robot is AC run through a transformer. This main power suppy provides votage and current to the robot's motor. The motor can be servo or non-servo. Servomotors, ike the one in Figure 2, are used for appications such as pick and pace that require the robot to move to a precise ocation. In addition to the main power suppy, there are separate power suppies to the robot that can be ocated in a cabinet, shown in Figure 3, or in a power suppy unit (PSU). The PSU provides DC votage to the robot's outputs and controer. Robots can be aso be powered by batteries, soar panes, springs, hydrauics, and pneumatics. However, most industria robots use a pug-in power suppy. In order to run its program and interface with inputs and outputs, a robot must have a controer. The controer can be ocated in a cabinet that is externa to the robot, or it can be a microcontroer (MCU) inside the robot. A hand-hed remote contro caed a teach pendant is connected to the controer and is used to program the robot. Teach pendants are connected to the controer by a cabe. The axis contro modue, which is aso connected to the controer, aows the robot to move through the coordinates specified by its program. The axis contro modue aso contros the speed at which the robot's body moves. Figure 1. An industria robot is composed of a power suppy, controer, axis contro modue, and mechanica body. Figure 2. Servomotors are used for robotic appications that require precise positioning. Copyright 2009 Tooing U, LLC. A Rights Reserved.

8 Figure 3. A cabinet hoding the controer and teach pendant. [Courtesy of Kawasaki Robotics (USA), Inc.] Lesson: 6/17 The Parts of a Robot s Body A robot s body consists of different mechanica parts that are typicay made from some type of meta or aoy such as stee, cast iron, or auminum. For a robotic arm, the body parts can incude a base, shouder, ebow, arm, wrist, and even fingers. Figure 1 shows a basic robotic arm. Links and joints within the robotic arm aow the robot to move in different directions. An end-of-arm too (EOAT), aso known as the end-effector, is attached to the end joint of the arm. End-effectors can be shaped ike hands, ike the one in Figure 2, or they can be highy speciaized toos, ike the grinder in Figure 3. Hand-shaped effectors are caed grippers. Grippers come in many shapes and sizes. Toos aso come in a wide variety and are designed for specific tasks such as weding or grinding. Effectors are activated in response to signas that the robot sends and receives through an input/output modue. Input signas from sensors on or near the robot provide information about its surroundings. Output signas are then sent to the robotic arm to activate the work too. Figure 1. A robotic arm typicay incudes a base, shouder, arm, and end-effector. Figure 2. A gripper is an end-effector that is shaped ike a hand. Copyright 2009 Tooing U, LLC. A Rights Reserved.

9 Lesson: 6/17 The Parts of a Robot s Body A robot s body consists of different mechanica parts that are typicay made from some type of meta or aoy such as stee, cast iron, or auminum. For a robotic arm, the body parts can incude a base, shouder, ebow, arm, wrist, and even fingers. Figure 1 shows a basic robotic arm. Links and joints within the robotic arm aow the robot to move in different directions. An end-of-arm too (EOAT), aso known as the end-effector, is attached to the end joint of the arm. End-effectors can be shaped ike hands, ike the one in Figure 2, or they can be highy speciaized toos, ike the grinder in Figure 3. Hand-shaped effectors are caed grippers. Grippers come in many shapes and sizes. Toos aso come in a wide variety and are designed for specific tasks such as weding or grinding. Effectors are activated in response to signas that the robot sends and receives through an input/output modue. Input signas from sensors on or near the robot provide information about its surroundings. Output signas are then sent to the robotic arm to activate the work too. Figure 1. A robotic arm typicay incudes a base, shouder, arm, and end-effector. Figure 2. A gripper is an end-effector that is shaped ike a hand. Figure 3. This robot is using an end-of-arm too that is specificay for grinding. Lesson: 7/17 Copyright 2009 Tooing U, LLC. A Rights Reserved. Arm-Shaped Robots

10 Lesson: 7/17 Arm-Shaped Robots There are two major casses of robots: fixed robotic arms and mobie robotic vehices. The robotic arm in Figure 1 is aso known as a manipuator. A manipuator resembes a human arm with a shouder, ebow, wrist, and fingers. The manipuator is generay mounted on a patform or suspended from a track whie the arm reaches to various distances and ocations. The joints on a robotic arm can move in different directions aong particuar axes. An axis is an imaginary ine or circe aong which a robotic component can move. The axes of a robotic joint can aow movement side-to-side, up and down, in and out, or in a circe. Coectivey these axes represent the robot's degrees of freedom. Robotic arms have two basic types of joints. Prismatic joints, aso known as inear joints, side in a straight ine across one axis. A revoute joint, on the other hand, gives a robotic arm a wide range of movement. Revoute joints rotate amost excusivey around one axis ike a shaft in a bearing. To make a singe joint rotate around more than one axis requires a ba-and-socket type of bearing and drive. This is hard to buid, has accuracy and wear issues, and is difficut to drive. The robot in Figure 2 has two prismatic joints and one revoute joint. Figure 1. A robotic arm is generay mounted on a patform from which it reaches to various distances and ocations. Figure 2. Prismatic joints side in a straight ine across one axis whie revoute joints rotate around an axis. Lesson: 8/17 Robot Coordinate Systems In order to te a robot where to move, an operator must be famiiar with the Cartesian coordinate system. The Cartesian coordinate system defines the ocation of a singe point in three-dimensiona space using three axes. The X-axis, Y-axis, and Z-axis join together ike the corner of a box. The point where a the axes meet is the origin. The X and Y axes are horizonta, with one axis going in and out, and one axis going side-to-side. The Z axis goes up and down. An effective way to picture the three Cartesian axes is by using the right-hand rue. Pace your hand on a tabe or a bench. Turn your right pam up, and then extend ony the thumb and forefinger. This forms an "L," with the midde finger up to the ceiing, as shown in Figure 1. The thumb is the X-axis, the forefinger is the Y-axis, and the eevated center finger is the Z-axis. The positions of a robot are referenced according to different coordinate systems. The coordinate vary on the point of origin. Word coordinates Copyright 2009systems Tooing U, LLC.depending A Rights Reserved. use the robot s mounting base as a point of origin, as shown in Figure 2. Too coordinates use the too at the end of the robot s arm as the point of origin. Too coordinates are used for teaching the robot where to move. With too coordinates,

11 Lesson: 8/17 Robot Coordinate Systems In order to te a robot where to move, an operator must be famiiar with the Cartesian coordinate system. The Cartesian coordinate system defines the ocation of a singe point in three-dimensiona space using three axes. The X-axis, Y-axis, and Z-axis join together ike the corner of a box. The point where a the axes meet is the origin. The X and Y axes are horizonta, with one axis going in and out, and one axis going side-to-side. The Z axis goes up and down. An effective way to picture the three Cartesian axes is by using the right-hand rue. Pace your hand on a tabe or a bench. Turn your right pam up, and then extend ony the thumb and forefinger. This forms an "L," with the midde finger up to the ceiing, as shown in Figure 1. The thumb is the X-axis, the forefinger is the Y-axis, and the eevated center finger is the Z-axis. The positions of a robot are referenced according to different coordinate systems. The coordinate systems vary depending on the point of origin. Word coordinates use the robot s mounting base as a point of origin, as shown in Figure 2. Too coordinates use the too at the end of the robot s arm as the point of origin. Too coordinates are used for teaching the robot where to move. With too coordinates, the X, Y, and Z axes are set from the too s point of view. Figure 1. Using the right-hand rue, the thumb is the X-axis, the forefinger is the Y-axis, and the eevated center finger is the Z-axis Figure 2. A robot can have different sets of coordinates. Lesson: 9/17 Robotic Arm Configuration Robotic arms come in a variety of styes. Articuated robots, ike the one iustrated in Figure 1, most cosey resembe a human arm. The arm of an articuated robot has revoute joints, and the number of joints can vary. Articuated robots are very good at picking up sma objects. Copyright 2009 Tooing U, LLC. A Rights Reserved. A Cartesian robot, shown in Figure 2, has prismatic joints ony. The inear movement of the joints gives the Cartesian robot a highy rigid structure that aows

12 Lesson: 9/17 Robotic Arm Configuration Robotic arms come in a variety of styes. Articuated robots, ike the one iustrated in Figure 1, most cosey resembe a human arm. The arm of an articuated robot has revoute joints, and the number of joints can vary. Articuated robots are very good at picking up sma objects. A Cartesian robot, shown in Figure 2, has prismatic joints ony. The inear movement of the joints gives the Cartesian robot a highy rigid structure that aows it to ift heavy objects. Cartesian robots are aso extremey precise because of the accuracy and arrangements of the prismatic bearings. Cartesian robots can move through X, Y, and Z axes. The ength of each axis can be adjusted depending on the appication. Cartesian robots are used for assemby and injection moding appications. Cyindrica robots have a combination of revoute and prismatic joints that aow them to work we in round workspaces. Spherica robots, on the other hand, have a joint configuration that aows the robot to move in a desired direction and then extend to reach an object. Figure 3 shows a spherica robot. Spherica robots are used for weding and materia handing. A typica spherica robot has 4 to 6 revoute joints. Figure 1. An articuated robot has revoute joints ony. SCARA robots are a type of cyindrica robot. SCARA stands for Seective Compiance Arm for Robotic Assemby. The SCARA robot iustrated in Figure 4 has four axes of movement. It can move through X, Y, Z coordinates and a fourth Theta Z coordinate. Theta Z is a rotating axis that corresponds to the ange around the zaxis of the too at the end of the SCARA robot. SCARA robots are often used for inserting eectronic components into circuit boards. SCARA robots generay have three parae revoute joints and two parae prismatic joints that are both in the Z direction. Figure 2. A Cartesian robot has prismatic joints ony. Figure 3. This spherica robot can turn around on its base and reach for an object. Copyright 2009 Tooing U, LLC. A Rights Reserved. Figure 4. SCARA robots can move through X, Y, Z coordinates and a fourth Theta Z coordinate

13 Figure 4. SCARA robots can move through X, Y, Z coordinates and a fourth Theta Z coordinate corresponding to the end-effector. Lesson: 10/17 Mobie Robots The robotic arm is the most common type of industria robot. However, there is a second type of industria robot known as the automatic guided vehice (AGV). Unike a robotic arm, an AGV can move freey about the workspace. Instead of having a driver for navigation, the AGV uses ight refectors, coored tape, or wires that are embedded in the foor to guide it through a predetermined route. There are four types of AGVs: Tow vehices, aso known as tuggers (Figure 1), pu traiers oaded with materia. Tow vehices are capabe of puing extremey heavy oads, some weighing up to 60,000 bs. (27,215 kg). Tow vehices do not oad the materias; they simpy transport them. Unit oad carriers (Figure 2) have powered decks that ift and ower to transport paets oaded with materia. Cart vehices (Figure 3) are sma, reativey inexpensive AGVs that can oad materia ike a unit oad carrier or pu it ike a tow vehice. However, cart vehices are usuay imited to oads of no more than 2,000 bs. (907 kg). Fork vehices (Figure 4) ift and ower materias. Their oad capacity can range from 1,200 to 5,000 bs. (544 to 2,267 kg). Forks are avaiabe in different styes other than the standard dua fork. Figure 1. A tow vehice is capabe of puing extremey heavy oads. AGVs are extremey fexibe in the distance and direction that they can move. You can find AGVs in automotive, printing, chemica, medica and pharmaceutica, food and beverage, distribution, paper, manufacturing, and warehousing appications. Figure 2. A unit oad carrier has powered decks that ift and ower. Copyright 2009 Tooing U, LLC. A Rights Reserved.

14 Lesson: 10/17 Mobie Robots The robotic arm is the most common type of industria robot. However, there is a second type of industria robot known as the automatic guided vehice (AGV). Unike a robotic arm, an AGV can move freey about the workspace. Instead of having a driver for navigation, the AGV uses ight refectors, coored tape, or wires that are embedded in the foor to guide it through a predetermined route. There are four types of AGVs: Tow vehices, aso known as tuggers (Figure 1), pu traiers oaded with materia. Tow vehices are capabe of puing extremey heavy oads, some weighing up to 60,000 bs. (27,215 kg). Tow vehices do not oad the materias; they simpy transport them. Unit oad carriers (Figure 2) have powered decks that ift and ower to transport paets oaded with materia. Cart vehices (Figure 3) are sma, reativey inexpensive AGVs that can oad materia ike a unit oad carrier or pu it ike a tow vehice. However, cart vehices are usuay imited to oads of no more than 2,000 bs. (907 kg). Fork vehices (Figure 4) ift and ower materias. Their oad capacity can range from 1,200 to 5,000 bs. (544 to 2,267 kg). Forks are avaiabe in different styes other than the standard dua fork. Figure 1. A tow vehice is capabe of puing extremey heavy oads. AGVs are extremey fexibe in the distance and direction that they can move. You can find AGVs in automotive, printing, chemica, medica and pharmaceutica, food and beverage, distribution, paper, manufacturing, and warehousing appications. Figure 2. A unit oad carrier has powered decks that ift and ower. Figure 3. A cart vehice cannot pu oads greater than 2,000 bs. (907 kg). Copyright 2009 Tooing U, LLC. A Rights Reserved.

15 Figure 4. Fork vehices primariy ift and ower materias. Lesson: 11/17 Robots and Artificia Inteigence In order to be considered a robot, a machine must have some form of artificia inteigence. Artificia inteigence is simpy a computer software program that contains behavior rues, as shown in Figure 1. These rues te the robot how to act as it earns how to perform its job. For exampe, a robot coud be programmed to move toward a ight source when ight is detected by its photosensors. Or it coud be programmed to move away from any objects that come into contact with the robot s feeers. Figure 2 shows how a robot earns to adjust its path after coiding with an object. Like human inteigence, an artificia inteigence program contros different eves of behavior. The owest, most primitive eve of artificia inteigence simpy aows the robot to move its mechanica parts. The next eve contros the robot s refexes so it can respond to its environment and make decisions based on the information detected by its sensors. The highest eve of artificia inteigence is devoted to the robot s memory and probem-soving abiities. Figure 1. Artificia inteigence is simpy a computer software program. [Courtesy of Kawasaki Robotics (USA), Inc.] Copyright 2009 Tooing U, LLC. A Rights Reserved.

16 Lesson: 11/17 Robots and Artificia Inteigence In order to be considered a robot, a machine must have some form of artificia inteigence. Artificia inteigence is simpy a computer software program that contains behavior rues, as shown in Figure 1. These rues te the robot how to act as it earns how to perform its job. For exampe, a robot coud be programmed to move toward a ight source when ight is detected by its photosensors. Or it coud be programmed to move away from any objects that come into contact with the robot s feeers. Figure 2 shows how a robot earns to adjust its path after coiding with an object. Like human inteigence, an artificia inteigence program contros different eves of behavior. The owest, most primitive eve of artificia inteigence simpy aows the robot to move its mechanica parts. The next eve contros the robot s refexes so it can respond to its environment and make decisions based on the information detected by its sensors. The highest eve of artificia inteigence is devoted to the robot s memory and probem-soving abiities. Figure 1. Artificia inteigence is simpy a computer software program. [Courtesy of Kawasaki Robotics (USA), Inc.] Figure 2. After coiding with an object, this robot earns to adjust its path. (Courtesy of Kawasaki Robotics (USA), Inc.) Copyright 2009 Tooing U, LLC. A Rights Reserved.

17 Lesson: 12/17 Robot Teaching Methods Like a human worker, a robot must be trained to do its job correcty. Whie it is possibe for some robots to simpy earn on their own by tria and error, most robots are taught by humans. The three main methods for teaching robots are ead-through programming, wak-through programming, and off-ine programming. In ead-through programming, shown in Figure 1, the robot is paced in "teach mode" whie the trainer uses a remote teach pendant to manipuate the robot through the different steps of the job. This is the most common programming method. The robot is moved manuay via the teach pendant, which contros the robot axes. In wak-through programming, shown in Figure 2, the trainer physicay moves the robot through different steps of the job process. The robot earns which positions it must move through, and which functions it must perform. Because it invoves physica contact with the robot, wak-through programming is done inside the work enveope of the robot. This is extremey hazardous. To ensure worker safety, the robot must be paced in manua mode. In manua mode a robot cannot move uness the trainer hods down a pushbutton. Figure 1. In ead-through programming the trainer uses a remote teach pendant to program the robot. Lead-through and wak-through teaching methods are considered onine. They require the robot to remain "on" in order to earn. Off-ine programming, shown in Figure 3, aows the trainer to work from a remote ocation. The trainer writes a program and downoads it into the robot. From there, the program can be refined with eadthrough or wak-through programming. Figure 2. In wak-through programming the trainer physicay moves the robot through different steps of the job process. Figure 3. In offine programming a trainer writes a program from a remote ocation and downoads it into the robot. Copyright 2009 Tooing U, LLC. A Rights Reserved.

18 into the robot. Lesson: 13/17 Robot Safety Industria robots can be extremey fast and strong. When robot accidents occur, they can resut in serious injury, oss of imb, and even the death of a worker. Never enter the robot s work enveope uness it is absoutey necessary. The work enveope or work ce is the defined area of space through which a robot can move. A worker within the robot s work enveope can be struck by the robot or crushed between equipment, as shown in Figure 1. Even if you are famiiar with the work pattern of the robot, do not assume that you can predict its movements. Changes to the robot s program, program errors, and equipment mafunctions can cause sudden, unpredictabe movements by the robot. If you must be inside the robot s work enveope for instaation, programming, or maintenance, use a ockout/tagout key ike the one in Figure 2 to prevent the robot from starting up. Aways read the robot s user manua and make sure you are famiiar with the manufacturer s safety guideines. In addition, aways wear persona protective equipment (PPE) such as a hard hat, safety gasses, and stee-toed boots. Figure 1. Within a robot s work enveope, a worker is in danger of being struck or crushed. Workers must be trained and supervised in the operation, maintenance, and emergency procedures of the robot. Workers shoud earn and compy with the guideines from the Occupationa Safety and Heath Administration (OSHA), the Nationa Institute for Occupationa Safety and Heath (NIOSH), and the American Nationa Standards Institute (ANSI). Safety devices such as security gates, pressure mats, aarms, and emergency stop circuitry shoud be instaed near the robot as we. Figure 3 shows a robot secured behind a safety fence. Figure 2. Use a ockout/tagout key whenever you are inside the robot s work enveope. Copyright 2009 Tooing U, LLC. A Rights Reserved. Figure 3. Insta safety devices near the robot to protect workers. [Courtesy of Kawasaki Robotics (USA), Inc.]

19 Lesson: 13/17 Robot Safety Industria robots can be extremey fast and strong. When robot accidents occur, they can resut in serious injury, oss of imb, and even the death of a worker. Never enter the robot s work enveope uness it is absoutey necessary. The work enveope or work ce is the defined area of space through which a robot can move. A worker within the robot s work enveope can be struck by the robot or crushed between equipment, as shown in Figure 1. Even if you are famiiar with the work pattern of the robot, do not assume that you can predict its movements. Changes to the robot s program, program errors, and equipment mafunctions can cause sudden, unpredictabe movements by the robot. If you must be inside the robot s work enveope for instaation, programming, or maintenance, use a ockout/tagout key ike the one in Figure 2 to prevent the robot from starting up. Aways read the robot s user manua and make sure you are famiiar with the manufacturer s safety guideines. In addition, aways wear persona protective equipment (PPE) such as a hard hat, safety gasses, and stee-toed boots. Figure 1. Within a robot s work enveope, a worker is in danger of being struck or crushed. Workers must be trained and supervised in the operation, maintenance, and emergency procedures of the robot. Workers shoud earn and compy with the guideines from the Occupationa Safety and Heath Administration (OSHA), the Nationa Institute for Occupationa Safety and Heath (NIOSH), and the American Nationa Standards Institute (ANSI). Safety devices such as security gates, pressure mats, aarms, and emergency stop circuitry shoud be instaed near the robot as we. Figure 3 shows a robot secured behind a safety fence. Figure 2. Use a ockout/tagout key whenever you are inside the robot s work enveope. Figure 3. Insta safety devices near the robot to protect workers. [Courtesy of Kawasaki Robotics (USA), Inc.] Copyright 2009 Tooing U, LLC. A Rights Reserved.

20 (USA), Inc.] Lesson: 14/17 Trends in Industria Robotics For the past severa years, saes of industria robots have risen steadiy. It is ikey that the use of robots in industry wi continue to increase. In addition to various manufacturing industries, the miitary is aso expected to increase its use of robots. One of the most important deveopments in robot technoogy is the addition of vision to the robot s abiities. Sensors and cameras on the robot aow it to see its environment, as shown in Figure 1. When couped with the memory provided by a computer, vision aows the robot to find specific objects and features to determine their position. This aows the robot to pick randomy positioned and oriented objects. As continuing advancements are made in deveoping artificia inteigence, there wi be more opportunities for robots to assist peope. New types of robots may be deveoped for persona use. Figure 2 shows a robot that can perform the simpe househod chore of vacuuming. Someday, having your own robot may be as common as having a ceuar phone. Figure 1. The addition of vision sensors, such as cameras, is an important deveopment in robot technoogy. Figure 2. This Roomba vacuum ceaner runs without an operator. (Courtesy of Larry D. Moore) Lesson: 15/17 Careers in Robotics As the use of robots increases in manufacturing, there wi aso be an increased need for robot technicians to maintain the robots. Robot technicians may be required by an empoyer to earn at east a two-year degree in robotics, engineering, or computer science. Copyright 2009 Tooing U, LLC. A Rights Reserved. Some of the day-to-day tasks performed by a robot technician incude: Assisting the robot engineer in designing end-of-arm toos and accessory equipment

21 Lesson: 14/17 Trends in Industria Robotics For the past severa years, saes of industria robots have risen steadiy. It is ikey that the use of robots in industry wi continue to increase. In addition to various manufacturing industries, the miitary is aso expected to increase its use of robots. One of the most important deveopments in robot technoogy is the addition of vision to the robot s abiities. Sensors and cameras on the robot aow it to see its environment, as shown in Figure 1. When couped with the memory provided by a computer, vision aows the robot to find specific objects and features to determine their position. This aows the robot to pick randomy positioned and oriented objects. As continuing advancements are made in deveoping artificia inteigence, there wi be more opportunities for robots to assist peope. New types of robots may be deveoped for persona use. Figure 2 shows a robot that can perform the simpe househod chore of vacuuming. Someday, having your own robot may be as common as having a ceuar phone. Figure 1. The addition of vision sensors, such as cameras, is an important deveopment in robot technoogy. Figure 2. This Roomba vacuum ceaner runs without an operator. (Courtesy of Larry D. Moore) Lesson: 15/17 Careers in Robotics As the use of robots increases in manufacturing, there wi aso be an increased need for robot technicians to maintain the robots. Robot technicians may be required by an empoyer to earn at east a two-year degree in robotics, engineering, or computer science. Some of the day-to-day tasks performed by a robot technician incude: Assisting the robot engineer in designing end-of-arm toos and accessory equipment Copyright 2009 Tooing U, LLC. A Rights Reserved. for specific tasks. Inspecting eectronic components and other robot parts for defects.

22 Lesson: 15/17 Careers in Robotics As the use of robots increases in manufacturing, there wi aso be an increased need for robot technicians to maintain the robots. Robot technicians may be required by an empoyer to earn at east a two-year degree in robotics, engineering, or computer science. Some of the day-to-day tasks performed by a robot technician incude: Assisting the robot engineer in designing end-of-arm toos and accessory equipment for specific tasks. Inspecting eectronic components and other robot parts for defects. Instaing and testing the robot. Instaing safety systems for the robot. Training robot operators, troubeshooting probems, and providing technica support. Disassembing the robot for service and repair. Figure 1. The working conditions for a robot technician can vary. The working conditions for a robot technician can vary. A technician may be required to trave to different ocations. He or she may work on the robot in a cean, quiet test ab, ike the one in Figure 1, or in a dirty, noisy factory. If there is a probem with the robot or there is an instaation deadine, the technician may be required to work overtime. Lesson: 16/17 The Pros and Cons of Robots Robots improve worker safety by reieving workers from dangerous and tedious jobs, as shown in Figure 1. For exampe, robots reieve workers from handing harsh chemicas or radioactive parts. They can aso hep to prevent repetitive motion injuries by performing repetitive tasks. The growth of robotics means that there wi be a greater demand for workers who can operate and maintain robots. Robots aso provide economic advantages to empoyers. Robots do not take sick days or vacation days, and they never get tired. They can work 24 hours a day without stopping. In addition, robots can repeat a task many times without varying the quaity or consistency of the work. This reduces waste, increases productivity, and improves product quaity. Moreover expenses associated with defective parts and workers compensation caims are eiminated when robots do the work. Despite the many benefits of using robots in the workpace, there are some disadvantages to using robots. In past studies, the Bureau of Labor and Statistics predicted that increased automation in the workpace coud ead workers to fee stressed, oney, and ike they ost of contro of the process. Moreover, instaing robots to perform menia tasks does not aways mean that human workers are advanced to higher-functioning tasks. Sometimes workers are merey shifted to a different ow-ski task. The cost of buying and instaing a robot ike the one in Figure 2 can be very high. There is an initia investment in support technoogy for the robot, and the robot itsef can cost $200,000 or more. It takes time to program and troubeshoot a robot after it has been instaed. In addition, workers must be trained to operate and maintain the robot. Copyright 2009 Tooing U, LLC. A Rights Reserved. Figure 1. This robot can stack containers on a paet a day without getting bored, tired, or injured. [Courtesy of Kawasaki Robotics (USA), Inc.]

23 Lesson: 16/17 The Pros and Cons of Robots Robots improve worker safety by reieving workers from dangerous and tedious jobs, as shown in Figure 1. For exampe, robots reieve workers from handing harsh chemicas or radioactive parts. They can aso hep to prevent repetitive motion injuries by performing repetitive tasks. The growth of robotics means that there wi be a greater demand for workers who can operate and maintain robots. Robots aso provide economic advantages to empoyers. Robots do not take sick days or vacation days, and they never get tired. They can work 24 hours a day without stopping. In addition, robots can repeat a task many times without varying the quaity or consistency of the work. This reduces waste, increases productivity, and improves product quaity. Moreover expenses associated with defective parts and workers compensation caims are eiminated when robots do the work. Despite the many benefits of using robots in the workpace, there are some disadvantages to using robots. In past studies, the Bureau of Labor and Statistics predicted that increased automation in the workpace coud ead workers to fee stressed, oney, and ike they ost of contro of the process. Moreover, instaing robots to perform menia tasks does not aways mean that human workers are advanced to higher-functioning tasks. Sometimes workers are merey shifted to a different ow-ski task. Figure 1. This robot can stack containers on a paet a day without getting bored, tired, or injured. [Courtesy of Kawasaki Robotics (USA), Inc.] The cost of buying and instaing a robot ike the one in Figure 2 can be very high. There is an initia investment in support technoogy for the robot, and the robot itsef can cost $200,000 or more. It takes time to program and troubeshoot a robot after it has been instaed. In addition, workers must be trained to operate and maintain the robot. Figure 2. The initia cost of instaing this pastic moding robot may be very high. [Courtesy of Kawasaki Robotics (USA), Inc.] Lesson: 17/17 Summary An industria robot is a programmabe mechanica device used in pace of a person to perform dangerous or repetitive tasks. Industria robots were first used in the 1960s. One of the most common industria appications for robots today is weding. The basic components of a robot are the power suppy, controer, teach pendant, axis contro modue, input/output modues, and mechanica body. A robot s body consists of 2009 Tooing LLC.wrist, A Rights acopyright base, shouder, ebow,u,arm, andreserved. an end-of-arm-too. Robots use different coordinate systems to determine where to move. The Cartesian coordinate system defines the ocation of a singe point in three-dimensiona space using X, Y, and Z axes.

24 Lesson: 17/17 Summary An industria robot is a programmabe mechanica device used in pace of a person to perform dangerous or repetitive tasks. Industria robots were first used in the 1960s. One of the most common industria appications for robots today is weding. The basic components of a robot are the power suppy, controer, teach pendant, axis contro modue, input/output modues, and mechanica body. A robot s body consists of a base, shouder, ebow, arm, wrist, and an end-of-arm-too. Robots use different coordinate systems to determine where to move. The Cartesian coordinate system defines the ocation of a singe point in three-dimensiona space using X, Y, and Z axes. Word coordinates have the robot s mounting base as a point of origin. Too coordinates have the too at the end of the robot s arm as the point of origin. Robotic arms come in different styes. Articuated robots cosey resembe a human arm. Cartesian robots have prismatic joints ony. Cyindrica robots have a combination of revoute and prismatic joints that aow them to work we in round workspaces. Spherica robots have a joint configuration that aows the robot to move in a desired direction and then extend to reach an object. SCARA robots can move through X, Y, Z coordinates and a fourth Theta Z coordinate. Automatic guided vehices can move freey about the workspace. Tow vehices pu traiers oaded with materia. Unit oad carriers have powered decks that ift and ower to transport paets oaded with materia. Cart vehices can oad materia ike a unit oad carrier or pu it ike a tow vehice. Fork vehices ift and ower materias. Artificia inteigence is a computer software program that contains behavior rues for robots. Robots are trained to do their jobs through different programming methods. In ead-through programming the trainer uses a teach pendant to program the robot. In wak-through programming, the trainer physicay moves the robot through the job process. In off-ine programming the trainer writes a program remotey and downoads it into the robot. Figure 1. An industria robot is composed of a power suppy, controer, axis contro modue, and mechanica body. Robot accidents can resut in serious injury and even the death of a worker. Therefore, workers must earn the proper operation, maintenance, and emergency procedures of the robot. Figure 2. A robotic arm typicay incude a base, shouder, arm, and end-effector. Figure 3. Robot accidents can resut in serious injury and even the death of a worker. Copyright 2009 Tooing U, LLC. A Rights Reserved. Cass Vocabuary Term Definition aoy A uniform mixture of two or more materias, one of which must be a meta. Industria robots are usuay

25 Cass Vocabuary Term Definition aoy A uniform mixture of two or more materias, one of which must be a meta. Industria robots are usuay composed of aoys. American Nationa Standards An organization that oversees industry standards for commercia products and services. ANSI provides Institute guideines for manufacturing, instaing, and safeguarding robotic systems. articuated robot A type of robotic arm that cosey resembes a human arm. The arm of an articuated robot has revoute joints and the number of joints can vary. artificia inteigence A computer software program that contains behavior rues for robots. Artificia inteigence is one of the characteristics that distinguishes robots from other programmabe machines. assemby The process of fitting components together into a arger or competed part. automatic guided vehice An industria robot that can move freey about the workspace. AGVs can take the form of carts, forkifts, or tow vehices. axes The pura of axis. An axis is an imaginary straight ine or circe used to describe the ocation or movement of an object in the Cartesian coordinate system. axis contro modue A component that aows a robot to move in different directions. The axis contro modue aso contros the veocity and torque of the robotic arm. cabinet An encosure containing a robot's controer, axis contro modue, input/output modue, and power suppies. camera A device used to capture sti images, such as photographs, or moving images, such as videos. Cameras give a robot vision. cart vehice A sma AGV that can oad materia ike a unit oad carrier or pu it ike a tow vehice. Cart vehices are usuay imited to oads of no more than 2,000 bs. (907 kg). Cartesian coordinate system A numerica system that describes the ocation of an object by numericay expressing its distance from a fixed position aong three inear axes. Cartesian robot A type of robotic arm that has prismatic joints ony. The inear movement of the joints gives the Cartesian robot a highy rigid structure that aows it to ift heavy objects. cean room A room in which temperature, humidity, and air pressure are controed and maintained at a specific eve. controer The main device that processes information and carries out instructions in a robot. Aso known as the CPU, or processor. cyindrica robot A type of robotic arm that has a combination of revoute and prismatic joints. Cyindrica robots work we in round workspaces. degrees of freedom The avaiabe ways a component can move in three-dimensiona space. Robots typicay have 3 to 6 degrees of freedom. dross A type of scum formed by oxidation at the surface of moten metas. end-effector The end component of a robotic arm that is shaped ike a hand or ike a speciaized too. Aso known as endof-arm too (EOAT). end-of-arm too The end component of a robotic arm that is shaped ike a hand or ike a speciaized too. Aso known as an end-effector. feeer A sensor on a robot that responds to touch or pressure. fork vehice A type of AGV that can ift and ower materias. Forks are avaiabe in different styes other than the standard dua fork. gripper A hand-shaped end-effector designed for seizing and hoding. industria robot A programmabe mechanica device that is used in pace of a person to perform dangerous or repetitive tasks with a high degree of accuracy. input/output modue The jack where an input/output device is physicay connected to a robot. Inputs and outputs aow the robot to interact with its environment. integrated circuit A miniaturized eectronic circuit. The deveopment of integrated circuits heped to improve the performance of industria robots. inteigence The abiity to earn, reason, and sove probems. joint The ocation at which two or more parts of a robotic arm make contact. Joints aow parts to move in different directions. ead-through programming A programming method in which a robot is paced in "teach mode" whie the trainer uses a remote teach pendant to manipuate the robot through the different steps of the job. Lead-through programming is the most common programming method. inear joint A joint that moves in a straight ine across one axis. Aso known as a prismatic joint. inear movement Movement in a straight ine across one axis. ink A fastener that joins or connects the parts of a robotic arm. ockout/tagout A method of protecting empoyees from accidenta robot startup through proper ocking and abeing of robots that are undergoing maintenance. machine oading The process of oading raw materias into machinery for processing. main power suppy The power suppy that provides votage and current to a robot s motor. A robot's main power suppy is AC run through a transformer. manipuator A robotic arm. A manipuator is generay mounted on a patform or suspended from a track whie the arm reaches to various distances and ocations. materia remova The process of removing substances or matter from a surface. Materia remova processes incude cutting, grinding, deburring, defashing, poishing, waterjet cutting, and routering. Copyright 2009 Tooing U, LLC. A Rights Reserved. materias handing The process of oading, unoading, pacing, or manipuating materia. Types of materia handing incude machine tending, part transfer, packaging, and paetizing. microcontroer A tiny computer that is sef-sufficient.