🏭Intro to Industrial Engineering Unit 14 – Automation and Industrial Robotics

Fundamentals of Automation

• Automation involves using technology to perform tasks with minimal human intervention, increasing efficiency and productivity in various industries
• Consists of three main components: sensors (gather data), controllers (process data and make decisions), and actuators (execute actions based on controller decisions)
• Utilizes feedback control systems where the output is continuously monitored and compared to the desired input, allowing for automatic adjustments
  • Open-loop systems do not use feedback and rely on pre-determined settings
  • Closed-loop systems incorporate feedback for real-time adjustments
• Enables consistent quality by reducing human error and variability in processes (manufacturing, assembly lines)
• Facilitates mass production by streamlining repetitive tasks and increasing output rates
• Improves safety by removing humans from hazardous environments (handling toxic materials, working at heights)
• Enhances precision and accuracy in tasks requiring fine motor skills or intricate movements (electronics assembly, surgery)

Types of Industrial Robots

• Articulated robots have rotary joints and resemble a human arm, offering high flexibility and a wide range of motion (welding, painting)
  • Can have 4 to 10 degrees of freedom (DOF) depending on the number of axes
• Cartesian robots move linearly along three perpendicular axes (X, Y, Z), providing precise positioning and handling (3D printing, CNC machines)
• SCARA (Selective Compliance Assembly Robot Arm) robots have parallel joint linkages and excel at fast, repeatable planar motions (pick and place, assembly)
• Delta robots utilize parallelogram-shaped arms connected to a common base, enabling high-speed, lightweight operations (packaging, food processing)
• Collaborative robots (cobots) are designed to work safely alongside humans, featuring force-limiting and collision detection capabilities (small parts assembly, machine tending)
• Mobile robots can navigate autonomously using sensors and mapping technology, offering flexibility in material handling and logistics (warehouse automation, delivery)
• Soft robots are made from compliant materials and can adapt to delicate or irregular objects (fruit harvesting, biomedical applications)

Robot Components and Systems

• Manipulators are the mechanical arm and end-effector that interact with the environment, determining the robot's reach, payload capacity, and dexterity
• End-effectors are specialized tools attached to the manipulator, designed for specific tasks (grippers, welding torches, spray nozzles)
  • Grippers can be mechanical (fingers), vacuum (suction cups), or magnetic depending on the object being handled
• Actuators generate motion and force, converting energy into mechanical action (electric motors, hydraulic cylinders, pneumatic muscles)
  • Electric actuators offer precision and efficiency but may have limited power
  • Hydraulic actuators provide high force output but require a fluid power system
  • Pneumatic actuators are lightweight and fast but less precise than electric or hydraulic
• Sensors gather data about the robot's environment and internal states (position, velocity, force, vision)
  • Encoders measure joint angles and distances traveled
  • Force/torque sensors detect contact forces and moments
  • Vision systems (cameras) enable object recognition and tracking
• Controllers process sensor data, execute control algorithms, and send commands to actuators, acting as the robot's "brain"
  • Microcontrollers and PLCs (Programmable Logic Controllers) are commonly used
• Power supply systems provide the necessary electrical power to all robot components, ensuring stable and efficient operation

Programming and Control Methods

• Online programming involves teaching the robot points and trajectories using a teach pendant, allowing for quick setup and modifications
  • Lead-through teaching physically guides the robot through the desired path
  • Teach pendant programming uses a handheld device with buttons and a screen to input commands
• Offline programming uses computer software to create and simulate robot programs, enabling complex tasks and integration with CAD/CAM systems
  • Requires accurate models of the robot, end-effector, and workcell
  • Allows for program optimization and verification before deployment
• Point-to-point (PTP) control moves the robot from one point to another without considering the path taken, suitable for simple pick and place operations
• Continuous path (CP) control generates smooth, controlled motions along a defined path, essential for applications like welding and painting
• Sensor-based control uses feedback from sensors to adapt the robot's actions in real-time (force control, vision-guided systems)
• Adaptive control techniques enable robots to learn and improve their performance over time based on data and reinforcement learning algorithms
• Collaborative control strategies ensure safe and efficient interaction between robots and humans in shared workspaces (speed and separation monitoring, force limiting)

Applications in Manufacturing

• Material handling tasks involve moving, stacking, and palletizing raw materials, work-in-progress, and finished products (automated storage and retrieval systems)
• Assembly processes use robots to put together components and sub-assemblies, improving speed and consistency (automotive, electronics industries)
• Welding applications rely on robots for precise and repeatable joining of metal parts, reducing human exposure to hazardous conditions (arc welding, spot welding)
• Painting and coating tasks employ robots for uniform application of paint, powder, or other finishes, ensuring consistent quality and minimizing waste (automotive painting)
• Machining operations use robots for loading/unloading machine tools, as well as performing cutting, drilling, and grinding tasks (CNC machine tending)
• Quality control and inspection processes leverage robot vision systems and sensors to identify defects and measure part dimensions (automated optical inspection)
• Packaging and palletizing tasks utilize robots for high-speed, accurate placement of products into containers and onto pallets (food and beverage industry)

Safety and Human-Robot Interaction

• Risk assessment identifies potential hazards associated with robot operation and develops appropriate safeguards and procedures
• Physical safeguards include barriers, fences, and light curtains that prevent human access to the robot's working area during operation
  • Interlocked gates stop the robot when opened, allowing for safe maintenance and troubleshooting
• Sensors detect human presence and trigger safety responses (slowing down, stopping) to avoid collisions (pressure-sensitive mats, laser scanners)
• Emergency stop (e-stop) buttons allow operators to quickly halt robot motion in case of an emergency or unexpected behavior
• Collaborative robots incorporate force and speed limiting features to minimize the risk of injury during human-robot interaction
  • Soft and rounded edges, padding, and compliant materials reduce impact forces
• Training programs educate workers on safe robot operation, programming, and maintenance practices
• Personal protective equipment (PPE) such as gloves, glasses, and helmets provide additional protection for operators working near robots
• Regular maintenance and testing ensure the proper functioning of safety systems and prevent malfunctions that could lead to accidents

Economic Considerations

• Initial investment costs include the purchase price of the robot, end-effectors, sensors, and control systems, as well as installation and setup expenses
• Operating costs encompass energy consumption, maintenance (regular inspections, replacement of wear parts), and programming/reprogramming efforts
• Labor cost savings result from the reduced need for human workers to perform tasks now handled by robots, particularly in industries with high labor costs
• Productivity improvements lead to increased output and shorter cycle times, enabling faster time-to-market and higher production volumes
• Quality enhancements and consistency in robot-performed tasks can reduce scrap, rework, and warranty claims, leading to cost savings
• Flexibility and adaptability of robots allow for quicker changeovers between products and the ability to handle a wider variety of tasks, reducing the need for dedicated equipment
• Return on investment (ROI) evaluates the financial benefits of implementing robots compared to the total costs incurred over the robot's lifetime
  • Factors influencing ROI include the robot's expected lifespan, maintenance requirements, and the value of increased productivity and quality
• Societal and economic impacts of automation should be considered, such as the potential for job displacement and the need for worker retraining and education programs

Future Trends in Automation

• Advances in artificial intelligence (AI) and machine learning will enable robots to adapt to changing environments and learn from experience, reducing programming efforts
• Cloud robotics will allow for the sharing of data and knowledge between connected robots, facilitating collaborative learning and optimized performance
• Miniaturization of robot components will lead to the development of smaller, more agile robots suitable for tasks in confined spaces or on a micro-scale (medical applications)
• Soft robotics will continue to evolve, with the development of more compliant and adaptive materials that can safely interact with delicate objects and humans
• Mobile manipulation will combine the strengths of mobile platforms and robotic arms, creating versatile systems capable of navigating and performing tasks in unstructured environments
• Human-robot collaboration will become more seamless, with advances in natural language processing, gesture recognition, and intent prediction enhancing communication and coordination
• Sustainable and eco-friendly robot designs will prioritize energy efficiency, recyclability, and the use of environmentally friendly materials
• Integration of robots with other technologies, such as the Internet of Things (IoT), big data analytics, and digital twins, will enable more intelligent and connected automation systems