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Robot, RRS, RCS

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1. What is Robot??

2. Applications of the Robots.

3. Automotive Industrial Robots.

4. Singularity Error

5. Selection Criteria in BIW Lines

6. RRS and RCS.

7. What is the difference between different controllers??

8. What are the attributes we give while doing OLP and what are their significance??

9. What info we store in .src and .dat files (Downloads from Robcad)??

10.What are $config.dat and $machine.dat??

11.What are Humming Bird and Exceed??

Contents

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What is Robot??

A Robot is a reprogrammable, multi-functional

manipulator designed to move material, parts, tools,

or specialized devices through variable programmed

motions for the performance of a variety of tasks.

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Mobile. The interconnection structure of the kinematic chain

is that of two or more wheels connected to the same base.

The base itself can, in turn, carry a kinematic chain too.

Serial. The interconnection topology of the kinematic

chains is a chain without loops or without multiple

branches.

Humanoid. The interconnection structure of the

kinematic chain is a tree.

Parallel. The interconnection structure of the kinematic chain

consists of two "platforms" connected by a number of “legs” in

parallel. These legs often have identical (mostly serial)

kinematic structures.

Types of Robots on the basis of construction

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1. Cartesian Robot (Gantry Robot)

Three linear joints provide the three axes of motion and define the x, y and z planes.

This robot is suited for pick and place applications where there are no orientation requirements

Industrial Robots

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2. SCARA (Selective Compliance Articulated Robot Arm)

The robot has three joints. This is the typical “Assembly and Pick & place" robot.

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This robot has six independent joints, also called six degrees of freedom.

3. Six axes Robot

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• Axis 1 This axis, located at the robot base.

• Axis 2 This axis allows the lower arm of the robot to extend forward and backward.

• Axis 3 The axis extends the robot's vertical reach. It allows the upper arm to raise and lower.

• Axis 4 Working in conjunction with the axis 5, this axis aids in the positioning of the end effector and manipulation of the part.

• Axis 5 This axis allows the wrist of the robot arm to tilt up and down. This axis is responsible for the pitch and yaw motion.

• Axis 6 This is the wrist of the robot arm. It is responsible for a twisting motion, allowing it to rotate freely in a circular motion, both to position end effectors and to manipulate parts.

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Robot arms: The robot arm is the part that positions the end effectors.

End effectors: Connects to the robot's arm and functions as a hand.

This part comes in direct contact with the material the robot is

manipulating.

Drive (Motors): is the engine or motor that moves the links into their

designated positions.

Sensors: Allow the robot to receive feedback about its environment.

Controller: The „brain' of the Robot

Main Components of the Robots

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• Painting

• Arc welding

• Palletizing

• Sealing/dispensing

• Spot welding

• Assembly

• Stud Welding

• Hemming

• Inspection

Major Applications of Robots in Automotive Industries

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Other Applications

Electron Beam

Flux Cored Welding

Mig Welding

Plasma Cutting

Resistance Welding

Robot Laser Welding

Tig Welding

Welding Automation

Dispensing

Machine Loading

Machine Tending

Material Handling

Order Picking

Packaging

Palletizing

Part Transfer

Pick and Place

Press Tending

Bonding / Sealing

Cleanroom

Deburring

Drilling

Flame Spray

Grinding

Material Removal

Milling

Painting Automation

Polishing

Robotic Assembly

Robotic Coating

Thermal Spray

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Robot in Transport Position

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Singularity Error

1. Wrist Singularity

2. Alignment Singularity

Wrist Singularity occurs when the axes of Joints 4 and 6 are aligned.

Alignment Singularity occurs when Joint 6 (wrist) and Joint 1 axes are aligned. (This has not yet occurred in the following figure, but is about to.)

A condition caused by the collinear alignment of two or more robot axes resulting in unpredictable robot motion and velocities

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Selection Criteria

• Depends on the Application

• Reach ability

• Payload

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Equivalent Robot selection with same Reach (Kuka Specific)

KR150_2 KR150L130_2 KR150L110_2

KR180_2 KR180L150_2 KR180L130_2

KR210_2 KR210L180_2 KR210L150_2

KR240_2 KR240L210_2 KR240L180_2

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Equivalent Robot selection with same Payload (Kuka Specific)

KR150_2 KR150L130_2 KR150L110_2

KR180_2 KR180L150_2 KR180L130_2

KR210_2 KR210L180_2 KR210L150_2

KR240_2 KR240L210_2 KR240L180_2

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REACH (mm) 1100 1300 1500

KUKA

ROBOT

KR 150

KR 150 L130

KR 150 L110

KR 180 KR 180 L150 KR 180 L130

KR 210 KR 210 L180 KR 210 L150

KR 240 KR 240 L 210 KR 240 L180

130

150

180

110

210 240

PAY LOAD (Kg)

SAME REACH ROBOTS SAME PAY LOAD ROBOTS

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REACH (mm) 1025 1275 1525

KUKA

ROBOT

KR 360-2

KR 360 L280-2

KR 360 L240-2

KR 500-2 KR 500 L420-2 KR 500 L340-2

KR 360

450-2 PA

KR 360

L340-2 PA

KR 360

L280-2 PA

KR 500

570-2 PA

KR 500

L 480-2 PA

KR 500

L420-2 PA

SAME REACH ROBOTS

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Payload Robot ReachKR150_2 1100

KR180L150_2 1300

KR210L150_2 1500

KR180_2 1100

KR210L180_2 1300

KR240L180_2 1500

KR210_2 1100

KR240L210_2 1300

150

180

210

Reach Robot PayloadKR150_2 150

KR180_2 180

KR210_2 210

KR240_2 240

KR150L130_2 130

KR180L150_2 150

KR210L180_2 180

KR240L210_2 210

KR150L110_2 110

KR180L130_2 130

KR210L150_2 150

KR240L180_2 180

1100

1500

1300

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RRS and RCS

1. Until the early 1990s, the motion behavior of robot simulation often strongly deviated from real behavior.

2. RRS is the interface between Simulating Software and Robot specified Controller

3. Robot Controller Simulation (RCS-) Modules is supplied by controller manufacturers as black-boxes to any simulation system supporting the RRS Interface.

4. Today the RCS-Interface is the world-wide de-facto standard for precise simulation of robot motion behavior.

Figure. 2: The RRS-Interfaces enable to integrate any

robot software into any simulator

• Realistic Robot Simulation • Realistic Controller Simulation

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User activity model

RRS Interface Overview

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Partners for RRS Project

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Difference between Default controller and Robot specified Controller

Controller:

•An object able to perform a task which contains logical operations, calculations and

signal handling, but which does not include motion commands.

•A default controller is a Controller model which has only basic attributes which are required to

move the robot in the simulation model and the motion need not to be so exact as the Real-time.

•But a Robot specific controller is integrating the motion controller software of any robot controller

into the simulation system that has the attribute set up which is similar to the actual controller

used in the Real time environment.

•The simulation will be as exact as the motion that is going to be executed in the plant.

• And so we can directly download the Programs/paths from the simulation software and even we

can adjust the Programs in an interactively and simultaneously.

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These all are the Files required

to run Default controller

These all are the Files required

to run VKRC controller.

Please note that for the simulation and to define tool it has separate

program subroutines logics are used in robot specific controller.

But in case of default controller it is a simple program which reads just the

motion attribute of the location

Overview of the Files in ROBCAD

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What are the attributes we give while doing OLP and what are their

significance??

Tool & Base

Motion Type: Joint/Linear/Circular

Accuracy Profile

Tool Type: External/Mounted

Configuration: status and turns

Load Data

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Process Paths:

The TCP is measured from the flange of the robot and BASE is car origin measured w.r.t robot base.

E.g. Spot/stud Welding, Arc Welding, Hemming,

In case of External TCP, it is measured from the base of the robot and Base is Car origin measured w.r.t

Robot Flange.

E.g. Stationary Spot/stud Weld, Gluing, Clinching,

Handling Path:

We use TCP at the top of the fixed pin of gripper.

Parallel to robot flange axis and co-ordinates are w.r.t. Robot Flange.

For material handling equipment, Robot base will be taken as BASE.

For fixtures, BASE will be at Car origin.

Note: These definitions may vary with OEM to OEM.

General TOOL and BASE Definitions

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Motion Type

It is the fastest path (Takes minimum time).

TCP movements are not defined.

All the joints accelerates and decelerates at the same time.

Joint will move in one direction only.

It is preferred to use in all via location.

1. Joint Motion:

2. Linear Motion: It is the shortest path (Takes maximum time).

TCP movements are in a straight line.

All the joints accelerates and decelerates independently.

Joint may not move in one direction.

It is preferred to use at process locations.

3. Circular Motion:

TCP moves in an arc.

Can be useful in the processes like Hemming, Glue, Arc Welding Etc.

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Linear Motion

Joint (PTP) Motion

P1

P2

Circular Motion

Comparison Between Linear, Joint and Circular Motion

P0

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Accuracy

Flyby means that the controller can look ahead and take into account more

than the current target when planning a path and calculating robot‟s motion.

The biggest advantage of the flyby mode is that the corners can be rounded to

maintain a constant speed.

It is the amount by which the TCP will reach to each programmed location. For Ex. If

it is 0% than TCP will reach and touch to each location and if its 100% it will do the

maximum approximation (for clarification pls see the images)

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P1

P2

P3

P4

Accuracy profile 100%

Accuracy profile 0%

Accuracy profile <100%

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Without approximate positioning (Accuracy Profile 0%) (No Flyby)

With approximate positioning (Accuracy Profile 100%) (Max Flyby)

P1 P2 P3 P4

Vprog

Vprog

P1 P2 P3 P4

Time (s)

Time (s)

Ve

loc

ity

Ve

loc

ity

5 10 15 20 25 30

5 10 15 20 25 30

Time Study for Approximate positioning.

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Tool Type

Normally Tool are of two types:

– Basic TCPF • In which the TCPF has been defined at the tool mounted

on the Robot, and the Robot will move to match the Target with the TCPF defined.

– External TCPF • The work piece is mounted on the robot, and the tool is

stationary (external) to the robot.

• Such a TCPF definition is used in case of gluing and static Spot welding.

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Load Data

In order to maintain the Simulation accordance with the Real time model the Load data value must match with the Simulation data.

The Mass, Centre of gravity and M.I. w.r.t. Robot flange of the tool mounted must be defined in Load data.

In the absence of Load data the robot will move with full payload value which results in wrong Cycle time calculation.

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Configuration

Robot can Move to a location defined by Cartesian transformation with different joint positions and consequently different robot configurations

To move robot to a location in space with a specific configuration Precision point must be used.

That precision point specifies the joint values of that particular location & the position and orientation of the point .

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What info we store in .src and .dat files??

SRC

The SRC file is where all the "executable" code resides like Tool, Base, Motion and

Accuracy Profile.

In SRC file, we need to make sure to set active Tool, Base, and Speed (Joint speed and

linear speed both) before we actually perform any motion commands.

It contains the sequence of the program with attributes assigned for the points.

DAT

The DAT file is where the persistent variables are stored, like point positions (usually

E6POS or E6AXIS variable types).

It contains list of all the points i.e. via and process, and its coordinate values, tool and base

frame assigned for the points.

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.src File

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.dat File

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What are $config.dat and $machine.dat

config.dat In this, we store TOOL- and BASE- DATAS, LOAD-DATAS and all moving parameters we

use.

I/O signals are also declared here. But pay attention, each costumer have his own

modification.

machine.dat It contains DATAS given by the Robot-provider. In this data You find all parameters which

define the robot-type. Each type needs his own special data.

Do not change this data without permission from the provider, especially the typical movement

parameters.

Some parameters, for example IN/OUT-signals for safe-robot, You can change according to

the needed configuration.

The function of this machine.dat is the same like the controller in Robcad. It contains the

typical movement behavior of the robot system.

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What are Humming Bird and Exceed

Hummingbird / exceed is something that sits between windows and Robcad.

RobCAD originally ran on unix, but when they released the Windows version of

Robcad they had not rewritten robcad, they ported it instead (exceed acts like a unix

environment for Robcad to run on).

If you don‟t have exceed, current versions of robcad will not run on windows

based Systems.

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Major Robot Manufacturers

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References

• www.Realistic-Robot-Simulation.org

• www.Robots.com

• www.learnaboutrobots.com

• Kuka Robot Programming Handbook

• www.kuka.com

• www.americanrobotcorporation.com

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Thank You!!