Roboticss Essay, Research PaperADVANCED FabricationTECHNOLOGY & A ; AUTOMATIONCoursework 2RoboticssDrumheadAt present BL Cars Ltd industry a portion of an car suspension assembly known as a Crosstube. They are sing traveling from manual to robotic production in either a individual cell/single automaton or line/multi automaton layout. The undermentioned study recommends the usage of the Fanuc Arc Mate automaton, which is a compact, six axis, modular-built, electric servo-driven automaton which is controlled by the a R-J3 accountant with ArcTool application package. All accessory equipment options are considered.The two layouts are considered and all wellness and safety deductions are detailed. The study concludes with a treatment on the cogency of each layout. For low volume industry it is recommended that a single-cell layout is utilized.

For economic production of high volumes a line layout would be the primary pick.Contentss1.0 Introduction2.0 Robot Specification2.1 Mechanical Features2.

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2 Performance Specifications2.3 Programming & A ; Control Methods3.0 Specification Of Ancillary Equipment3.1 Welding Tool3.2 Gripper4.0 Robotic Assembly4.1 Cell Layout4.

1 Line Layout5.0 Health and Safety5.1 Cell Layout6.2 Line Layout6.0 Discussion7.0 Mentions8.0 Appendix1.

0 IntroductionBL Cars Ltd manufactures a portion of an car suspension assembly. It is known as a Crosstube. The complete portion consists of four thin sheets of steel presswork. Two parts are indistinguishable and are positioned either terminal of the larger cross brace, which has been formed from two larger pieces of sheet steel..The diagram below illustrates the complete assembly:Soon the two parts doing up the cross brace are secured utilizing specific gigues.

Once secure they are spot welded along the rim edges. The following measure is to procure the two mounting home bases to the presswork. The procedure is completed by discharge welding the constituent to add excess strength to the topographic point dyer’s rockets and procure the climb home bases. N.B. When the parts are pressed from the sheet steel turn uping points are incorporated. This ensures each portion is located in the right place in the gigue.

The usage of industrial automatons is of all time increasing. The automaton normally does a secondary machinery operation after a primary defining operation. When performed manually, this secondary operation frequently requires the operator to work in an unpleasant environment, to transport out a repetitive and palling undertaking with bulky tools.BL Cars Ltd is sing utilizing automatons to automatize the Crosstube assembly procedure. The automatons will be used for stuff handling, topographic point and discharge welding in one of two contrasting layouts:1. Single-cell, individual automaton & # 8211 ; low volumes2.

Line-layout, multi-robot & # 8211 ; high volumesCompared to manual dyer’s rockets, robot dyer’s rockets provide the undermentioned benefits:? A higher quality dyer’s rocket? Greater consistence? Increase discharge on clip as a proportion of entire clip? Increased operator safety? Automatic dyer’s rocket quality monitoring.Compared to manual handling, automatons managing provides the undermentioned benefits:? Greater consistence? Greater truth? Increased repeatability? Low running costs2.0 Robot SpecificationBL Cars Ltd have decided to utilize the Fanuc Arc Mate 50il. This automaton is a compact, six axis, modular-built, electric servo-driven automaton which is controlled by the R-J3 accountant with ArcTool application package.

The automaton has been designed to maximize throughput and usage of floor infinite by supplying a compact, high velocity design in a proven and dependable mechanical unit.Fanuc Arc Mate 50il? Monetary value: Single robot? 30,000Mechanical Features? The automaton has six axes of motion. The diagram below illustrates axis motion:? The diagram below illustrates the floor infinite required for climb:? Physical dimensionsPerformance SpecificationsPrograming & A ; Control MethodsThe bulk of MIG welding occupations are conducted manually. It is comparatively late that machines have come on to the market with sufficient positional repeatability to automatize the procedure faithfully and flexibly. Arc welding utilizing MIG is a complex multi-variable control undertaking. Therefore is imperative that an effectual accountant is chosen.The accountant BL Cars LTD has chosen to utilize is the R-J3 shown below:FANUC Robotics & # 8217 ; SYSTEM R-J3 Controller uses advanced engineering packaged in a proven, dependable 3rd coevals accountant design. Process capableness and unfastened architecture characteristics improve application and gesture public presentation while simplifying system integrating.

SYSTEM R-J3 incorporates FANUC Robotics & # 8217 ; alone & # 8220 ; plug-in-options & # 8221 ; construct which allows the flexibleness for applications specific constellations while keeping a commonalty for all users of the system.Features:? 32-bit chief CPU with double processor architecture permits fast computations, reduces plan executing times and increases way truth? Provides extended line of compact I/O faculties for both digital and linear signals? Allows for fast power-up and plan executing with car sketch after rhythm start? High-speed, preciseness control of up to 6 axes of gesture? Auxiliary axes options can back up up to three separate gesture groups, each with its ain control plan and simple kinematic theoretical accounts? Advanced communications and networking capablenesss include constitutional Ethernet and PCMCIA interface? AccuPath provides enhanced way tracking during additive and round gesture while minimising velocity fluctuations? Collision sensing minimizes possible harm to the automaton or end-of-arm tooling? Collision sensing minimizes possible harm to the automaton or end-of-arm tooling? Use of surface climb and 3-D packaging reduces constituents and additions dependability? Quick alteration servo amplifier reduces care clip? Distributed I/O options cut down telegraphing costs and simplify troubleshooting? Increased usage of fibre optics simplifies connexions and enables faster communications? Increased usage of fiber optics simplifies connexions and enables faster communications? Multi-tasking runing system allows executing of several coincident user plans? Instant trigger response ( *4 MS ) increases repeatability and improves procedure control.Benefits:? Reduces capital disbursals: -Modular bundle allows rotator to be added merely if needed -Eliminates expensive tools typically required to pare parts -Reduces figure of automatons required to accomplish a mark throughput? Increases throughput and quality up to 35 % over competitory robotic tracking systems and manual welding? Adaptive good bias optimises weld wire placement to make full lap articulation spreads without cut downing travel velocities ( 100 inches per minute )? Root Pass Memorization ( RPM ) allows users to execute multi-pass dyer’s rockets without retracking.3.

0 Specification Of Ancillary EquipmentWelding ToolBL Cars have two options:1. Use mindless automatons and comparatively precise tooling, better gigue, and more efficient transit. This method reduces dimensional fluctuation.2. Use a automaton and detector system to turn up the start and terminal points of each dyer’s rocket. This method besides traces the seam maneuvering the dyer’s rocket torcH, and as a consequence reduces the mistake.Precise tooling is really expense. Taking into history capital and recurrent costs BL Cars will use automatons with detectors.

Seam Tracking Sensor& # 8216 ; The MIG EYE seam tracking detector equips FANUC Robotics & # 8217 ; welding systems with a laser-based trailing detector. Designed specifically for arc welding sheet metal stampings, MIG EYE locates weld seams and provides existent clip control of the automaton & # 8217 ; s way to keep proper alliance between dyer’s rocket wire and joints. & # 8217 ; The purpose of this equipment is to maximize the quality and the velocity of the dyer’s rocket.Assuming BL Cars Ltd choose to incorporate this tool with an ARC Mate automaton and Arc Tool package, MIG EYE reduces entire scheduling clip, enhances uptime and increases throughput for a broad assortment of welding systems.The illustration below shows a tool which incorporates a detector and MIG welder.Figure 2 torch/sensor bundle ( 57mm Diameter )Managing ToolTo automatize the line layout a handling tool is required.

The tool will be used to keep the occupation whilst it is welded. It is necessary to see the form, orientation, weight, and the Centre of gravitation of the portion. Once these variable have been determined an appropriate gripper can be selected.For exposure of chosen tool, and farther information on managing tool application package please mention to appendix 1.4.0 Robotic AssemblyA robotic assembly cell is an independent unit dwelling of one or more automatons and associated peripheral equipment, by agencies of which a complete merchandise can be assembled every bit far as possible.? Relatively long rhythm times? Relatively big figure of assorted parts assembled per automatonIn the automotive industry the ratio of assembly cells to assembly lines is about 2:1.

Cell LayoutThe diagram below illustrates a simple cell layout.Robotic Assembly LineA line layout comprises two robotic Stationss which are installed in series. The rhythm times are comparatively short, and besides a limited figure of parts per station and merchandise conveyance between Stationss.Line LayoutThe diagram below illustrates possible line layout:Fiscal ConsiderationsSet-up costs are greater in a line layout since there are two automatons and excess accessory equipment. However all line layout is capable of significantly higher throughput degrees. Therefore if high volume industry is required a line layout will be the most economic option, supplying a lower overhead cost/unit.5.0 Health and SafetyWhen implementing any signifier of system within a fabrication environment it is imperative that all wellness and safety deductions are taken into history and the appropriate safeguards are incorporated.

The bulk of accidents affecting automatons have occurred:1. Whilst an operator is programming2. Whilst carry oning experimental automaton sequences3. Whilst an operator is seting and/or keeping peripheral devices4.

As a consequence of hapless proviso or installing of safety equipmentFrom the above information it is evident that when puting up a robotic cell it is of import to see1. Operator safety whilst programming and/or keeping the robotic system2. Equipment protection.

With robot systems, the type of automaton, its usage and its relationship to other works will all act upon the design and choice of precautions. Any safeguard chosen must allow the needed operations to be conducted and where necessary, instruction, scheduling, puting, care and trouble-shooting operations to be carried out.Prior to safeguard design all jeopardies and hurt hazards must be identified. In this instance a individual automaton cell will necessitate a different degree of safeguarding to a multi automaton line layout.Perimeter fence will be used to protect all members of staff from the equipment line.

The fence will dwell of a hollow subdivision steel model in filled with mesh. All subdivisions will be 2m high and firmly fastened to the modelWhere there is a danger of liquefied metal and welding flash conflicting ordinances, the filling between the model will be manufactured from sheet steel. A sliding entree gate will be located either side of the line to let for regular entree. A presence feeling device will be linked to the control system to immediately cut power to all machinery within the restricted country.

Cell Layout SpecificAn operator will be working with the automaton within the cell. Therefore it is of import that suffient safety devices are incorporated within the cell to guarantee operator safety.Four exigency halt buttons will be strategically positioned in and around the cell to let exigency close down in the event of a job.

An flight way and guidelines will be displayed outside the cell to foreground to the operator the action that should be taken if the automaton goes out of control.Pressure mats will be placed around the automaton. When force per unit area is applied to the mat the system is shut down. An dismay system will besides be incorporated within the system to bespeak human presence.The operator within the cell will ever hold ultimate control over robot activity.Infra-red drapes are flexible and dependable and do an first-class method of operator protection.Line Layout SpecificWhilst runing under normal conditions its is improbable that a automaton will necessitate manual human input.In add-on to the general safety safeguards, it is necessary to see the possibility of the two automatons damaging themselves and other equipment.

This will be achieved by utilizing positive Michigans which limit the motion of the automaton to portion of its envelope. Trip devices will be utilised to halt the automaton if it comes into contact with people or other equipmentA trapped cardinal exchange will be used to procure all Gatess. This system will positively insulate the power supply to all parts of the automaton installing. There is a lock on all margin Gatess and a lock on an isolator commanding the automaton actuators. The key can non be removed from the lock to open the gate unless the system is in a safe province.7.

0 DiscussionThe crosstube is mass produced, i.e. high volumes are required. The most cost effectual layout pick would be the line-layout. Although higher set-up costs are involved ab initio the cost of implementing cells with an tantamount rate of throughput would be greater.However it is likely that this merchandise will travel into diminution and the figure of these merchandises demanded will fall.

When this occurs the line layout could be abandoned, the infinite utilised for a portion in growing, and a individual cell could be established for dedicated production of the cross tubing.BL Cars Ltd must see utilizing automatons cell for the economic industry of paradigm and growing merchandises. As growing slows and a merchandise is nearing adulthood a line-layout can be considered ( volume determined ) This method of assembly would be partly utile in the diminution period of the merchandises life rhythm, as the cell would be capable of bring forthing other similar parts or parts within the merchandise household.8.0 Mentions? www. Rooks. B.

, Rover 75 Sets New Standard In Body In White Assembly. International Journal, Vol. 26, Is 5, 1999? Bromley. J. S.E.

, Davey. P.G. , Vidler. A. R.

, Clocksin. W. F. , Morgan. C. G.. An Implementation of Model Based Visual Feedback for Robot Arc Welding of Thin Sheet Steel.

International Journal of Robotics Research Vol. 4 No. 1 1985? Asfahl. R.

C. 1992. Automatons and Manufacturing Automation. John Wiley? Rampersad.

H.K. 1994. Intergrated and Simultaneous Design for Assembly. John Wiley317


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