Lecture Robotics Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E.

López
TUHH
2 - 2249 - 0

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López

CONTENTS 1700 J.D. Vancanson built music playing dolls
1805 H. Maillardet designed a picture painting doll
• 1. Introduction • 4. Controls 1946 G.C.Devol developed a controller which can store electrical
• 1.1 Historical Review signals, to use them later for the controlling of mechanical devices
• 4.1 Measurement Systems
1947 Patents for manipulation for the handling of radioactive materials
• 1.2 Definitions • 4.2 Programming of IR 1952 Prototype of a NC-Mashine at MIT demonstrated
• 1.3 Kinematic Structure – online 1954 C.W. Kenword received a patent for a 2-Arm-Robot
1959 First commercial robot (Planet Corporation)
• 1.4 Coordinate Systems – offline 1960 First Ultimate Robot (with hydraulic drive, numerical control) installed
• 4.3 Programming Languages 1966 Tralfa developed and installed color spraying robot
1968 “Stakey”, a mobile robot is demonstrated at the Standard Research Institute
• 2. Structure of IR • 4.4 Collision Control 1971 First purely electrically actuated robot (Standford-Arm)
• 2.1 Construction + Drive Tech. 1973 Robot programming language - WAVE was developed
1975 First assembly operation by Olevettis SIGMA robots
• 2.2 Actuators • 5. Sensors 1979 Development of SCARA robots at the Yamanashi university
• 5.1 ... 1981 Direct Drive robot developed at the Carnegie Mellon University
1984 Several programming systems for development demonstrated
• 3. Grippers • 5.2 Optical Sensors 1985 World-wide development of mobile autonomous robots
• 3.1 Construction of Grippers • 5.3 Video Technical Devices
• 3.2 Gripper Change Systems • 5.4 ...
History of Robots

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 2363 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 -2248 - 3
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Robot Industrial robot

— Like humans — Universally substitutable — Manufacturing,

— Learning — Motion automata assembly —Aerospace
— Freely programmable
technique — Nuclear science
— Handling/manipulation — Under water
production task
technique
— Service industry

Robot and industrial robot in comparison Applications of Robot-technique 1

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2251 - 3 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2247 - 6
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Autonomy of robot
Requirements leading to Flexible Production Techniques
by

— Automatic planning
— Automatic control
— Short delivery time
— Supervision of performance
— Individuality of products
— Recognition of a conflict
— High constant product quality
— Deletion of errors
— Competitive prices

Autonomy of robot Changing of production basis to flexible production

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 0477 - 7 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 8 -0936 - 8
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An automatic machine is an artificial system,

which autonomously follows a program.
Muscle, tendons Memory, mind and nerve
mechanization (control technique)
Coin
insertion

Automation
yes Coin no
acceptance
Semi-Automation
(partially functions Fully Automation
Return coin
from hand) (all function automatic)

Goods delivery

Human activity, mechanization and automation Definition of automatic machine 2

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 -1697 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 -0479 - 0
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An Industrial robot is a multi-functional handling device,

which is free programmable in several axes
and is able to move workpieces, tools or special devices in such a way,
that a specific task will be executed properly.

Definition of Industrial Robot (short version) Industrial robot

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 8 - 1518 - 9 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0480 - 0
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30 points Handling equipment

Special devices for Universal devices

Change Change
Storing Holding Manually controlled Automatically controlled
place direction
43 points

Fixed operational sequence Programmable operational sequence

21 points
Rigid Adjustable Adjustable Programmable
movement movement movement desired
stop limitation limitation position

Cam- Robot with

Mater- Pick and Path
controlled point to
Slave place controlled
handling point
clamp devices devices
equipment control
robots

- banker - slides - guide bars - jaws - micro- -special - loading - handling -assembly - arc welding
11 points Industrial robot - magazine - chute - swivel - expanding manipulators purpose portals automata robot robots
- feed grippers mandrel - tele- equipment - iron hand - handling - spot welding - painting
- turn - stepped manipulators delivery system robot robots
devices clamping - industrial devices - loading
plates manipulators robots

Part of car body with weld points Systematic of the handling equipment 3
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1698 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0290 - 0
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Robot
Industrial robots are universally applicable handling devices with severa
axes, whose movements, regarding motion sequence and paths or angles, Stationary Mobile
are freely (i.e. without mechanical intervention) programmable and if necessary
are sensor-led. Not bound to a fixed path Bound to a fixed path

They are equipable with grippers, tools or other

production devices and can execute handling sensor- manually sensor- track-
led led led bound
and/or manufacturing functions

inductively optically
led led

Definition of Industry Robot (complete version) Structuring of the mobile Robots according to the type of the guidance

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4
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0564 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0484 - 0
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Robot in basic condition (axes

Axes denotation (according to VDI 2861)
Axes denotation (according to VDI 2861)
X horizontal main linear axis, parallel to the first
axis of reference coordinate system
Y horizontal mail linear axis, parallel to the first
axis of three-dimensional coordinate system
Z vertical main linear axis, parallel to the third
axis of reference coordinate system
U linear axis parallel to the X-axis or any linear axis
V linear axis parallel to the Y-axis or any linear axis
W linear axis parallel to the Z-axis or any linear axis
R turnable linear axis (radial axis)
Q second turnable linear axis (radial axis) or any
axis
parallel to three-dimensional
coordinate system)
Axes denotation (according to VDI 2861)
A main axis of rotation parallel to the X-axis or
other main axis of rotation*
B main axis of rotation parallel to the Y-axis or
other main axis or rotation*
C main axis of rotation parallel to the Z-axis
D axis of rotation parallel to the X-axis or any axis
of rotation, preferably 1st rotational secondary axis*
E axis of rotation parallel to the Y-axis or any axis
of rotation, preferably 2nd rotational secondary axis*
F axis of rotation parallel to the Z-axis or any axis
of rotation, preferably 3rd rotational secondary axis*
S any axis
T any axis

Denotation of IR Axes Motion possibilities of a body in space

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0631 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 2706 - 0
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Kinematic chain

Joints Limbs

Linear Rotational Movable

Frames
joints joints limbs

Kinematic concept

Variation of the join

Space

Work space <=

movement space

Collision region

Positioning accuracy/
- Kinematics
manufacturing costs - Drives
Mobility/flexibility/ - Controls
Control-expenditure
- Sensors
Kinematic conception of IR working space Modules of a robot 5
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Direct communication with
Driving space external world

Information input Human to human

Movement space Safety space Genes

Sheer perception
Work space Unusable space
Sheer action

Data processing Unconscious reaction

Main work space Extra work space
Conscious reaction
Characteristics and abilities
of humans Reflex

Short time memory

Information storage
Long-term memory

Speech

Information output Scripts

Gestures, mimics/miming

Space layout for robots after VDI2861 Characteristics and abilities of humans

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Subsystems Subfunctions
System-boundaries
of the workplace Information
System-boundaries Measuring
Generating the local allocation between of the PHG system
Kinematics workpiece/tool and manufacturing equipment
Information

Functional elements Access/supply workpiece Control

Secure position of workpiece while moving Manufacturing Sensors

Control equipment Drives
Energy
and
To convert and supply the necessary energy to all organization
Drivers Material
movement axes
Kinematics

Measuring the position, speed and acceleration

Measuring device of single axis
Material
Energy
Acquisition of stochastic influences in the surrounding field of IR
Sensors Measuring physical magnitudes
Pattern and position recognition

Subsystems of Robots Structure of a workplace with robot 6

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1553 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 0630 - 7
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Subsystem Task
Control - Program execution, memory, controlling, Kinematic Chain
monitoring
- Logic combination, manufacture with equipment,
peripheral device,
- Other controls
Drives - To convert and transfer the necessary energy to all
movement axes Joints Limbs
Kinematics - Spatial correlation of workpiece/tool and
manufacturing equipment
- Start points, travel along of paths
Gripper - To grasp and release objects
- Secures the object during movement
Path- and speed - Acquisition of stochastic influences from the Translation joint Rational joint Movebable limbs Frame
acquisition surrounding field
Sensors - Acquisition of stochastic influences from the
surrounding field
- Pattern and position recognition

Function of the subsystems Parts of a kinematic chain

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Rotational arm
b Possibility of movement bmax= 6

u Restrictions of movement for a joint umin= 1

Translational arm
Cantilever arm f Joint degree of freedom f=b–u

F Structural degree of freedom F=∑f

Portal Bending arm

Folding arm

Kinematics of industrial robots 7

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0485 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0486 - 0
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(i-1)i
12
(i-1)
1 i
2 4
3
23 34
open kinematic chain
12
2
23
1 1, 2, 3 - parts of the open kinematic chain
3
51 I, II - closed kinematic chain
34
5 4 A12, A23 - actuators for joints 12 and 23
closed kinematic chain
45

Kinematic chains Multiple-drives system in serial arrangement

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0487 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0488 - 0
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z z
TR

R T

RR
TT

y y RT

x x

Structures with F=1 Structures for F=2 8

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Axes
1 2 3 4 5 Space-describing
structure structure
Joint
structure P structures with
TTT P P P P parallel translational
axes, or three parallel
TTR P P axes of rotation
TTT TTR TRT RTT
TRT P P
structures with
RTT P P a translational axes
RRT orthogonal relative
to two parallel axes
TTR of rotation or
TRR with an axes of
rotation orthogonal
RRT RTR TRR RRR
RRR P to two orthogonal
translational axes

Structures for F=3 Structure variation for F=3

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0491 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0500 - 0
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Z 2
3

Z
1

3
2

Y
1
X

Positioning with RRR- and TTT-Structure Industrial robot with TTT-Axes 9

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1952 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0501 - 0
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Linear axes for handling device Industrial robot with TTR-Axes

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0502 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1695 - 0
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1
Rigid (vertical)
2
1
3
3
Flexible
(horizontal)

2
Folding wall

Rigid

Flexible

SCARA = Selective Compliance Assembly Robot Arm

Industrial robot with TRR-Axes Definition SCARA 10

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1953 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1954 - 0
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Axis 3
Arm 1 Arm 2

Axis 1 Axis 2 Axis 3

SCARA-Robots Swivel (rotating) arm robot SR 800

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0503 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0504 - 0
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2 1
2
1
3 3

Special designs of industry robots 11

Industrial robot with RRR-Axes
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2D-displaceable robot Modular handling and positioning system with direct drives

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1889 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 2037 - 0
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Effector coordinate system

Effector position Indices
(Absolute cartesian coordinates) W : Global cartesian coordinate system
M : Assembly coordinate system
R : Robot coordinate system
TCP : Tool coordinate system
Effector position 1; 2; 3 : Joint coordinate system
Direct kinematic Inverse kinematic
problem problem
(Forward (Backward
Robot base coordinate system transformation) transformation)

Joint vector G
(Robot coordinates)

Coordinate system of an IR 12
Kinematic relation for robot arm
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1925 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1926 - 0
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Backward-transformation

Xw Forward-transformation
Yw Tool coordiante system Θn : Angle between axes
NPK: reference point offset correction Zw

Industrial robot with RRR-Axes Transformation of cartesian position data in axis information

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 2379 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1927 - 0
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3-axis industrial robots

a) with cartesian work space b) with cylindrical work space c) with spherical work space

LEFT and ABOVE RIGHT and ABOVE

• 3 linear joints • 1 rotational joint • 2 rotational joint

• 3 linear points • 3 linear points
• Position of the effector • Position of the effector • Position of the effector
x s3 x s2 cosθ1 x s2 sin θ 2 cosθ1
P = y = s1 P = y = s2 sin θ1 P = y = s2 sin θ 2 sin θ1
RIGHT and DOWN
z s2 z s1 z s2 cosθ 2 + s1
LEFT and DOWN • Axis positions • Axis positions • Axis positions
s1 = y y y
θ1 = arctan θ1 = arctan
x x
s2 = z
s1 = z z − s1
s3 = x θ1 = arccos
s2
s2 = x 2 + y 2
s2 = x 2 + y 2

13
Determination of the axis positions for 3-axis industrial robots
Arm configuration at joint robots
Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 1928- 1 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 2253 - 0
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cos u1
n1 = s1
sin u1
cos(u1 + u2 )
n1 = s2
sin(u1 + u2 )
x s1 cos u1 + s2 cos(u1 + u2 )
p= =
y s1 sin u1 + s2 sin(u1 + u2 )
With the application of the cosine law the position angles of axis 1 and 2 follow
y s2 sin u2
u1 = arctan − arctan
x s1 + s2 cos u2
Axis 3
with
cos γ = cos(180 − u2 ) = − cos u2
x 2 + y 2 − s12 − s22
u2 = arccos
2 s1s2
Axis 1 Axis 2 and
y s2 sin u 2
Axis 4 u1 = arctan − arctan
x s1 + s2 cos u 2
with s1, s2 as characteristic data of the kinematic chain

Kinematics of a rotational joint robot Positioning for axis 1 and 2

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 1929 - 1 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 1931 - 1
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a) Graph of the transformations for b) Position of the joint coordianate system
6-axis robots
Coordinate systems

Axis 2

Axis 3
Axis 1
Axis 4
c) Joint parameters according to Hartenberg-Denavit

Axis 6
Joint Variable θ l d α
1 θ1 θ1 0 d1 π/2
Axis 5 2 θ2 θ2 l2 0 0
Origin 3 θ3 θ3 0 0 π/2
4 θ4 θ4 0 d4 -π/2
5 θ5 θ5 0 0 π/2
Matrix of transformation: 6 θ6 θ6 0 d6 0
T6= A1 · A2 · A3 · A4 · A5 · A6

14
Backward transformation for a 6-axis folding arm robot
Kinematics of a 6-axis folding arm robot
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 1930 - 1
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Swiveling range and arm’s position
OVER HEADÍNG MOVEMENT
Ende Abschn. 1
Arm right

• Es folgen Reservebilder.
Arm left
ROTATION

Axis 4 and 6 Orientation of the axis

positive negative

Axis 3 and 5 Orientation of the axis

positive negative

Ambiguites of the transformation at 6-axes folding arm robot

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 1549 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 -0640 - 0
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Need levels Satisfaction by

- Realization of one’s own potential

- Enlargement and learning progress
Self realization
- Rise of responsibility

Number of utilized robots

- Professional competence
Preceding social development

Self esteem - Independence

- Authority to decide

- Security in the community

Social contact - Human contact
- To be approved

- Long period backup of income for

Security need satisfaction of physiologic needs
- Safety of workplace

- Nutrition
Physiology need - Apartment
- Clothing

Hierarchy of need Development of industrial robots in Germany 15

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 2828 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 2829 - 0
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Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2766 - 9

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Necessary exact description: geometrical

Beginn Abschnitt 2 cinematical
dynamical demands
on the robots structure

path (distance, form, given points)

time (cycle time, acceleration, speed)
force (weight, inertia, function)

path- time and force- specification have an

important influence on robots structure

flexibility is an additional important

demand on robots

Demands on Robots structure 16

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0492 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0642 - 0
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F Palletization of workpieces
D1 T1 A1 D1 T1 A1 D2

D2 T2 A2
C T2 Differnt structures for solving
palletizing tasks
D3 T3 A3

A3 T3 D3 A2

C serial
parallel
Simplified co-operatin structure
D - Drive element, T - Transmission element, A - Actuator, C - Control element, F - frame

Basic structure of Multi-drives system Influence of handling tasks on IR-structure

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 1875 - 2 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0301 - 0
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Spur gears Planetary gears

An elliptical body The turn of the ... results in a full Since the number
(wave generator) wave generator rotation of the of teeth at the
Harmonic drive Akim deforms a flexible, causes a wave generator a circular spline
Cyclo interlocked body displacement of the torsion of the and flexible spline
over the balls and meshing region flexible splines is different...
the bearing cup in accordance with
(flexible spline) the number of teeth
different...

Duplex worm gear Toothed belt transmission

Transmission for robot axes of rotation Method of operation of the Harmonic drive 17
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Electrical equipment with industrial robots Pneumatic equipment with industrial robots

Advantages Disadvantages Advantages Disadvantages

- cheap - limited stokes
- extremely precise - bad strength and/or power density
- easy to install - reprogramming of the firm installed
- it can be arranged easily in such - frequently cooling equipment often
- pneumatic contacts are usually control units is expensive
a way that no movements would necessary
available - only limited number of programs are
easily occur in the case of energy - adjustable three-phase current drives
- precise positioning by stops is practical
disturbance are complex
possible - uncontrolled movement is possible
- automatic control loops - unfavorable dynamic behavior
- simple control - control chain
- small noise - almost always mechanical
- very reliable - noise
- inexpensive through standardized transmission necessary
- small maintenance costs - air supply is partially problematic
components
- not influencable through electrical (cleanness, constant pressure level)
- strength of three-phase drives
fields

Electrical equipment with industrial robots Pneumatic equipment with industrial robots

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1053 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 8 - 1358 - 9
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Hydraulics at Industrial robots
LOGIC DC BUS
Advantages Disadvantages LINE INPUT
POWER SUPPLY

- very good strength and/or power - hazard with circuit break (in PROGRAMMED
COMMANDS
serial
FAULT
PROTECTION
RS374
density particular in the case of high pressure RS232
EXTERNAL I/O
- good dynamic behavior hydraulics) PARAMETERS
SYSTEM
CONTROLLER A
- closed-loop control systems are - oil must be well filtered POSITION
ANOLOG REF I/O B
DIRECT
TORQUE MOTION PHASE POWER DRIVE
AMPLIFIER
practicable - leakage VELOCITY CONTROLLER CONTROLLER C MOTOR/
RESOLVER

- very reliable - temperature dependence CONTROL

OUTPUT

- standardized elements are - combustibility of the hydraulic fluid DRIVE INHIBIT

BRAKE CONTROL

available - within some areas not applicable DECODER

FEEDBACK
INTERFACE
LED INDICATORS POSITION FEEDBACK
(food industry, hospitals, clean room) OVER TEMP
FEEDBACK LOSS
OVER CURRENT

- without mechanical additional GROUND FAULT

REGEN. LOAD DUMP
LINE VOLTAGE OUT OF RANGE

equipment there is no automatic locking FAIL SAFE BRAKE INERGIZED POSITIONER/CONTROLLER POWER AMPLIFIER

Hydraulics at Industrial robots 18

Block diagram of a drive regulation for a direct drive (Slo-Syn)
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2767 - 9 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1356 - 0
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Synchronous Asynchronous Reluctance
drives drives motors
high dealock torques
Dynamics z z Š
Overload range z z Š
high positioning accuracy Positioning z z {
Rotary speed region z z z
high dynamics Degree of efficiency z Š Š
Torque weight Š { z
Standard outlay z { Š
good maintainability and low wear
Temperature behavior z { Š
Drive costs { z z
good controlability with synchronus drives
Converter costs Š { Š
z = good Š = middle { = bad

Features of Direct drives in Industrial robots Evaluation of different drive concepts for direct drives

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400
Permanent-exited
direct current motor Static frequency changer
(INDRAMAT MHT 140) Comtrol
Reluctance motor Drive controller Service part
300 (MEGATORQUE 18”)
Three-phase
analog/ digital
digital digital (analog)
asynchronous drive
(AMK EBM 200)
][
M[Nm]

200
Reference position
value Position RPM Current
Torque

+XS regulator +NS regulator +IS regulator

100
Real position Real RPM
value -II Real current value
vale
-XI -nI
M
Transducer
∼
0 20 40 60 80 100 120 140 160

Revolutions per minute RPM n[min-1]

Characteristics of different direct drives Design of a digital drive control 19

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0493 - 0
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NC (Numerical Modul) - Drive modul
4
Ende Abschnitt 2 3
1 2
Drive

• Es folgen Reservebilder. Measurement

system

Servo-valve

Brake
Gripper or other
switching valve

Control

Components of pneumatic Servo-Drive Systems

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2633 - 7

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Beginn Abschnitt 3 Greifer

Main functions
Auxiliary functions
of a gripper

Execute a position-securing Ø Centering

force on a workpiece Ø Orienting
Ø Executing additional
movements
Ø Collecting information
Ø Gripp about workpieces
Ø Hold
Ø Release

Main functions of a gripper 20

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0497 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2376 - 6
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Environmental influences
Factors of influence on gripper construction
Gripper system Effect part
Handling Handling Peripheral Handling

Form closure interface

Environment
object equipment device function

Interface
Amount Mounting- Position- Functions Contamination Grab
Movement Handled
Mass position accuracy Lot size Moisture equipment
Material Storing position Acceleration Cycle time Vibrations setting object Orders,
Temperature Positioning- Type of energy Temperature supply,
Handle areas accuracy Connection- store setting
Dimensions Process forces dimension
Sensitivity
Forms
Accessibility Control Effect part
Moment of inertia Preparation time Pay load
Tolerance
Inset- Interface
Withdrawal- Clamping device for
forces
manufacturing equipment

Process
Factors of influence on the gripper construction Interfaces of a gripper arangement

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2- 0494 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0495 - 0
TUHH TUHH

Object
gripper

Ball
flange control
f=5 f=4 f=3

industrial robot hold system kinematics workpiece

Cylinder

f=4 f=2
drive sensors

Disk
f - degree of freedom
f=3
Degrees of freedom between object and gripper Gripper with its Subsystems 21
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0568 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 0506 - 5
TUHH TUHH Order criterion
Single Dual Multiple Double Turret - Number of grippable
gripper gripper gripper gripper gripper
bodies
Number of grippers Type of closure - Number of available
1 2 n
- single gripper - press fit grab area at the body
- multiple gripper Factors of influence - form closure Material
closure
Press fit Press fit
Press fit/
Form closure - Type of closure
Form closure
on grippers
adhesive magnetically fluid electrical fluid mechanically - Gripper principle
- adhesive - vacuum - electro-
Gripp area Gripper movement gripper
- permanent
magnet with cap static elastic flexible rigit
- Types of fingers
- inside - circular moulded - sucker gripper finger finger finger
element
- outside - parallel - mechanically circular
circular/ transla-
- Jaw movement
Gripper principle selected permanent magnet parallel tional
- permanent electromagnet
- electromagnet 1 2 3 4 - Number of fingers
- magnet cushion
wander field gripper
Mechanically Fluid Magnetically Other central parallel - Finger movement
- scissors gripper - vacuum gripper - electromagnet - electrostatic
- pliers gripper - sucker - adjustable gripper - all possible inner outer inner
inner/
outer - Grab direction
outer
- vice gripper - bellow gripper permanent combinations
- extension thorn - extension - knee - vice - knee
magnet - bending spring sleeve joint joint

Factors of influence on grippers Systematics of the grippers

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0496 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2317 - 4
TUHH TUHH
Hold principles of grippers
operation Hold by press Hold by form closure
to only activate to activate
number of together separately
workpieces Hold by Hold by Hold by Hold by Hold by Hold by
Friction Negative Magnetic Intermolecular pairs of form throatiness
forces pressure forces forces forces items hooking
1 workpieces single gripper

- Direct clamping - Adhesion suction - Permanent magnets - Adhesion foils - Rigid form - Pricing of needles
e.g. with apparatus - Permanent magnets elements on the into the handling
compressed - Vacuum suction with electrical gripper form object
2 workpieces dual gripper double gripper air subjected apparatuses field displacement negative copy from (e.g. textiles,
diaphragm admitted by a - Electromagnets shape of the foam material, etc.)
- Indirect clamping vacuum pump wokpiece elements
by active pressing - Venturi nozzle and - Flexible modeling
of mobile items vacuum suction jaws are modeled
(gripper finger) apparatus (vacuum at part form
n workpieces multiple gripper turret gripper - Indirect clamping
by under effect
generation through
overpressure)
elements

of gravity force
self-locking
mechanisms

Kinds of the grippers Hold principles of grippers 22

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0498 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0507 - 0
TUHH TUHH

consumption adhesive tape

fresh adhesive tape

pressure bodies

Gripper with adhesive tape Gripper with electromagnet

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0505 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0499 - 0
TUHH TUHH

Mechanical enclosure gripper Pneumatic bending finger 23

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0508 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 2377 - 0
TUHH TUHH

γ = Angle of prism
α = Gripper opening angle
G = Center of gravity
of the object
∆X = Displacement

Rotational movement with linear drive Center displacement with scissors grippers

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1 2 3 4

Kinematics for grippers Parallel guidance of gripper jaws 24

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0511 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2323 - 9
TUHH TUHHM

MOVEMENT ENERGY
Actuator for gripper functions valuation pneumatic hydraulic electro- electro-
criteration magnetic motor
electrical

ENERGY
rotation
pneumatic
Drive linear
hydraulic High grab force

controllability

Actuator for gripper Drive movement transfer of

energy
1 Electrical drive sensitiveness
1.1 Stepping motor rotation agains dirt
1.2 Direct current motor rotation Maintenance
Emergency
2 Pneumatic drive
stop behavior
2.1 Pneumatic cylinder linear
2.2 Pneumatic motor rotation Size
2.3 Swivel cylinders (low number of revolutions rotation
per minute, limited rotation angle) costs

3 Hydraulic drive
3.1 Hydraulic cylinder linear
3.2 Hydraulic motor (unlimited rotation angle) rotation favorable middle unfavorable
3.3 Swivel cylinders (limited rotation angle) rotation

Actuators for gripper functions

Advantages and disadvantages of different gripper actuators

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2325 - 9 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0512 - 0
TUHH TUHH

manual resetting automatical resetting

Conversion or
Conversion Resetting with Resetting without
regulation on
of forms element changing element changing
form elements

Copying with Copying with

passive elements active elements
(without senors) (with senors)

- Cutting - Adjust of - Change of - Magnetic - Many joints

- Casting lamella gripper jaws powder driven by
packages - Change of gripper cables
- Adjust of gripper - Vacuum - A parallel
prisms kinematics granulates pair of gripper
- Change of gripper jaws with
complete tactile sensors
gripper in the gripper
jaws

Flexibility levels of gripper Resetting procedure for gripper 25

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0559 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 2254 - 0
TUHH TUHH

Aspects of selection of grippers

Drill 1. High power factor (large relation of grab strength to gripper mass)
Milling Cutter 2. Practicable mechanical and electrical interfaces for lever link and gripper jaws
pencil grinder
3. The size spectrum of the grab objects adapted or adaptable gripper stroke/shift with
etc. Drive Hhg
acceptable closing and open- hours
4. Grab force protection with power failure
5. Small friction losses in transmissions and guidance
6. Possibilities for the kinematic supplement around wrist rotational and sliding axis (short-stroke)
7. Sensitive setting options for jaw movements and forces
8. As contactless query of the end positions of gripper jaws as possible
9. Integrated guidance of supply lines for energy and information
10. Insensitivity in relation to oscillations and impacts or absorption in the end positions
Interface 11. Great maintenance intervals
Jaws Fingers Transmission Drive Hhg
12. High service life

Interfaces of gripper Aspects of selection of grippers

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1034 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 2255 - 0
TUHH TUHH

Operation types for gripper change devices

1. Self Actuation
uses the movement possibilities of the handling equipment itself
(easy, small; actuating forces by IR)

2. Internal Actuation
by external drive in the handling equipment
(large, heavy; only once necessary

3. External Actuation
actuator mounted to the magazine frame
(high reliability, smallest influence on IR)

Gripper changing system Operation types for gripper change devices 26

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0513 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0514 - 0
TUHH TUHH

2 1 1 2

3 4 5
4
5
6

6
3

1. Stator
2. positioning bolt
3. housing
4. Bushing
released clamped
5. Electromagnet
6. Proximity switch Tool
Change mechanism for permanent electromagnet Support element with ball (sphere) adapter

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0515 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 2322 - 0
TUHH TUHH

Sensors for grippers

parallel
Switching Sensors Measuring sensors

touching contactless touching contactless

Drive

Conical Examples Examples Examples Examples

- Switch for - Attendance - Position measure- - Distance measurement
movement by supervision and ment with linear by ultrasonic
mechanical one position test potentiometer - Distance measurement
(e.g. limit switch) - Light barriers - Gripper force by laser triangulation
- Inductive proximity measurement with - Position measurement
Star-shaped switches strain gages by video processing
- Capacitive - Multidimensional
proximity switches force measurement
by strain gages
- Pattern recognition by
tactile surface sensors

Turret Gripper Sensors for Grippers 27

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1520 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0520 - 0
TUHH TUHH
Description of the environment
intelligence
Artificial

and the function Control types problem tool application

During tool movement not Drill
point-to- in mesh Spotwelding
Strategic model
x(t) point control
Path interpolator no necessary
Robot control

Open and/or closed loop control During tool movement Rotation (cylindrical)
simple straight in mesh Milling machines
cut control (parallel to axis)
Coordinate transformation
Path interpolator no necessary

During tool movement Rotation (conical)

straight cut Milling machines
in mesh
Standard automatic

p(t) Individual feed back control control (any straight lines

expanded
control

with gear switching or

Single drives linear interpolar
Robot limbs Rotation
During tool movement
Internal measurement Milling machines
continuous in mesh
flame cutting
path control
Path interpolator (according to 2 (any line)
External measurement order or higher degree equation

Function of robotic control Control types

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0566 -0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0439 - 0
TUHH TUHH
Ranges of path control for handling
and assembly

Jerk-free movement Following straight

Prescribed path Synchronization with
while carrying heavy lines with non carte-
movement moving object
loads sian handling facilities

Linear interpolation Circular interpolation

Work task Workpiece Peripheral equipment Kinematics

Approximation of a trajectory Parabolic interpolation

Influence of by linear interpolation

Field of application for control with flexible handling facilities Interpolation method 28
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0413 - 0
TUHH

Computer integrated Manufacturing

Information capacity

Direct Numerical Control

Beginn Abschnitt 4
Computerized Numerical „Steuerungen“
Control

Numerical
Control

Hierarchy of control

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1519 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2008 - 7
TUHH TUHH

Human as a strategist Simulation Direct programming Indirect programming

Real robot system and system Computer model of robot system
x(t) environment necessary
soll and model of the system are
necessary
Manufacturing equipment is not Programming in production
Path generation available during programming planning department
Coordinate transformation
Tests of the user program Tests of the program through
at the real system simulation
+ p(t)
soll
Limited accesses to operational Full integration of operational
individual automatic informational systems information systems possible
controllers
+ Quality of the user programs depends Support of the programmer by
Internal measurement Control on the experience of the programmer intelligent computer-based aids
+

single drives FEATURES OF DIRECT AND INDIRECT

robot members PROGRAMMING PROCEDURES

Present implementation of the control tasks 29

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0520 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0525 -0
TUHH TUHH

Control types problem tool application

During tool movement not Drill
point-to- in mesh Spotwelding Memory content Function
point control
Path interpolator no necessary Manual
During tool movement Rotation (cylindrical) programming 102 handling
simple straight in mesh Milling machines
cut control (parallel to axis)
Teach-in Welding, painting,
Path interpolator no necessary 104 coating, palletizing
During tool movement Rotation (conical)
straight cut
in mesh Milling machines Programming with
control (any straight lines programminglanguages
>106 assembling
expanded with gear switching or
linear interpolar

During tool movement Rotation

in mesh Milling machines
continuous
flame cutting
path control
Path interpolator (according to 2 (any line)
order or higher degree equation

Control types Types of programming classified for application

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0524 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0517 - 0
TUHH TUHH
programming
Sensorics
Input/ peripheral devices
Output other controls
information input Control panel
Readout
control with
memory
comparison between desired
Information processing
and actual Memory
Sequence control
amplifiers Displacement and
velocity measurement
system
sensor driving mechanism with Power modul
Excitation of drivers Actuators
drive position measuring system
gripper external data processing
internal data processing
object

Internal and external data processing Control structure of industrial robot 30

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0521 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0439 - 0
TUHH TUHH
motion measuring
functioning application as
system:

digital- electromechanical : collector with brushes synchro transmitters

incremental
(rotational) photoelectrical - glass rod with photodiode
inductive - index plates of permanent
magnet with Hall generator
digital-
photoelectrical - grid scanned by photodiode
incremental linear alarm unit
(translational)
Linear interpolation Circular interpolation

electro mechanical - coded disc with brushes

digital- optical angle coder
photoelectrical- coded glass disc with photodiode
absolute inductive angle coder
inductive – index plates of permanent
(rotational)
magnet with Hall generator

analog-
absolute rotary potentiometer, inductive synchro transmitter spiral potentiometer Approximation of a trajectory
(rotational) Parabolic interpolation
by linear interpolation
overview of robotic motion measuring systems Interpolation method

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0413 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0410 - 0
TUHH TUHH

Basic functions
NC program management
Computer integrated Manufacturing
NC data distribution
Information capacity

Direct Numerical Control

NC data correction
Extended functions

Computerized Numerical NC data creation

Control
Data input and processing
Numerical
Control Control functions for the flow of materials

Subfunctions of the manufacturing control

Hierarchy of control Functions of a DNC system 31

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0517 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López
9 - 2090 - 2
TUHH TUHH
Program name Mandatory
Sensorics
Input/ peripheral devices Variable declaration alternative
Declaration of section
Output other controls
Control panel Value instruction alternative
Readout
Main program ;Mainprogram start Comment line
....Movement instruction
Statement part .... Mandatory
Information processing ....
Memory
Sequence control Stop
Displacement and ;Main program end
velocity measurement Comment line
system Subroutine ;subroutine start Comment line
Power modul UP <Name> (Parameter)
Excitation of drivers Actuators Variable declaration
Value instruction alternative
Statement part ....Movement instruction
....
RSPRUNG
Program end END Mandatory
Control structure of industrial robot
Program structure of BAPS

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0369 -0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0409 -0
TUHH TUHH printer
Manual
programming
Terminal catridge device

Central
External data bus Memory 32 digital 32 digital 8 analog
Computer 16K Eprom Interface Interface
12K Eprom 4/8/16 K RAM Input output In/Output
4K RAM

MC Micro computer
Micro processor
power supply
CPU Central processing unit internal data bus computer
Axes Axes Axes Axes Axes Axes
Computer Computer Computer Computer Computer Computer
4K Eprom 4K Eprom 4K Eprom 4K Eprom 4K Eprom 4K Eprom
MPU Accumulator Status Reg Reg 0,5K RAM 0,5K RAM 0,5K RAM 0,5K RAM 0,5K RAM 0,5K RAM 220 V
Microprocessor signal B C ~

Reg Reg
Control D E
Input/ Com- Command- power supply
output RAM putation decoder Program- controller
counter 4 Quadrant 4 Quadrant 4 Quadrant 4 Quadrant 4 Quadrant 4 Quadrant
Power Power Power Power Power Power
Computation Controller Controller Controller Controller Controller Controller 380 V
Control ~

R M T G R M T G R M T G R M T G R M T G R M T G

Reset Control signals Adress bus Axes 1 Axes 2 Axes 3 Axes 4 Axes 5 Axes 6

Construction Information flow basic axes hand axes

Micro computer 32
Block diagram of MPS085 control (Jungheinrich system)
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 1823 - 1 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 1822 - 5
TUHH TUHH

According to the measurement principle:

analog digital
in a similar physical size
(as resistance test)

after the determination of the measured value:

absolute ciclically incremental

absolute (as relative
measuring absolute measurement)

According to the type mounting of the measuring system:

Direct-measuring indirect-measuring

carriage carriage
measuring system
measurement embodiment
measuring spindle

Classification of measuring systems Measuring systems

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0519 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2791 - 9
TUHH TUHH

1 Glasmaßstab
lens aperture 6 2 Strichgitter
1
Segment disk Ga As Diode 7 3 Spur mit Referenzmarken
photo transistor
2 4 Optik
5 Lichtquelle
3 6 Fotoelement
A B
7 Abtastplatte
4

5
photoelectric cells
cut A-B output code disk
segment disk

coding lamp
parabolic reflector

Teilungsperiode

Segment disk Prinzip der optischen Abtastung von Strichgittern 33

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 8 - 1515- 9 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 2792 - 0
TUHH TUHH

digital
Voltage amplifier and output
supply Schmitt-triggers
lens aperture

light emitting diode

photo transistor
Lens

Division Disk

Principle of the incremental angular sensor Impulsfolgen und deren Auswertung bei
einem mehrkanaligen Inkrementalgeber

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 8 - 1516 - 9 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1056 - 0
TUHH TUHH
Givers Electronics
Control unit Performance Stepping motor
(program) control
Generation of the Interval
exciter voltage timers

Control unit Performance Stepping motor

(program control

Digital signal
Recipient Converters
Control unit Attitude Performance
(program controls control
Voltage

UR
UM Stepping motor

Time Control unit Attitude Servo

(program controls Amplifier

Phase shift Servo motor

Principle pattern of a resolver Position systems 34

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0444 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0518 - 0
TUHH TUHH

Offline program
digital incremental digital absolute similar-absolute
measuring system measuring system measuring system Factory networks Operation

- small manufacture - absolute measure- - simple measuring CAD Teach - In

expenditure indicated system
- simple comparators - simple actual value- - simple zero point Robot
Advantages - not expensive displays - simple comparators
- simple zero shift - stationary zero point - absolute measuring
Controls
- security against procedure
measuring/ transfer
errors
Data protection Sensor technology
+peripheral device
Disadvantages - no zero point - expensive - A-D-converter is Inputs + Outputs Measuring
- error propagation - complex necessary for difficult system
- procedure of point - trouble-prone digital display Power supply
of reference

Measuring systems Control interfaces

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1493 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0523 - 0
TUHH TUHH
Programming process for Industrial Robots Programming of handling systems

Direct programming (On-line) Indirect programming (Off-line) Direct programming Indirect programming
“Online” “Offline”

Movement of Problem oriented

Learning Sensor led Hybrid Program Interactive Handling System programming
process programming process languages graph

Video display Machine oriented

- following a - Automatic - Off-line - Implicit - Graphic input programming
course sensor led programming of - Explicit programming
(Play-back) programming program - CAD adaptation e.g.
- Driving to and - Sensor execution Playback Teach -in ROBEX
storing of controlled hand - On-line
important path Guidance geometry data NC- Dialog
e.g.
points recording Program “User’s
DIN 66026
(Teach-in) Editor Guidance”

Programming process for Industrial Robots Programming process for Industrial Robots 35
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0649 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0524 - 0
TUHH TUHH
Handling sequence Assembling Sequence programming
ET 1 M BG 2
Functions

Lager
BG 1 M BG 3 M

ET 2 ET 3
information input
control with
memory
Description

Program structure elements

comparison between desired
items

Geometry Flow
Control and
Communication
and actual
monitoring
Instructions Instructions instructions amplifiers
instructions

z A B C
y P SENS1/ READ WRITE
1
0 1 0 YzM
sensor driving mechanism with
P2

STOP
1 2 3 4
1
0
0
1
1 m>^s
1 XYz
OFF
SENS3/
! F? KNR.
WIDTH
KNR.
RT
Surface and space

x drive position measuring system

Disturb and error

ON

Emergency stop
Straight line

instructions

instructions
instructions

instructions

instructions
instructions

instructions

instruction
instruction
Logical
gripper external data processing
GO TO

Output
Sensor
Loops
Stops
Point

Input
Path

internal data processing

object
Basic instructions

Program structure elements for IR Internal and external data processing

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0567 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2228 - 3
TUHH TUHH

on-line off-line
Output Diode Plug
manual Computer
programming
Play back Teach in Sensor led
aided Function
Wrenches

Principle
Handle punched Tape
Control console
no computer is quick and sample exact starting is hardly describable Possible to simulate
necessary programming possible paths can be simply the program off-line
high accuracy is without programming procedure in Cartesians programmed partially uniform
possible languages coordinate is possible Row material programming language
Advantages Re-programming inaccuracies can be simple correction
(update) in steps is also settled no deadlock of
possible the robots

difficult Process expertise is locally programming Sensor and time Exact information
re-programming necessary stop the system are necessary for entry about tool
Robot and surrounding
Correction only
possible by new field are necessary Plug
Disadvantages program optimization locally
Difficulties in Counting expenditure Input: Program Step
Optimization
Large storage

Programming process for Industrial Robots Cross Section Distributor 36

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0525 -0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0526 - 0
TUHH TUHH
1 Horizontal forward rate
2 Horizontal feed rate
3 vertical lifting
4 vertical lifting
Memory content Function 5 rotating clockwise left
6 rotating clockwise right
Manual 7 close gripper
programming 102 handling 8 Open gripper

Command No.
9 gripper turn left

Function
10 gripper turn right
Teach-in Welding, painting, 11 gripper stroke off
104 coating, palletizing 12 gripper stroke on
13 Intermediate deadlock forwards
Programming with 14 Intermediate deadlock
programminglanguages
>106 assembling backwards
15 End of Cycle
16 Reserve
17 Time 0.5 s
18 Time 1 s
19 Time 2 s
20 Time 4 s

Types of programming classified for application Punched card information input for IR

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 1490 - 9 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 1489 - 9
TUHH TUHH

Roboter Program frame

Teach-In Programming Play-back-programming 37

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0707 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 0657 - 9
TUHH TUHH
Position input
Computer Emergency Stop
Display
Programming
hand Position PKT-Point name with TI position Operational task
device input of the individual axltes program
actively notes error messages
Position Velocity when driving with HGB
Decoding Fast -small jump Functional states
memory
Slow - big jump keys for axles 1-8
Teach coordinates 1 reference point
Cartesian 2 procedures in space coordinates
coordinates 3 Axis coordinates, machine coordinates
Path 4 gripper coordinates
Monitor
calculation
Keyboard 1 transfer of the positions into the point Agreement key
Transformation Teach memory + Fktt STATUS: Position shows with the TEACHEN
+ Sensor
2 switching to terminals with Fktt STOP: Program is still available, continues
Auto 3 START operates F1-F8 off after start
Cartesian 4 Fktt for transfer and switching
coordinates

PKT- point name shift

Robot
coordinates Fktt = function key
K
TI = teach in
- -
Tachometer

Resolver

Teach-In programming system Hand Control Panel

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 0527 - 6 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2256 -6
TUHH TUHH

Without deeper understanding for processes by the shop personnel, own

work programs for running process can be created after a short training
period;
program correction can be carried out subseqently during the program
test and require no new programming;

introduction and deletion of individual statements as well as the modification

of parameters are basic function of all considerable teach-in-systems;

collision problems can be prevented to a large extent with this way

of programming site;

input of false coordinate is excluded by the derivative of the position

of the robot axles.

Program recording and replay with the teach in procedure Advantages of teach-in-procedures 38
Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2257 -6 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1498 - 0
TUHH TUHH

Sensor for distance

In the case of small lot sizes,the proportionate programming times are
and orientation
economically no more justifiable;

programming of complicated lines and the optimization of complex

processing steps are time-consuming processes, those presuppose a
great intuition of the programmer;

the common programming of the pathes and of the frame program achieves
in large sized user programs with conditioned branches a degree of
complexity, wich is nearly unmanageable in most cases;
Conducting
a separation of the movement programming and the creation of the (Guidance) feed
program framework, i. e. the logical program flow function is
meaningful only in those cases if both systems are parts of an integrated
system, so that no problems can occur with a subsequent program correction.

Disadvantages of teach-in-procedures Automatic sensor-led programming

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Programming system Pilot actuated hand guidance 39

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 0709 - 5 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2569 - 5
TUHH TUHH
EDITOR Advantages Disadvantages
Creation of the programming system
- Reduction of the idle times of robot and - Complex system configuration
work program peripheral equipment
Data bases
- Missing standardized interfaces
Compiler - Description of the handling - comfortable program preparation because
Creation of an control equipment of computer aid and higher programming - Problems due to variety of IR-controls
independent user program - Environmental description languages
- Lacking of clearness
Postprocessor Data bases - easy alteration of programs
Control specific - Description of the control
user program - good documentation possible

- Subroutine technique;
Control control system program jumps possible

- easy alteration of programs

Handling equipment
- simple inclusion of external data inputs

Components of an external programming system Pros and cons. of external programming

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0529 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2008 - 7
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Industrial Direct programming Indirect programming

robot
Sensor Real robot system and system Computer model of robot system
control
environment necessary and model of the system are necessary

Manufacturing equipment is not Programming in production

available during programming planning department

Tests of the user program Tests of the program through

at the real system simulation
Workpiece hopper Limited accesses to operational Full integration of operational
with separation informational systems information systems possible

Subsequent Quality of the user programs depends Support of the programmer by

treatment on the experience of the programmer intelligent computer-based aids

Arrangement of equipment with the storage of pictures 40

Features of direct and indirect programming procedures
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 0710 - 5 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 0656 - 9
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Main program program first statement of a program
declaration end last statement of a program
Subroutine UP name first statement of a program
declaration RSPRUNG last statement of a program
Programming languages of industrial robot go
trough point...
absolute moving
points without delay
to point ... points exactly start
Movement shift incremental moving
instruction points without delay
points exacly start
linear linear interpolation
PTP point to point proceed
Elementary World-model-oriented WDH number MAL beginning of the repetiton
Repetition with repetition number
movement-oriented Job-oriented WDH_end end of the repetition
Caused statement if condition
Program flow-oriented problem-oriented then statement condition fulfilld
else statement condition not fulfilld
Branch instruction bransch label
direct movement instruction descriptions of movement WAIT value retention time in 0,1 s
WAIT UNTIL condition waiting for a condition to be fulfilled
function Delay and stop PAUSE program stops, restart necessarily
stop end of program
elementary program simple and composed Definition input: X=name X,Y number of the input or output
flow functions description of program flow input/output
Value assignment
output: y=name
variable=value i.e. ventil =1 (valve on)
description of robot V=value velocity in mm/s
Velocity/acceleration A=value acceleration in mm/s2
geometry V_PTP = value velocity für PTP in %
Arithmetic, logical +,-,*,/, und, oder, nicht
description of work space and comparison <, >, <=, >=, <>, =
Comment ;

Language structure of industrial robot Basic elements of the language BAPS

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 1491 - 8
9 - 2090 - 2
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Program name Mandatory

Declaration of section Variable declaration alternative

Value instruction alternative

Main program ;Mainprogram start Comment line

....Movement instruction
Statement part .... Mandatory
....
Stop
;Main program end
Comment line
Subroutine ;subroutine start Comment line
UP <Name> (Parameter)
Variable declaration
Value instruction alternative
Statement part ....Movement instruction
....
RSPRUNG
Program end END Mandatory
BAPS programming system 41
Program structure of BAPS
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 1492 - 4 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 1497 - 4
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PROGRAM MONTAGE
INPUT 9=TAKEN ;Binary input sensor at clamp 9=conveyor
INPUT 13 = GRIPPER_ON ;Exit signal on clamp 13
DISTANCE = (0,0,100) ;Difference vector with Z=100
DRIVE TO OSC_CONV ;Arm movement to the osc. conveyor
GRIPPER_ON = 0 ;Close the gripper
DRIVE TO OSC_CONV+DISTANCE ;Move to a position above the conveyor
WHEN TAKEN = 0 THEN ;The readout on the display:
PAUSE „PART not taken“ (display text)
;if the pieve was not taken
DRIVE OVER DRILL+DISTANCE ;Reaching the insertion position
DRIVE LINEAR WITH V=10 TO DRILL ;Insert the pin with small velocity
GRIPPER_ON = 1 ;Open the gripper
WAIT 0.5 ;wait for 0.5 sec

DRIVE OVER DRILL+DISTANCE TO OSC_CONV*DISTANCE

END

Assembly task Example of a program in BAPS

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0711 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0852 - 0
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Input data
programming system
Compiler
(processor)
CAD System
IRDATA, VDI 2863

Post processor

control system
codeinterpreter

VDI 2864 Direct coupling

Teach-In sensors robot control
Peripheral device

control system
Interfaces for external programming systems 42
Automatic generation of a robot program from CAD data
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 2380 - 4 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 2643 - 0
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Creation of user programs for assembly robots
Phase 1 Phase2 Phase 3 Phase 4

Structuring of the
Specifications assembly function
Conversion of the
- Performances assembly function Determination of
- Sequence of geometrical
operations - Program design
- Process logic
information Testing and Collision is defined as the temporal
- Movement patterns - Space points optimization
- Resources - Control function
- Communication
movements and spatial unintentional crash
- Test functions - Assembly strategies - Checking of the
- Flow of - Modularization
- Structuring of the
- Synchronization task execution of 2 bodies, whereby at the moment
information - Coordination - Collision control
program flow
- Coding
- Velocities - Optimization of meeting at least one body has
- Times of movements
- Testing of a kinetic energy different than zero
strategies
during troubles

Modification
User program

Specifications Iterative processes Automatic operation

Methodology for the programming of assembly robots Collision

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1060 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1059 - 0
TUHH TUHH

COLLISION CONTROL
Collision objects Collision points
of time OFFLINE ONLINE

Graphic visual CAD-Functions Mathematical Direct Indirect

WER? WANN?

Spatial Temporal
properties behavior
Robot external Robot internal
Collision Visual assessment Boolean Connection Algorithms sensor data sensor data

CAD Mathematical Real Simple mathe-

WO? WARUM? Model Model environment matical model

Description of environment
Description of robots
Collision spaces Collision causes
Mathematical Selected
CAD Model ...
Model points

Variables which influence collisions Methods of the collision control 43

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1058 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1057 - 0
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Mathematical test
Test method Call of the collision test Simple model Simple algorithms
- 1 wrapping body - Gravitation points
mathematical graphic visual use of CAD functions Information retrieval per axle comparison
- fewer wrapping - Distance to the
body for the straight line
Rough model (1st step) Collision test,1st step environment

no Mathematical test
Collision ?
yes Mean model Mean algorithms
- several wrapping - Calculation focal
Collision test, 2nd step
body per axle straight line
- some wrapping - Piercing points
Mean model (2nd step) no
Collision ? body for the - Line segments
environment
yes
Collision test, 3rd step Graphic visual test
yes
no Exact model Exact model
Collision ?
- CAD model in - Use of CAD
Exact model (3rd step)
accordance with auxiliary
Output of the Output of collision modeling by the functions
information about information user
free collision

Leave of the collision test

Methods for the collision test during off-line programming Strategy for an automatic collision test

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0228 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 2258 - 0
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Process Sensor system = sensor + transducer + amplifier (+ evaluation)
environment Problems in production, for the direct application of sensors:

Sensor Machines 1. Production runs are not always 100% automizable

the remainder workstation are unsatisfactory for humans, since
one-sided load of humans through check or difficult assembly work.
Information
2. Not sufficiently flexible devices are for automation for the order.
processing
3. The actual process,but also the peripheral mechanism do not only
have to be automated.
Environment
From this result 3 principal reasons for the use of sensors with
assembling and handling functions:
Sensory
Limbs
perception 1. Monitoring of the process variables (forces, length etc.), around process
errors if necessary promptly to detect.
Brain 2. Log (and analysing) from process variables, over from it trends´s able
to derive
3. Correct the process variables and a monitoring of the correction.

Analogy of the automatic control loops of industry processes and human Sensors 44
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0530 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0521 - 0
TUHH TUHH
motion measuring
functioning application as
system:
SENSOR
digital- electromechanical : collector with brushes synchro transmitters
incremental
(rotational) photoelectrical - glass rod with photodiode
inductive - index plates of permanent
magnet with Hall generator
digital-
photoelectrical - grid scanned by photodiode
incremental linear alarm unit
Receivers Transducers Amplifiers Analysis (translational)

- with contact - Analog-Digital - Linear - Measurement electro mechanical - coded disc with brushes
digital- optical angle coder
photoelectrical coded glass disc with photodiode
- without contact - Digital-Analog - Nonlinear - result absolute inductive angle coder
inductive – index plates of permanent
- Pulse count (rotational)
magnet with Hall generator

analog-
absolute rotary potentiometer, inductive synchro transmitter spiral potentiometer
(rotational)

Subsystems of a sensor Overview of robotic motion measuring systems

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Carrier pulse Harmonious carrier
Amplitude analog Digital Frequency-analog
Measured signal is transferred Measured value is transferred Measured value will be
to an amplitude value to a data-work of a certain converted into a frequency
Disturbances of the measured length and/or period-length of pulse-
(Primary)
(Signal function)
signal by electrical Disturbance-free transfer via duration
interference data-protection using suitable Precise and non-sensitive to
Multiplexer, filter, sample- codes disturbance signal transfer
hold-circuit and analog/digital Greater bandwidth needed Offset voltages and –flows
converter required Measured signal in computer- cause no loss of accuracy
Cycle-time of the sensor- compatible form available Simple and cheap digitizing
sampling will be strongly Digitally optimized system using a counter circuit
influenced by the multiplexer concept There can be a
sample-hold-circuit and A/D- Easier connection of all frequency/digital converter
converter digital system components to assigned to every measuring
Parallel instrumentation of the computer via bus channel
multiple signal-channels is Process disturbances of the Low-cost instrumentation of
very expensive bus lead to failure of the multiple parallel signal-
Central multiplexer and A/D- complete system channels
converter diminish the Restrictions of the dynamic Extended reliability
reliability of the system properties Restricted dynamic properties

Modulation procedure 45
Properties of the different signal representation methods
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0584 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0533 - 0
TUHH TUHH

Sensor without contact and tactile sensors

Sensors Distance range Sensibility against malfunction

Optical Recognition and Carrying out of Recognition of Making Recognition and

correction of simple movements sequence- programming classification of
position errors disturbances easier workpieces
Acoustical
- Assembly - Inserting of a pin - Collisions - Tracking-control - Recognition of
Inductive (putting parts into a bore hole - Overloading for following 3-dimensional
together, joining) - Latching cranks - Errors of the edges patterns
- Finding of bore and joints contour of the - Force-reduction by - Organize
Capacitive holes - Adjustment workpiece path-programming - Qualification
- Recognition of - Testing the - Gripping-force of weight
surfaces and edges movability of control
Tactile
- Positioning of the assembled modules
gripper to the object

s
- Getting a workpiece

ld
fie
e
out of the bunker-

Lig ratur

cal
No on
storage

Du g
Distance in mm

rati
pe

ctr i
ise
hti
st
Tem

Vib

Ele
Distance-measuring systems for Industrial Robots Possibilities of applications for Industrial Robots with tactile sensors

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0532 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0624 - 0
TUHH TUHH
tactile sensors

measuring of single variables pattern recognition

(force, moment, route,...)
analog position- and
composition measuring
strain gages piezo-sensor
2-dimensional 3-dimensional
pneumatic converters,
capacitive sensors
potentiometers pressure-sensitive inductive pin-matrix
plastics-matrix

inductive sensor-pins
embedded threads
automated insertion- and position-recognition in automated
assembly processes manufacturing and assembly installations

constructions of tactile sensors Schematic insertion process 46

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0534 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 0535 - 9
TUHH TUHH
RCC-rotational z y
Gripper part
connection x

Workpiece Py- Px+

Qy+
Translational
part
Qy- Qx+
Rotational
part

Remote
center

Passive-insertion support 6-Components sensor for robotarms

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 1890 - 1 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0536 - 0
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metal (transparent) layer (gate)

Transmitted light
SiO2

Reflex
p-type silicon

Principle of glass-fiber

MOS - Condensator Operating modes of glass-fiber conductors 47

 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0537 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0538 - 0
TUHH TUHH

Signal
converter layer

transparent
focusing coil front plate
fiber-glass cross-sectional (signal plate)
area converter
steering coil

scene
electronic beam

picture signal
cathode

localization of cast burr Tube of a TV camera

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0258 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0539 - 0
TUHH TUHH
photo electrode transfer electrode
diodes row

conveyor belt integration

workpiece
sensor range transport range

photo electrode transfer electrode

movement direction
transfer

sensor range transport range

object detection with a semiconductor - diodes row CCD - picture sensor 48

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 1891 - 0 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López
2- 1072- 0
TUHH TUHH
L1
L2 Horizontal analog transfer register
L3
G1 G2 G3 G1 G2 G3
Row

p-type silicon SiO2

4

P V P V P V P V

Column A B C D

P=Photosite Vertical analog transfer register

Potential sequence by 3-phase CCD Information processing in CCD

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 2 - 0540 - 0
2- 0702- 0
TUHH TUHH

1111
1110
1101
1100 single point center of gravity length contour form contour
1011
1010 bright
1001
1000
0111
0110
0101 dark
0100
0011
0010
0001
0000

T0 t surface number of moment of circumscription

silhouette surface hole inertia rectangle
Luminosity (light) signal digitilization of an image line Rotation-independent feature criteria 49
 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 0703 - 6
2- 0701- 0
TUHH TUHH

Angular sequence

terminal

pre- picture micro- arithmetic-

camera processing storage processor processor
Measurement circle

Center of gravity of
Angle of reference the surface

Workpiece
ROM/RAM
Interface program and
data memory

Polar check for workpiece identification Computer components of an image preprocessing system

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López 9 - 0626 - 4 Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López
2- 1859- 0
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Scene for workpiece identification sensors
recognition so far only in trial partly possible recognition only with existing systems Measuring
amplifier PSI

camera camera

Laser light source

more workpieces in image
workpieces in disorder and one
area trial partly in contact
upon the other in the memory

camera camera Row of diodes

Optic

more workpieces in image

one layer workpieces in trial partly area trial partly not in contact MD
upon the other

camera
MR

MR - measurement region
one workpiece in image area MD - Measurement distance

optical workpiece identification sensors Triangulation process 50

Prof. Dr.-Ing. K. Rall & Prof. Dr.-Ing. E. López
2- 1860- 0
TUHH

PSI

Read Laser
in outline measuring
head

Wanted
pattern
Measurement region

Ring gap

Montage hole Montage hole

Control of securing with laser scanner

51