Robotics & Automation

Assignment : Analysis and design of a robot system

Vazguene AKOPIAN 10006669 Module Number : CE00453-7

Contents
Introduction...................................................................................................... .........................3 Section 1 1.1 1.2 Section 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 The Task.................................................................................................... ..........9 The Workspace...................................................................................... ...........10 The Robot.............................................................................................. ...........11 The Sensors............................................................................................. ..........12 The Gripper............................................................................................ ...........14 The Safety.............................................................................................. ...........16 Approximate cost and payback.................................................................. ......17 Study of the Puma 560 robot kinematics .............................................. .............3 Creation of a three link robot..................................................................... ........5

Conclusion.............................. .................................................................................... .............17

List of figures
Figure 1 : Joint angles positions Figure 2 : Velocity of each joint Figure 3 : Robot specifications Figure 4 : DH Matrix Figure 5 : Three link created robot Figure 6 : Results of the forward kinematics on MATLAB Figure 7 : Rotation component into RPY Figure 8 : Schematic of the robot-cashier system Figure 9 : STUBLI TX60 Figure 10 : CamCube 3.0 by PMD Figure 11 : Torquemeter SCAIME DR1 Figure 12 : Gripper METAL WORKS Series P9-32 Figure 13 : Design of the pinch of the gripper

Vazguene AKOPIAN 10006669

Module : CE00453-7

Introduction

In this report we will treat some aspects of the manipulation and the creation of robots. The first section will explain the simulation of a robot with MATLAB and the robotic toolbox , the study of its kinematics and the design of a three link robot with DH matrices. In the second part we will see the design and requirements of a robot -cashier system.

Section 1

1. 1 Study of the Puma 560 robot kinematics

First of all is the creation of the point B which will be the final position of the robot. Its coordinates are x = 0.211, y = 0.851, z = 0.010. Now that we have this point we can use the 'ikine' function (inverse kinematics) to obtain the joint angles in the final position :

clear all; puma560; %drivebot(p560) P=transl(0.211,0.851,0.010); % movement of the arm to coordinates PointB=ikine(p560,P) % inverse kinematics to get the joint angles

The joint angles obtained are : 16.8637 28.2835 -14.1317 -75.3982 -14.1518 71.1009 .

To get position and velocity graphs we calculate the trajectory of the robot with the function 'jtraj' which needs the initial and final coordinates, the total time and the sampling rate.

Vazguene AKOPIAN 10006669

Module : CE00453-7

P=transl(0.211,0.851,0.010); movement of the arm to coordinates % % PointB=ikine(p560,P) inverse kinematics to get the joint angles %% t=[0:0.125:7]' % total time and sampling rate (in sec) start=[0 0 0 0 0 0]; initial position : all joint angle at 0 % stop=PointB;% final position %calculation of the trajectory to the point B [p v]=jtraj(start,stop,t); subplot(6,1,1);plot(t,p(:,1)) position graphs % subplot(6,1,2);plot(t,p(:,2)) subplot(6,1,3);plot(t,p(:,3)) subplot(6,1,4);plot(t,p(:,4)) subplot(6,1,5);plot(t,p(:,5)) subplot(6,1,6);plot(t,p(:,6)) figure; subplot(6,1,1);plot(t,v(:,1)) velocity graphs % subplot(6,1,2);plot(t,v(:,2)) subplot(6,1,3);plot(t,v(:,3)) subplot(6,1,4);plot(t,v(:,4)) subplot(6,1,5);plot(t,v(:,5)) subplot(6,1,6);plot(t,v(:,6))

Figure 1 : Joint angles positions

  

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Figure 3 : Robot specifications

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Figure 4 : DH Matrix

The following program permits to give to our robot the decided dimensions in this DH matrix. The command 'link' permits to write each line separately then they are put together in the matrix 'R' which is used to simulate the robot.
clear all; l1=link([0 300 0 0]); l2=link([0 200 0 0]); l3=link([0 80 0 0]); R{1}=l1; R{2}=l2; R{3}=l3; S=robot(R) drivebot(S)

Figure 5 : Three link created robot

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Now that we have set up the dimensions, we must choose the angles to use in the forward kinematics. We get : 1 = 90 = 1.570 rad 2 = 60 = 1.047 rad 3 = 90 = 1.570 rad
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The following code allows to give to our robot the angles of its joints and to perform the forward kinematics with 'fkine'.
angle=[1.570 1.047 1.570] T=fkine(S,angle)

The result of this command shows the coordinates of the final point :

By using 'tr2rpy' we can get the values of the roll, the pitch and the yaw the end point. The results are shown below : roll = 0 pitch = 0 yaw = -2.0962

Vazguene AKOPIAN 10006669

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Module : CE00453-7

To verify these results we do some manual calculation using the rotation and translation matrices applied to this case. For this robot we only need the rotation about Z and translation along X matrices to calculate the forward kinematics. We replace with our values of angles and lengths and after the multiplication of the three rotations by the three translations we obtain these results : -0.5 -0.86 0 0 0.86 -0.5 0 0 0 0 1 0 -213.2 331.2 0 1

The slight differences between the results are due to approximations done in previous steps of the calculation. To calculate the roll, pitch and yaw we will use the formulas below :

Figure 7 : Rotation component into RPY

As our r31, r32 and r33 e ual to 0, X and Y e ual to 0 and we find Z = -2.0974. The difference of 0.0012 is due to previous approximation. The manual calculation and MATLAB give almost the same results.

Vazguene AKOPIAN 10006669

Module : CE00453-7

Section 2

2.1 The Task

The goal of the robot from this case study is to replace a human cashier in the supermarkets. The customer arrives and lays his items on the first convey er (the slow one). The items go then to a faster conveyer which will split the items from each other. Inside the Plexiglas shield (level 0), the 3D camera placed on the top of the system (level 2) will see the items arriving in the workspace. The conveyer will stop when an item arrives at the laser sensors and, guided by the camera, the robot arm will take the closest item on the conveyer. The robot will bring th e item above the barcode readers and turn the item until it receives the signal that the item has been scanned. Once the price recorded, the arm will put the item in the hole on the last conveyer (level -1), which will bring it to the customer, on the weig hing machine. The arm will repeat the operation while items are coming on the conveyors. The customer will have plastic bags available on one side of the system. He will have 2 seconds to take an item and put it back on the weighing machine, inside the bag . If this operation takes too long, the customer will hear the message to put the item back on the weighing machine, the robot will stop and a red light high placed on the system will switch on, attracting the attention of security guards. Once the client has paid his items he can leave and the next customer can put his own items on the first conveyer.

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Module : CE00453-7

2.2 The Workspace

Figure 8 : Schematic of the robot-cashier system

The robot has to work in the same workspace as the human operator did before, so more than the Plexiglas box, one bumper pole one each side of the arm will stop it if , in case ofa problem, the arm decides to go behind its workstation. Besides, these bumpers are an additional security for the worker, in case he has to penetrate inside the Plexiglas fence through the gate. Also there is the possibility to put another cashier robot in the other side, next to this one to optimise place.

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2.3 The Robot

The arm that seemed the most adapted to this situa tion is the industrial robot arm STUBLI TX60.

Figure 9 : STUBLI TX60

This arm has six degrees of freedom which assures an excellent mobility.The robot is quiet compact so a small work-envelope fits. Also, it is waterproof and it benefits a total dust protection. The payload of this arm is 3.5 kg with a maximum of 9 kg. To this we must add the weight of the gripper and the pinch, so approximately 1.5 kg which gives us 2 kg to 7.5 kg for the payload of the robot, which is enough for supermarket items. The reach at wrist of this arm is 670 mm, but once the gripper and the pinch (gripper's fingers added the reach becomes 940 mm.

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2.4 The Sensors

The most important detector of this system is the Time O Flight (TOF 3D Camera. f

Figure 10 : CamCube 3.0 by PMD

This camera will see and analyse the size of each item. It is wide-angle so it sees everything from the arrival of the items on the conveyor to the arm robot placing the item after scanning on the last conveyor. This camera gives directions to the robot arm in all its movements. On each side of the camera there is a matrix of infrared light which spreads in the area and the camera gets the light when it returns and calcula the distance from the time that the tes light needed to come back.

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The second sensor to be used in this case is the torque meter.

Figure 11 : Torquemeter SCAIME DR1

The torque meter will detect if something opposes resistanceon the arm's motor in two cases : y when the gripper grabs an item from the conveyer it must not be cashed by the robot, so the torque meter will detect this and stop the motor y if something goes wrong and the arm touches one of the bumper poles, to avoid any mechanical damage the sensor will also stop the motor. Also, there is the possibility to add a slip detector to improve the robot's abilities if necessary.

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2.5 The Gripper

For this kind of task the robot-cashier has to grab every kind of objects, of every size, every shape so choosing an angular gripper was the only thing left.

Figure 12 : Gripper METAL WORKS Series P9-32

The METAL WORKS Series P9-32 has a jaw opening angle adjustable up to 180, so it can grab objects of any size. The clamping force at 20 mm from the jaw pivot is 180 N so it can lift even big bottles or beer packs.

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Then we had to find a pinch that could be versatile enough to fit to all items of a supermarket. Is this system does not exist yet we had design the fingers of the grip.

Figure 13 : Design of the pinch of the gripper

This kind of design can grab big items like a bottle, a box of cereal with the wide inside part, and small items with the hole in the middle of the end of the fingers for cylindrical items, or between the end of fingers for any other shape. To benefit lightness and strength the pinch will made in aluminium.

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2.6 The Safety

In a supermarket the customer stays very close to the cashier so we had to secure the workplace of the robot without loss of place and with 100% safety guarantee for the customer. The whole workplace of the robot is secured with a Plexigla s fence accessible only through a service door. If an employee has to enter into the security fence, the fact of opening the door will automatically stop the robot. Moreover to guarantee the safety of the employee one bumper pole is fixed in the ground to create a guardrail in case of uncontrolled movements of the arm. Two emergency buttons have been installed : one at the end of the first conveyer and another one next to the weighing machine at the end of the process. The 3D camera's angle is wide enough to see the whole process, so it will b e able to detect if a human hand comes inside the workplace of the robot and shut down the arm before it hurts anyone. The entire part of the supermarket will be monitored by a team of human operatives who will ensure that everything is working safely and intervene if anything goes wrong.

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2.7 Approximate cost and payback period

The calculation of the cost or the payback of this system includes every part's price : y y y y y y y y y y the arm the gripper and the pinch the 3D camera and the torque meter the Plexiglas fence the secured door of the fence the three conveyers the emergency buttons the bumper poles the weighing machine the installation costs

The price of all these parts must be compared to the cost per year of a cashier : his salary, the cost of an employee to the company , any other spending that the company has to do related to the employee. To get the payback period we have to divide the total price of the robot system by the total cost of a cashier employee per year. The approximate cost is the sum of the elements listed above.

Conclusion
Through this assignment we saw how to manipulate and understand a robot on MATLAB with the Robotic Toolbox, the possibilities of this software. We also learned a lot about how to design an entire robot system and how to apply it in the real world, the aspects of the conception that have to be treated and all the questions that have to b e answered.

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