Robot, RRS, RCS

Contents
1. What is Robot??
2. Applications of the Robots. 3. Automotive Industrial Robots. 4. Singularity Error

5. Selection Criteria in BIW Lines

6. RRS and RCS. 7. What is the difference between different controllers?? 8. What are the attributes we give while doing OLP and what are their significance?? 9. What info we store in .src and .dat files (Downloads from Robcad)?? 10. What are $config.dat and $machine.dat?? 11. What are Humming Bird and Exceed??

What is Robot??

A Robot is a reprogrammable, multi-functional manipulator designed to move material, parts, tools, or specialized devices through variable programmed motions for the performance of a variety of tasks.

Types of Robots on the basis of construction

Serial. The interconnection topology of the kinematic chains is a chain without loops or without multiple branches.

Humanoid. The interconnection structure of the kinematic chain is a tree.

Parallel. The interconnection structure of the kinematic chain consists of two "platforms" connected by a number of legs in parallel. These legs often have identical (mostly serial) kinematic structures.

Mobile. The interconnection structure of the kinematic chain is that of two or more wheels connected to the same base. The base itself can, in turn, carry a kinematic chain too. 4

Industrial Robots
1. Cartesian Robot (Gantry Robot)
Three linear joints provide the three axes of motion and define the x, y and z planes. This robot is suited for pick and place applications where there are no orientation requirements

2. SCARA (Selective Compliance Articulated Robot Arm)

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

3. Six axes Robot

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

Axis 1 This axis, located at the robot base. Axis 2 This axis allows the lower arm of the robot to extend forward and backward. Axis 3 The axis extends the robot's vertical reach. It allows the upper arm to raise and lower. Axis 4 Working in conjunction with the axis 5, this axis aids in the positioning of the end effector and manipulation of the part. Axis 5 This axis allows the wrist of the robot arm to tilt up and down. This axis is responsible for the pitch and yaw motion. Axis 6 This is the wrist of the robot arm. It is responsible for a twisting motion, allowing it to rotate freely in a circular motion, both to position end effectors and to manipulate parts.

Main Components of the Robots

Controller:
The brain' of the Robot

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

End effectors:

Connects to the robot's arm and functions as a hand. This part comes in direct contact with the material the robot is manipulating.

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

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

Major Applications of Robots in Automotive Industries

Painting Arc welding Palletizing Sealing/dispensing Spot welding Assembly Stud Welding Hemming Inspection

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Other Applications
Electron Beam Flux Cored Welding Mig Welding Plasma Cutting Resistance Welding Robot Laser Welding Tig Welding Welding Automation

Dispensing Machine Loading Machine Tending Material Handling Order Picking Packaging Palletizing Part Transfer Pick and Place Press Tending Bonding / Sealing

Cleanroom Deburring Drilling Flame Spray Grinding Material Removal Milling Painting Automation Polishing Robotic Assembly Robotic Coating Thermal Spray

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Robot in Transport Position

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

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

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

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Selection Criteria
Depends on the Application Reach ability Payload

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Equivalent Robot selection with same Reach (Kuka Specific)

KR150_2 KR150L130_2 KR150L110_2 KR180_2 KR180L150_2 KR180L130_2

KR210_2 KR210L180_2 KR210L150_2

KR240_2 KR240L210_2 KR240L180_2

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Equivalent Robot selection with same Payload (Kuka Specific)

KR150_2 KR150L130_2 KR150L110_2 KR180_2 KR180L150_2 KR180L130_2

KR210_2 KR210L180_2 KR210L150_2

KR240_2 KR240L210_2 KR240L180_2

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SAME REACH ROBOTS

SAME PAY LOAD ROBOTS

1500
PAY LOAD (Kg)

REACH (mm)

1100

1300

KR 150

KR 150 L130

KR 150 L110

110

KR 180

KR 180 L150

KR 180 L130

130

KUKA ROBOT
KR 210 KR 210 L180 KR 210 L150 150

KR 240

KR 240 L 210

KR 240 L180

180

240

210
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SAME REACH ROBOTS

REACH (mm)

1025

1275

1525

KR 360-2

KR 360 L280-2

KR 360 L240-2

KR 500-2
KUKA ROBOT

KR 500 L420-2

KR 500 L340-2

KR 360 450-2 PA

KR 360 L340-2 PA

KR 360 L280-2 PA

KR 500 570-2 PA

KR 500 L 480-2 PA

KR 500 L420-2 PA
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Reach Robot
1100 KR150_2 KR180_2 KR210_2 KR240_2 KR150L130_2 KR180L150_2 KR210L180_2 KR240L210_2 KR150L110_2 KR180L130_2 KR210L150_2 KR240L180_2

Payload Payload Robot

150 180 210 240 130 150 180 210 110 130 150 180

Reach
1100 1300 1500 1100 1300 1500 1100 1300

150

180 210

1300

KR150_2 KR180L150_2 KR210L150_2 KR180_2 KR210L180_2 KR240L180_2 KR210_2 KR240L210_2

1500

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RRS and RCS

Realistic Robot Simulation Realistic Controller Simulation
1. Until the early 1990s, the motion behavior of robot simulation often strongly deviated from real behavior. 2. RRS is the interface between Simulating Software and Robot specified Controller 3. Robot Controller Simulation (RCS-) Modules is supplied by controller manufacturers as blackboxes to any simulation system supporting the RRS Interface. 4. Today the RCS-Interface is the world-wide defacto standard for precise simulation of robot motion behavior.

Figure. 2: The RRS-Interfaces enable to integrate any robot software into any simulator

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RRS Interface Overview

User activity model

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Partners for RRS Project

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Difference between Default controller and Robot specified Controller

Controller:
An object able to perform a task which contains logical operations, calculations and signal handling, but which does not include motion commands. A default controller is a Controller model which has only basic attributes which are required to move the robot in the simulation model and the motion need not to be so exact as the Real-time.

But a Robot specific controller is integrating the motion controller software of any robot controller into the simulation system that has the attribute set up which is similar to the actual controller used in the Real time environment.
The simulation will be as exact as the motion that is going to be executed in the plant. And so we can directly download the Programs/paths from the simulation software and even we can adjust the Programs in an interactively and simultaneously.

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Overview of the Files in ROBCAD

These all are the Files required to run VKRC controller. These all are the Files required to run Default controller
Please note that for the simulation and to define tool it has separate program subroutines logics are used in robot specific controller. But in case of default controller it is a simple program which reads just the motion attribute of the location

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What are the attributes we give while doing OLP and what are their significance??
Tool & Base Motion Type: Joint/Linear/Circular Accuracy Profile Tool Type: External/Mounted Configuration: status and turns Load Data

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General TOOL and BASE Definitions

Process Paths: The TCP is measured from the flange of the robot and BASE is car origin measured w.r.t robot base. E.g. Spot/stud Welding, Arc Welding, Hemming, In case of External TCP, it is measured from the base of the robot and Base is Car origin measured w.r.t Robot Flange. E.g. Stationary Spot/stud Weld, Gluing, Clinching, Handling Path: We use TCP at the top of the fixed pin of gripper. Parallel to robot flange axis and co-ordinates are w.r.t. Robot Flange. For material handling equipment, Robot base will be taken as BASE. For fixtures, BASE will be at Car origin.

Note: These definitions may vary with OEM to OEM.

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Motion Type
1. Joint Motion:
It is the fastest path (Takes minimum time). TCP movements are not defined. All the joints accelerates and decelerates at the same time. Joint will move in one direction only. It is preferred to use in all via location.

2. Linear Motion:
It is the shortest path (Takes maximum time). TCP movements are in a straight line. All the joints accelerates and decelerates independently. Joint may not move in one direction. It is preferred to use at process locations.

3. Circular Motion:
TCP moves in an arc. Can be useful in the processes like Hemming, Glue, Arc Welding Etc.

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Comparison Between Linear, Joint and Circular Motion

Linear Motion Circular Motion

P1

P2 Joint (PTP) Motion

P0

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Accuracy
Flyby means that the controller can look ahead and take into account more than the current target when planning a path and calculating robots motion. The biggest advantage of the flyby mode is that the corners can be rounded to maintain a constant speed. It is the amount by which the TCP will reach to each programmed location. For Ex. If it is 0% than TCP will reach and touch to each location and if its 100% it will do the maximum approximation (for clarification pls see the images)

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Accuracy profile 0% P3 P2

P4

Accuracy profile 100%

P1

Accuracy profile <100%

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Time Study for Approximate positioning.

Velocity P1 Vprog P2 P3 P4

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

10

15

20

25

30

Time (s)

Velocity

Vprog

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

10 P2

15 P3

20

25

30

Time (s)

P1

P4

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Tool Type
Normally Tool are of two types:
Basic TCPF
In which the TCPF has been defined at the tool mounted on the Robot, and the Robot will move to match the Target with the TCPF defined.

External TCPF

The work piece is mounted on the robot, and the tool is stationary (external) to the robot. Such a TCPF definition is used in case of gluing and static Spot welding.

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Load Data
In order to maintain the Simulation accordance with the Real time model the Load data value must match with the Simulation data. The Mass, Centre of gravity and M.I. w.r.t. Robot flange of the tool mounted must be defined in Load data. In the absence of Load data the robot will move with full payload value which results in wrong Cycle time calculation.

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Configuration

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

To move robot to a location in space with a specific configuration Precision point must be used.
That precision point specifies the joint values of that particular location & the position and orientation of the point .
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What info we store in .src and .dat files??

SRC The SRC file is where all the "executable" code resides like Tool, Base, Motion and Accuracy Profile. In SRC file, we need to make sure to set active Tool, Base, and Speed (Joint speed and linear speed both) before we actually perform any motion commands. It contains the sequence of the program with attributes assigned for the points. DAT The DAT file is where the persistent variables are stored, like point positions (usually E6POS or E6AXIS variable types). It contains list of all the points i.e. via and process, and its coordinate values, tool and base frame assigned for the points.

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.src File

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.dat File

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What are $config.dat and $machine.dat

config.dat
In this, we store TOOL- and BASE- DATAS, LOAD-DATAS and all moving parameters we use. I/O signals are also declared here. But pay attention, each costumer have his own modification.

machine.dat
It contains DATAS given by the Robot-provider. In this data You find all parameters which define the robot-type. Each type needs his own special data.

Do not change this data without permission from the provider, especially the typical movement parameters.
Some parameters, for example IN/OUT-signals for safe-robot, You can change according to the needed configuration. The function of this machine.dat is the same like the controller in Robcad. It contains the typical movement behavior of the robot system.

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What are Humming Bird and Exceed

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

RobCAD originally ran on unix, but when they released the Windows version of Robcad they had not rewritten robcad, they ported it instead (exceed acts like a unix environment for Robcad to run on).
If you dont have exceed, current versions of robcad will not run on windows based Systems.

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Major Robot Manufacturers

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References
www.Realistic-Robot-Simulation.org www.Robots.com www.learnaboutrobots.com Kuka Robot Programming Handbook www.kuka.com www.americanrobotcorporation.com

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Thank You!!
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