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INTELLIGENT WORKCELL ROBOT SYSTEM IN

MANUFACTURING WITH ABB IRB 2000
Article January 2011

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Polytechnic University of Timisoara

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INTELLIGENT WORKCELL ROBOT SYSTEM IN MANUFACTURING WITH ABB

IRB 2000
Tihomir Latinovic1, Sorin Deaconu2, Gencho Popov3, Marcel Topor4
1
Faculty of Mechanical Engineering , Bosnia and Herzegovina,
2
Polytechnic Faculty in Hunedoara, Romania,
3
University of Rousse, Bulgaria,
4
Polytechnic Faculty in Hunedoara, Romania,
Abstract: Intelligence is the result of learning. Intelligent systems are capable of learning, responding, and reacting to the physical
world without or with minimal human assistance. Because of the intense competition in the current global economy, a company must
conceive, design, and manufacture new products quickly and inexpensively. In serial production, work cell settings are subjected to changes.
The set-up time for changeover and calibration are very interested. To reduce the set-up time, this paper aimed to develop an intelligent
work-cell robot that can on-line adapt to the work cell changes and the associated calibrations automatically. The results showed that this
intelligent robot is able to automatically re-organize itself for dynamic work cell changes including mal-functioning machines, newly
introduced or removed machines and product changes. A significant amount of time in system installation, re-setup, calibration and reprogramming can therefore be saved. To resolve manufacturing control problems and meet global trends, embedding intelligence in
manufacturing system has been recognized to be a very effective approach.
Keywords: INTELIGENCE, ROBOT, WORKCELL, MANUFACTURING

Similar to its predecessor, the major differences are that the new
IK-HR1S has HD-SDI output and increased sensitivity, whereas,
the IK-HR1D has DVI-I output.[1], [2]

1. Introduction
In mass production, set one robotics work is basis of cell
modern production. Just set the working robotic cell can often lead
to low utilization of robots. Our goal is to develop intelligent
robotic cell that responds to the mode and automatically
calibrated. The results showed that this intelligent robot cells are
able to automatically organize the dynamic changes in working
conditions, failure in the cell or product changes. Significant time is
used to install the system, reset, calibrate and re-programming.
[2],[4]

The future manufacturing system is expected to possess much

greater flexibility than such system here now. Today if a machine is
broken down, work cell has to be halted until setup, installation, and
programming have all been completed. Clearly, an intelligent
system capable of handling work cell changes automatically is
important for the future of manufacturing. The challenges and major
difficulties of developing such system are[5],[6]:

How to indentify the necessary subsystems

How to design and develop the subsystems

How to embedded intelligence in the system

How to integrate and coordinate subsystems properly

Small Form Factor (Single body)

Low Power Consumption
C-Mount
Auto Electric Shutter
Auto/Manual White Balance
Gain Function in Great Detail
Serial Command Setting via RS-232C

We need:

CAD based simulation

Robot work cell simulation data

Machine vision to realize object recognition

This system then culminates in high machine utilization,

especially for small-sized production manufacturers.

Fig. 1 Working principle of 3D the printer EOSINT M 270.

Robot System. This cell is based on an ABB IRB 2000 robot.

Some of the most important features of this robot are presented
below:
Degree of freedom - 6
Loading capacity - 10 Kg
Repeatability - 0.1 mm
Reach length - 800 mm
Operating area
o Axis 1 - 179
o Axis 2 - +100 to - 110
o Axis 3 - 60
o Axis 4 - 200
o Axis 5 - 120
o Axis 6 - 200

2. System Hardware Overview

Machine vision system. Progressive to interlace scanning
switchable while delivering very large bandwidth over longer
distances, Toshiba's new IK-HR1S is a Mini, single-chip HD
camera that makes an ideal solution for professional and specialized
broadcasting and/or industrial imaging applications. Third
in Toshiba Imaging's family of high-definition cameras, the very
small form factor camera (only 1.75in x 1.75in x 3in) features 2.1
MP, a 1/3 " CMOS sensor, an RS-232 serial interface, optional
720p or 1,080i scanning operation, both with HD-SDI output, and a
C-mount lens interface, offering clear, crisp HD imagery and
superior color resolution. [5]

43

Speeds

o
o
o
o
o
o

Axis 1 - max. 115/sec

Axis 2 - max. 115/sec
Axis 3 - max. 115/sec
Axis 4 - max. 280/sec
Axis 5 - max. 300/sec
Axis 6 - max. 300/sec
Drive - DC servomotor
Pressure range - 4 .. 8 bar
Digital Outputs - 16 (0.2A;24VDC)
Digital Inputs - 16 (24VDC)

3. System Software Overview

An important part of any computational architecture is the
software. In this system, the software provides system modeling,
planning, sensing and acting.[10] The architecture of the systems
functional modules is shown in Fig. 2

4. Conclusion
In this paper, the CAD simulation was built to provide the
background knowledge of the workcell for the robot to compare
with the physical world for proper actions. The vision system
was developed to realize object recognition and location
determination. A common database was structured to store
information. The integrated intelligent robot that can
automatically accommodate the frequent workcell changes was
thus constructed.[8], [10],[7]

The goals of the software modules were to provide

Image processing system and robot control system: A

data file was employed.
3D F/T sensor and robot control system: Neural networks
and C programs.
Common database: It contained the following subdirectories:
CADPATH: keeps robot moving path files generated by
ASM simulation.
IMGCDE: keeps image codes. Workpart might be
presented under camera in upside down, right side up, or
other poses. Therefore, it was possible to associate several
codes with one workpart.
JQC: Job Queue Centre keeps all job requests.
FRC: Fault Report Centre keeps machine status.

A flexible and friendly environment for coding,

debugging , and running programs
A friendly simulation environment for generating
necessary background data for proper system
performance,
Different library modules to be combined for various
applications

An intelligent workcell robot system is presented, which

was experimentally proven robust and valid in dealing with the
defined dynamic workcell changes. The time-consuming system
re-setup,
calibration,
and
re-programming
were
eliminated.[10],[6]

5. Reference
[1]

[2]

[3]

[4]

[5]

[6]
Fig. 2: System functional modules

The system functional modules, shown in Figure 2, include:

ASM (Advanced Solid modeler) ASM was developed to

simulate the camera and robot workcell operations [6] and
in this way allows you to display 2D perspective gray
image that is very similar to that of real cameras.
Workcell has also modeled and suggest the robot path
simulated time, which is stored in a shared
database.Image processing module (machine vision)
Communication among subsystems:

CommTools: between the personal computer and ABB

Robot Controller.

PC-NFS: It allows PC to access files on any NFS server

on the network.

[7]

[8]

Borangiu, Th., Intelligent Image Processing in Robotics

and Manufacturing, Romanian Academy Press,
Bucharest. (2004).
Borangiu, Th., F.D. Anton, S. Tunaru and N.-A.
Ivanescu, (2005). Integrated Vision Tools And
Signature Analysis For Part Measurement And
Recognition In Robotic Tasks, IFAC WorldCongress,
Prague,2005
James J. Solberg and R. L. Kashyap, ERC research in
intelligent manufacturing systems, Proceedings of the
IEEE, Vol.81, Iss.1, p.25-41, 1993
Bosnik, J.R.; Hemati, N.; Pourki, F.; Siegler, S.,
Robotics in intelligent manufacturing: IMPAQT
activities, Proceedings, 5th IEEE International
Symposium on Intelligent Control, Vol.2, p.1205-10,
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Tien-Fu Lu and Grier Lin, CAD, vision, and sensor
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Lu Tien-Fu; Lin Grier C. I. and He Juan R., Neural
Network Based 3D Force/Torque Sensor Calibration for
Robot Applications, Journal of Engineering
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Lu, Tien-Fu; Lin, Grier and Lambrinos, Evangelos, The
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th

Robotic Assembly Cell, the 5 Int Conf. on Industrial,

1999
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[9]

44

Lu, Tien-Fu, An Intelligent workcell robot the 6 Int

Conf. on Manufacturing Technology, 2000