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Approaches to industrial robots application in discrete manufacturing
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Approaches to Industrial Robots Application in Discrete Manufacturing Z d e n r k Kozar
I. Introduction
Research Institute VUSTE, Praha, Czechoslovakia Changes in mechanical and electrotechnical production processes in recent periods are discussed in this paper. Likewise, research and development and implementation of Industrial Robots and Manipulators in Czechoslovakia, governmental research and application programs and main future trends and research tasks in this field are dealt with.
The contemporary period brings forth an implementation of research results and new technology principle changes in production processes in mechanical and electrotechnical engineering. The main changes can be summarized in the following groups: -
Keywords: Industrial robots and manipulators, Typical application projects, Industrial implementation, Group application, Governmental program, Future trends.
Changes in operational modes of the production process - application of new technologies, tech-
nical means and devices, substantial performance increase and the like - Production process integration - in discrete production new principles and technical means allow for a shift from the former approach "separate individual operation" to the design of the production process in group mode and, in some cases, as a whole; an important role in this change is played by the control process of these operations, and the production process as a whole - implementation of low-cost computer technology and its broad flexibility allows for a larger autonomy of the production process in spite of an increase in multilateral and multiform features of production processes -Broad automation implementation in discrete manufacturing - in this type of production auto-
Dr. Z ~ n ~ k Kozar graduated in mechanical engineering at Technical University of Prague in 1954 and took his PhD in management science in 1976. Since 1972 he is managing director of Research Institute of Technology and Economy - VUSTE, Prague, the main Czechoslovak institute in mechanical engineering. His current research interests include manufacturing automation, CAM and flexible manufacturing systems. North-Holland Computers in Industry 7 (1986) 233-235
mation is no longer an exceptional element, but it changes into a common operational feature; multilateral application of electronics enables to adapt control systems to specific requirements of individual cyclic character phases in discrete manufacturing, and to incorporate artificial intelligence elements; - Production control in real-time is possible by computer miniaturization and efficient application software; -
Changes in range and character o f the solved problems o f discrete manufacturing, both techno-
logical and economic in nature and social problems connected with a new technology application; -
Changes in technical and control level o f coupling manufacturing and manipulation means - to miss
234
Industrial Robotics in Discrete Manufacturing
differences and to reach equal level of automation up to an integration of operational manipulation into machine tools as organic part. Very important means, which support these changes in discrete manufacturing, are industrial robots (IR) or industrial robots and manipulators" (IRM). Their application in cyclic manufacturing processes enables an efficient automation in many phases of discrete manufacturing. Our Research Institute VUSTE in Prague directs its researchand developmental efforts toward an introduction of industrial robots to automated production processes. The last decade has seen a remarkable advance in the development of IRM from mere technical devices to an independent industrial branch. This can readily be demonstrated by a number of factors. 2. Governmental Research and Application Program
In order to increase the rate of development of IRM and its wide application, an extensive program called Governmental Research and Application Program for the period 1981-1985 has been issued by the Czechoslovak government. It is intended to give technical, technological, production and financial support to the industry and research in this important field. The program has five parts:
2.1. Research and Development of I R M This includes development and production of our own IRM generation both universal (12 types) and technological in nature. Research and development are concentrated in the Institute of Technical Cybernetics, Slovak Academy of Sciences, and in the Research Institute VUKOV in Pre~ov.
2.2. Experimental Implementation in Main Industrial Branches The program determines and finances the main areas and trends in an application to the individual types of discrete manufacturing with the aim to specify optimal application conditions.
2.3. Typical Application Projects for Various Types of Production Solution, design and experimental verification of application of projects to implement efficiently
( ~m~puter.~ m Imh~Irv
and in a short time the individual types of discrete production with IRM, in machine building industry under concrete conditions from piece work to mass production.
2.4. Education in 1RM Preparation and implementation system of training and courses in this new branch, with emphasis on post-graduate courses; training of designers, technicians, operators, maintenance-specialists; with emphasis on an organic incorporation of IRM application into the production process and on creating an adequate working regime.
2.5. Preparation of New Support Program The program also includes the preparation of a new five-year governmental support program scheduled for 1985 with emphasis on adaptive IRM and practical application of artificial intelligence principles.
3. I m p l e m e n t a t i o n of I R M
The current Governmental Program and incorporated applications is intended, in the period 1981-1985, to reach rroduction in and application of more than 3500 IRM to different branches of the Czechoslovak industry. By the end of 1983 more than 1500 IRM had been implemented. Of course, other applications are realized besides this program, since the program is only supporting group-application of IRM. Almost one-half of all applications in the program will be prepared and implemented as complex units - automated technological cells. These cells are designed and projected as modules of automated production processes based on the principles of a flexible automation. It means an efficient utilization of one of the fundamental IR-properties, i.e. programmable principle connected with modularity. Application of IRM to the Czechoslovak industry is oriented above all to the following branches: - mechanical engineering, including the car and airplane industry - electrotechnics - electronics - light chemical and pharmacological industry
Computers in Industry
Z. Kozar / Industrial Robots Application
- civil engineering semifabricated goods (bricks, tiles, steps, etc.) glass and ceramic industry - food industry. In the present five-year period priority in the application of IRM has been given to mechanical and electrotechnical engineering, where IRM has been introduced to all primary production processes. Simultaneously, their function in the FMS (marked RFMS) has been tested in technologies of milling, pressing, welding, galvanotechnology, and painting. First steps have been taken in an assembly-application of IRM. When implementing IRM we try to identify and overcome the actual critical application points. Some of these are: reliability of IRM - implementation period reduction - easy programming user-oriented software dimension and weight decrease in IRM - price reduction - maintenance system and diagnostic optimal application conditions. -
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4.
M a i n
F u t u r e
T r e n d s
a n d
R e s e a r c h
T a s k s
In our research Institute VUSTE oriented to a flexible automation application in mechanical and electrotechnical engineering branches we have
235
specified recently the following main research
tasks: unification of new IRM families and their interface efficient control systems and artificial intelligence intelligent sensors and untypical peripherals development - testing methods for IRM - modular software interactive programming problem-oriented languages adaptive IRM typical automated technological cells (with IRM) - organic insertion of IRM in production process - group technology and IR evaluation of effectiveness requalification of production staff optimal application conditions. Presumptive future trends in IRM applications are: a. complex FMS with broad IR implementation b. IR and C A D / C A M systems c. IR and working environment d. new manufacturing processes with IR. In conclusion, it is necessary to emphasize the role of IRM as an effective and universal means of production automation. This was verified in many prepared and realized applications. In this, we should keep in mind the main and decisive aim a complex automation of the production process. -
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-
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Approaches to Industrial Robots Application in Discrete Manufacturing Z d e n r k Kozar
I. Introduction
Research Institute VUSTE, Praha, Czechoslovakia Changes in mechanical and electrotechnical production processes in recent periods are discussed in this paper. Likewise, research and development and implementation of Industrial Robots and Manipulators in Czechoslovakia, governmental research and application programs and main future trends and research tasks in this field are dealt with.
The contemporary period brings forth an implementation of research results and new technology principle changes in production processes in mechanical and electrotechnical engineering. The main changes can be summarized in the following groups: -
Keywords: Industrial robots and manipulators, Typical application projects, Industrial implementation, Group application, Governmental program, Future trends.
Changes in operational modes of the production process - application of new technologies, tech-
nical means and devices, substantial performance increase and the like - Production process integration - in discrete production new principles and technical means allow for a shift from the former approach "separate individual operation" to the design of the production process in group mode and, in some cases, as a whole; an important role in this change is played by the control process of these operations, and the production process as a whole - implementation of low-cost computer technology and its broad flexibility allows for a larger autonomy of the production process in spite of an increase in multilateral and multiform features of production processes -Broad automation implementation in discrete manufacturing - in this type of production auto-
Dr. Z ~ n ~ k Kozar graduated in mechanical engineering at Technical University of Prague in 1954 and took his PhD in management science in 1976. Since 1972 he is managing director of Research Institute of Technology and Economy - VUSTE, Prague, the main Czechoslovak institute in mechanical engineering. His current research interests include manufacturing automation, CAM and flexible manufacturing systems. North-Holland Computers in Industry 7 (1986) 233-235
mation is no longer an exceptional element, but it changes into a common operational feature; multilateral application of electronics enables to adapt control systems to specific requirements of individual cyclic character phases in discrete manufacturing, and to incorporate artificial intelligence elements; - Production control in real-time is possible by computer miniaturization and efficient application software; -
Changes in range and character o f the solved problems o f discrete manufacturing, both techno-
logical and economic in nature and social problems connected with a new technology application; -
Changes in technical and control level o f coupling manufacturing and manipulation means - to miss
234
Industrial Robotics in Discrete Manufacturing
differences and to reach equal level of automation up to an integration of operational manipulation into machine tools as organic part. Very important means, which support these changes in discrete manufacturing, are industrial robots (IR) or industrial robots and manipulators" (IRM). Their application in cyclic manufacturing processes enables an efficient automation in many phases of discrete manufacturing. Our Research Institute VUSTE in Prague directs its researchand developmental efforts toward an introduction of industrial robots to automated production processes. The last decade has seen a remarkable advance in the development of IRM from mere technical devices to an independent industrial branch. This can readily be demonstrated by a number of factors. 2. Governmental Research and Application Program
In order to increase the rate of development of IRM and its wide application, an extensive program called Governmental Research and Application Program for the period 1981-1985 has been issued by the Czechoslovak government. It is intended to give technical, technological, production and financial support to the industry and research in this important field. The program has five parts:
2.1. Research and Development of I R M This includes development and production of our own IRM generation both universal (12 types) and technological in nature. Research and development are concentrated in the Institute of Technical Cybernetics, Slovak Academy of Sciences, and in the Research Institute VUKOV in Pre~ov.
2.2. Experimental Implementation in Main Industrial Branches The program determines and finances the main areas and trends in an application to the individual types of discrete manufacturing with the aim to specify optimal application conditions.
2.3. Typical Application Projects for Various Types of Production Solution, design and experimental verification of application of projects to implement efficiently
( ~m~puter.~ m Imh~Irv
and in a short time the individual types of discrete production with IRM, in machine building industry under concrete conditions from piece work to mass production.
2.4. Education in 1RM Preparation and implementation system of training and courses in this new branch, with emphasis on post-graduate courses; training of designers, technicians, operators, maintenance-specialists; with emphasis on an organic incorporation of IRM application into the production process and on creating an adequate working regime.
2.5. Preparation of New Support Program The program also includes the preparation of a new five-year governmental support program scheduled for 1985 with emphasis on adaptive IRM and practical application of artificial intelligence principles.
3. I m p l e m e n t a t i o n of I R M
The current Governmental Program and incorporated applications is intended, in the period 1981-1985, to reach rroduction in and application of more than 3500 IRM to different branches of the Czechoslovak industry. By the end of 1983 more than 1500 IRM had been implemented. Of course, other applications are realized besides this program, since the program is only supporting group-application of IRM. Almost one-half of all applications in the program will be prepared and implemented as complex units - automated technological cells. These cells are designed and projected as modules of automated production processes based on the principles of a flexible automation. It means an efficient utilization of one of the fundamental IR-properties, i.e. programmable principle connected with modularity. Application of IRM to the Czechoslovak industry is oriented above all to the following branches: - mechanical engineering, including the car and airplane industry - electrotechnics - electronics - light chemical and pharmacological industry
Computers in Industry
Z. Kozar / Industrial Robots Application
- civil engineering semifabricated goods (bricks, tiles, steps, etc.) glass and ceramic industry - food industry. In the present five-year period priority in the application of IRM has been given to mechanical and electrotechnical engineering, where IRM has been introduced to all primary production processes. Simultaneously, their function in the FMS (marked RFMS) has been tested in technologies of milling, pressing, welding, galvanotechnology, and painting. First steps have been taken in an assembly-application of IRM. When implementing IRM we try to identify and overcome the actual critical application points. Some of these are: reliability of IRM - implementation period reduction - easy programming user-oriented software dimension and weight decrease in IRM - price reduction - maintenance system and diagnostic optimal application conditions. -
-
-
-
4.
M a i n
F u t u r e
T r e n d s
a n d
R e s e a r c h
T a s k s
In our research Institute VUSTE oriented to a flexible automation application in mechanical and electrotechnical engineering branches we have
235
specified recently the following main research
tasks: unification of new IRM families and their interface efficient control systems and artificial intelligence intelligent sensors and untypical peripherals development - testing methods for IRM - modular software interactive programming problem-oriented languages adaptive IRM typical automated technological cells (with IRM) - organic insertion of IRM in production process - group technology and IR evaluation of effectiveness requalification of production staff optimal application conditions. Presumptive future trends in IRM applications are: a. complex FMS with broad IR implementation b. IR and C A D / C A M systems c. IR and working environment d. new manufacturing processes with IR. In conclusion, it is necessary to emphasize the role of IRM as an effective and universal means of production automation. This was verified in many prepared and realized applications. In this, we should keep in mind the main and decisive aim a complex automation of the production process. -
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