ROBOT HÀN (Hay)

Robot SystemesKinematics of Robots Operation Space Positioner Tilt Turn Table Hints for Economic Welding Equipment... Robot: - Main Operation Space-The part of the operation zone ,tha

Fully Mechanized Processes

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Robot Systemes

Kinematics

of Robots

Operation Space

Positioner Tilt Turn Table

Hints for Economic

Welding Equipment

Industrial Robot with Main

and Secondary Axis

more than three freely programmable axis

Difference between main and secondary axis

Industrial Robots

Kinematic Structures

-Possible combinations of transnational and rotational axis systems

Classification of main and secondary axis

source: IPA

cylindrical

spherical Cartesian

secondary axis : S

main axis : M

main axis : M main axis : M

Industrial Robot with a

Bending arm Construction

source: IPA

Secondary axis : S Main axis : M

6 Axis Bending Arm Robot

Robot kinematics for a bending arm construction with 6 rotational axis

Application mainly for resistance spot and arc welding

Range of Application for Industrial Robot in 2000

and the Trend of the Total Stock

in Germany From 1985 to 1999

2.572 3.908

3.326 13.008

13.525 23.463

2.548

gluing/sealing machine

coating cont welding assembling spot welding others

handling

56.175 43.715

85.556

75.625

96.000

2.419 2.781 7.039

7.789 10.502

palletizing

die-/injection-cutting other work piece handling

Total Stock:

2000: 109.000

2004: 139.000

Arguments for the Using Robots

Economic reasons?

Less error frequency?

Less filler material consumption?

Definition of Industry Robots (according to DVS 0922)

Industry robots for welding

for welding purposes universally applicable automatic machines

with more than 3 axis

with regard to the motion sequence and paths or angles (without mechanical intervention)

if necessary sensor guided

welding tasks .

Robot: - Main Operation

Space-The part of the operation zone ,that is reached by the motion of all main axis

The part of the operation zone, which could be

reached e.g by the top of torch

Area that is reached additional to the main operation zone by the motion of the secondary axis

Robot : secondary Operation Space

-Border of the

main operation

zone

Reference point of the

main operation zone

additional components must be considered

Main working

area

Minor working area

Not usable area

Minor working area

M ain

w or

kin g

ar ea

Envelope of danger zone

Welding torch tip

Not usable area

Layout of Welding Robots

Suspended installation

– Enlarging of

operation area

– freely programmable – or mechanical end

stop

Overhead suspension

Rotating C-stand

for 8 positions fixable

Layout of Welding Robots

source: Cloos

Robot Application:

Overhead suspension

Detail View of the Jig

Load bearing capacity at the wrist :

mechanized joining

mechanized joining ,

Repeating and path accuracy :

6 Axis Bending Arm Robot

CO 2 - Laser Application

Twin CO 2 -laser beam-system (each 6 kW)

with beam guiding system

Process feed: 5 m/min

Application: top of a BMW (5 series)

Source: KUKA Schweißanlagen + Roboter

Precision Welding with Robots

source: Rofin Sinar

Video of the welding process Audi A6

Source: KUKA Schweißanlagen + Roboter

Precision Welding with Robots

source: Rofin Sinar

Video of

a cutting process

Nd:YAG- Laser Application

Robot Systems for Gas Shielded Metal Arc Welding

mass

welding robot welding torch

Current source

control board programming device

Welding Equipment of an Industry Robot

for Gas Metal Arc Welding

Welding current source

Controls

Wire feed system

Wire feed device

Welding torch and equipment

Tube pack Torch support Switch off safety device Torch adjustment device Torch exchange device Torch cleaning device Torch cooling device

Supervision

Wire uncoil unit

(Source: DVS leaflet 0922)Torch

Requirements for Current Source and Control

Suitability of the current source for a robot control

– Parameter transfer

100% ED (on-period)

by welding current

High idling voltage

– for a safe ignition

Net voltage compensation Adjustment possibilities for

– Pre- and after flow time of the shielding gas

– „Creeping“ of the filler wire (low speed)

– Time for burning back the wire

– Filling the end crater

If necessary impulse technology:

– Thin sheets – Out-of-Position – Aluminium

– small spatter formation

(avoiding transitional arc)

Manual programming device

control

current source

Requirements for Shielding

Gas / Filler Wire

shielding gas:

constant composition and flow

(gas mixer with up to 10%

tolerance)

decrease spatter formation

reducing CO2

filler wire:

if possible robot standards

– surface, copper plated (torsion's test)

big wire coils

– big mass (start-up problems)

– possible unbalance (buffer route, self driving)

welding robot welding torch

collision safety

device

gas/wire supply wire feed device

shield gas supply

flow regulator

4-roll wire feet unit

– few big curves

– adjustment to the main

welding direction

– tension relief (gallows)

regular maintenance

– e.g contact nozzle

water cooled torch

– as far at the tip of the gas nozzle as possible

load measuring cell

– collision control

torch testing device

Requirement on the Wire Feed, Tube Pack and Welding Torch

welding robot welding torch

collision safety device

gas/wire

shield gas supply

flow regulator

Detail

Torch Changing Systems

- TIG Welding -

Source: Binzel

Programming Processes

Automatically generates bases

Instruction of bases through teach-in

Inclined path sensor supported calculated

Alphanumerical programming

Fixing of coordinates (On-line) Program input on

an extra device

Alphanumerical programming

Graphical programming

Description of the use process with help of a language

Path points out of CAD-dates

Adding of welding dates

Robot Programming

TIG welding with wire feed

6 axis robot with turning tipping unit

Manual Programming Device

emergency stop safety during trial

override

Variations of Control

Point to point control (PTP):

– No defined path between 2 points

Applied for resistance spot welding

Continuous path control (CP):

– Functional context between the axis motion

Moving of the welding tool on a defined path Applied for shielded gas welding

Tool Center Point (TCP)

Point at the welding tool which is determined with help of the manual programming device.

The TCP process enables motion of the robot around the TCP to adjust the tool orientation to work piece without leaving the TCP.

Shielded gas welding: TCP at the tip of the wire electrode

Resist spot welding: TCP above the underlying electrode

In extreme situations the torch can remain at the welding position.

The robot could be driven around this point to allow a better torch position

For each adapted welding tool, a new TCP must be determined.

Coordinates of the tool are determined as variables

at the start of each program the defined tool have to called.

Straightening Tool

for Welding Torch

Automatic TCP Measurement

Determining the location of the TCP

(Tool Center Point) at the tool

For example driving a reference

point from four different directions

Automatic Control- and Adjustment Device

Coordinate Programming Systems

In addition to the motion of the single robot axis, the motion could be also programmed in several coordinates systems.

Robot based Wrist joint related Tool related Work piece related

Programming Functions (Utilities)

Programming Functions for

Workpiece position changes

Functions for Workpiece Position

Changes

- Robotertechnik - Dipl.-Ing M Holthaus

Funktionen bei Werkstücklageänderung

belie-Rob2.ppt

- Robotertechnik - Dipl.-Ing M Holthaus

Funktionen bei Werkstücklageänderung

belie-Rob2.ppt

Funktionen bei Werkstücklageänderung

Funktionen bei Werkstücklageänderung

Programmverschiebung und -drehung:

– Programm kann durch Definition von sechs Bezugspunkten an anderer Stelle ausgeführt werden

Programmspieglung:

– Mittels Definition von sechs Bezugspunkten kann das Programm spiegelbildlich ausgeführt werden

Program shift (translation): Program rotation (Rotation):

Rotation of the program to anyaxis and adjustment of the toolorientation

Translation and Rotation:

Program can be implemented

at a different place by the definition of six reference points

Workpiece Positioners

Tilt and turn table Tilt and turn table with an

inclined tilt axis

Single axis positioner with a

Single axis positioner

with a swivel axis

Tilt and turn table with an inclined tilt axis

Inert Gas Shielding Celle

Including Two Tilt and Turn Tables

Quelle: KUKA GmbH

Additional examples of Arrangements

Workpiece Positioners

Tilting axes Rotation axes

Tailstock

Turning axes

Tilting axes Rotation axes

Rotation Frame

Application Detail View

Inert Gas Shielding Celle

Source: KUKA GmbH

Positioner DKP

Positioner DW

Positioner DWPV

Source: KUKA GmbH

Inert Gas Shielding Celle

Including Workpiecehandling Device

Source: KUKA GmbH

Load of Tipping Turntables

Example for the calculation of safety

against tipping (load diagram)

2.750

580

center of gravity

Positioning for robot welding in consideration

of component tolerances (fillet weld)

Fixed edge Clamping cylinder

Weld preparation:

Preferred weld shapes:

– Fillet weld, butt weld with weld pool

backup or backing bar, lap weld,

single-bevel tee butt weld

Useful :

– flange weld

Weld shapes to be avoided:

– Butt weld without pool backup,

edge weld without overlapping,

single-bevel butt weld

Single-bevel butt weld

Single-bevel tee butt weld

unfavorable | favorable

Common Construction Principles

Application

-General Construction Principles

Keeping distance to the edge

General Construction Principles

Application

-Construction Rules for the Use of Robots

Programming

amount

Avoiding of oval or free curves

Design of pipe connections Weld accessibility

Robot position

Robot Systems

Accessibility

-favorable unfavorable

Accessibility due to the weld position

(1)

Production in just one fixture

(3)

favorable unfavorable

[mm]

50 25

Safety area for weaving

[mm]

(2)

50

25

Sensors (According to DVS 0927-1)

Sensors for full mechanical arc welding

Sensors for full mechanical arc welding

process variables

primary process variables

secondary process variables

secondary process variables

- magnetic arc deflection

- double wire welding

- mechanical weaving torch

- magnetic arc deflection

- double wire welding

Taktile sensors

Mechanical (pressure roll) Electrical (gas nozzle)

range of tolerance

real position programmed position

a a

1 2 3

d

a amplitude of torch weaving motion

d deviation of workpiece position

L length of arc

Seam sensing through the arc

Different Sensor Systems (1)

real programmed position of seam

torch

field of view

welding direction

camera

Seam sensing via camera

Different Sensor Systems (2)

Arc Sensor

Process Limits

-Analysis of mistakes while using an arc

sensor:

Incorrect position

Correct position

Principle of the Laser Scanner

Mirror

Mirror

Laser beam unit Detector

Robot Welding: Laser Scanner

-Surveys of weld geometry

by adapting weld parameters

single-V butt groove with gap

Cost factor „Component Tolerance“

Welding costs

Preparation costs

Thank You!