RAMAIAH

Institute of Technology

Material handling robots

By
Manoj K
1MS16MCM09
M.Tech(CIM)
Content
 Introduction
 General Considerations
 Need to replace human by robots
 Applications
 Case Study 1
 Case Study 2
 Conclusion
 References

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Robots
 Robot is a Machine designed to
execute one or more tasks
automatically by means of variable
programmed motions with high speed
and precision.
Material Handling Robots
 Material handling (MH) makes use of the
robot's simple capability to transport
objects. By fitting the robot with an
appropriate end of arm tool (e.g. gripper),
the robot can efficiently and accurately
move product from one location to another.
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 Introduction
 Material handling is the essence of industrial robotics with
most robotic applications falling within this category.

 Material handling robots can automate some of the most

tedious and unsafe tasks in a production line.

 Material handling robots enhance the efficiency of production

line, increase in quality of products and productivity.

 End-users deploy robots to improve throughput, quality,

flexibility and consistency while decreasing ergonomic
hazards for workers.
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 General Considerations
 If a robot has to transfer parts or load a machine, then
the following points are to be considered.
1. Part Positioning and Orientation
2. Gripper design
3. Minimum distances moved
4. Robot work volume
5. Robot weight capacity
6. Accuracy and repeatability
7. Robot configuration

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Need to replace human by robots
 Work environment hazardous for human beings
 Repetitive tasks
 Boring and unpleasant tasks
 Multi-shift operations
 Infrequent changeovers
 Operating for long hours without rest
 Responding in automated operations
 Minimizing variation

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Applications

 Part Transfer
 Packaging
 Palletizing
 Machine Loading
 Machine Tending

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 Part Transfer

 Though part transfer was once done entirely by hand, companies have
now converted to robot part transfer systems as a way to save on labor
costs and speed up production processes.

 Part transfer automation also increases accuracy and precision, which

helps shops to create a better product.

 Recent technological advancements in robot end-of-arm-tooling (EOAT)

and vision systems are making robot part transfer automation even more
attractive.
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 KUKA KR 60-3

 The diverse KUKA KR 60-3 is

flexible enough to handle several
different material handling and
removal applications, saving the
manufacturer money on equipment.

 With so much versatility in one

machine, the KR 60 3 KRC4 is one
of the most cost effective robots on
the market today. 9
 Packaging

 Packaging robots are very flexible.

 By adjusting the end-of-arm-tooling (EOAT), a robot can complete any

packaging process. The application-specific capabilities of packaging
robots have expanded with improvements to EOAT and vision technology.

 In fact, many manufacturing managers see robot packaging as a necessity.

 Packaging robots offer companies savings on labour costs, as well as

higher ROI (return on investment) with the increase in productivity.

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 Motoman HP20-6
 Offering superior performance in
packaging, handling, machine
tending, cutting, and dispensing
applications, the Motoman
HP20-6 is a great fit for many
factory automation applications.
It is a dynamic, high speed
robot with a compact design
and built-in collision avoidance.
 This design allows the robot to
be placed close to the work
piece holding fixtures to improve
part accessibility.
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 Kuka KR 16
 The Kuka KR 16
packs a lot of power
into a small frame.
The accurate, swift
mover KR16 has a 16
kg payload and
1610mm maximum
reach.
 Its compact structure
allows for floor, ceiling
and wall mounting.
Protected joints give
the KR 16 KR C2 a
clean, streamlined
build. 12
 Palletizing

 Industrial palletizing refers to loading and unloading parts, boxes or other

items to or from pallets.

 Robot palletizing can be seen in many industries including food

processing, manufacturing, and shipping.

 A robotic palletizer is able to handle heavy payloads and have large

horizontal and vertical reaches that allow parts to be palletized from
varying distances.
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 Motoman EPL160
 Designed specifically for
palletizing applications,
the four-axis Motoman
EPL160 "Expert
Palletizing" robot is a
high-yield manipulator
that features internally
routed air and I/O signal
lines.
 The EPL 160 NX100 can
service multiple infeed
conveyors and/or pallet
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stations.
 FANUC M410

 The FANUC M410

industrial robot is great
for industrial automation
jobs that require high-
speed and performance.
 The Fanuc M-410
Palletizing Robot
features linear motion
speeds up to 4200
mm/sec.
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 Machine Loading & Tending

 Machine loading involves loading a part onto a machine.

 Machine tending refers to overseeing a machine while it performs a job, as well
as the process of feeding parts in and out.
 This applications can sometimes be a dangerous work environment.
 By using industrial robots to automate the machine loading & Tending process,
you can protect workers from injury while increasing your part cycle time
 Machine loading & Tending robots work efficiently, tirelessly, and accurately. They
do not need breaks, days off or vacations.

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 FANUC F-200iB
 The Fanuc F-200iB reduces
tooling and build costs, has a
simpler design, is low-
maintenance, has the ability
to reprogram for fast and
cost-effective model
changeovers, has fail-safe
brakes on each leg, and
makes it possible to perform
more welds per station;
reducing the number of
stations per system.

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 Motoman HP165

 This high-speed robot offers

minimal footprint and
superior performance in both
spot welding and heavy
payload handling
applications.
 The work envelope extends
behind the body, allowing
tools to be placed behind the
robot and providing easy
access to tools for
maintenance.
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Case Study 1

Automated Wheel Assembly System Using PLC

Controlled Robot
J. Dilipsingh1, S. Jeyanthi2, R. S. Jagadeesh
Abstract :
 The current process of mounting a wheel in an automotive industry is done
by manually which is difficult and time consuming .
 In order to over come this problem automated wheel assembly system with
PLC Controlled Robot is used to reduce human effort , time and energy.

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Introduction

 There are many challenges to automate the wheel loading process

 When the car is moving on the production line as it tends to move at
random speed along x and y direction
 The automated loading system should be able to track the random
motion of the car accurately
 since it is a final step of whole assembly thus small damage to the car
could be a big loss
 Hence more intelligent industrial robot system have to be developed for
complex assembly
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 Methodology
 The system includes a ABB IRB6600(7 axis) robot with sensor ,controller
and conveyor
 Initially the car position is identified by the robot using IR sensor and
motion is tracked.
 Since the wheels are loaded randomly into station the robot picks the wheel
in required position and orientation by robot gripers then moves towards car

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 To perform an assembly, the robot has to be controlled to approach the
moving part.
 Therefore, force control along the Z axis is applied to control the motion of
the robot to perform the wheel loading process.

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Conclusion

 In this paper, an automated wheel loading system is developed based on the

synergic combination of visual servoing and force control strategy.
 Visual servoing is used to track the 2D motion of the car on the conveyor.
Experiments were performed successfully and the results demonstrated that
the developed technology can be used for wheel loading.
 Since huge amount of time and resource can be saved using the developed
robotic system, this innovative technology will have great impact in the
automotive industry, especially when automotive manufacturing is facing
difficulties

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 Case Study 2
Implementation of Motoman IA20
by Bennett Brumson, Contributing Editor, Robotic Industries Association.

 Abstract :
A component manufacturer purchased a new CNC machine tool for processing a
variety of parts. In order to maximize their return on investment they decided to implement
a robotic automation solution from Yaskawa Motoman.
Challenges
 Floor space is very limited; the entire automation system must fit within a 21 sq ft area.
 Ability to run unattended in order to increase productivity.
 Flexible, mobile robot system that can dock with various machine tools.
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 Case Study (cont.….)

Solution
 A highly flexible, integrated machine tending system was designed,
including:
1. Motoman IA20 7-axis robot
2. Pallet storage
3. End-of-arm dual gripper
4. Pallet lifter
5. Re-grip stand
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Case Study (cont.….)
Motoman IA20
 The IA20 robot features an
extremely small footprint,
outstanding flexibility and large
working envelope.
◦ With seven axes, a footprint of
only 280 x 404 mm and a
minimum height of only 549 mm
(to top of joint two), the IA20 can
"squat" down as well as get into
positions that are not possible
with a traditional six-axis robot.
This robot flexibility is very similar
to the human arm.
……….
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 Case Study (cont.….)
Process
 The cell can hold up to ten pallets. Each pallet
holds parts to be processed in a defined
position for the robot. A lift raises the pallet to
the correct level for the robot.
 Using a dual gripper, the IA20 robot picks a part
and loads it into the machining tool, where it is
clamped and machined.
 The robot then picks up a new raw part, and
using the empty gripper removes the semi-
finished part.
 The new raw part is inserted in the machining
tool. The semi-finished part is placed on the
turnover station, where it is re-gripped and
positioned for the final machining. Parts are
returned to the pallet when finished. 27
 Case Study (cont.….)

Results
 This solution meets project expectations for both the machining center and the robot.
 The compact Motoman IA20 robot keeps the complete system size within the
footprint requirement. The solution enables the CNC machine to run attended for ten
to thirteen hours depending on the part, resulting in increased production.
 The entire robot cell can be moved with a forklift, allowing the unit to dock with any
suitable machine tool.

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References
 http://www.robotics.org/content-detail.cfm/Industrial-
Robotics-Industry-Insights/Robotic-Material-
Handling/content_id/3767
 https://www.robots.com/applications/material-handling
 http://www.motoman.com/applications/robotic_packagin
g.php
 “Automated Wheel Assembly System Using PLC
Controlled Robot” by J. Dilipsingh, S. Jeyanthi, R. S.
Jagadeesh.
 “An Overview of Robotics and Autonomous Systems for
Harsh Environments” by Cuebong Wong1, Erfu Yang,
Xiu-Tian Yan and Dongbing Gu.
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30
 Part Positioning and Orientation
 Wrist assembly is attached to end-of-arm
 End effectors is attached to wrist assembly
 Function of wrist assembly is to orient end effectors
 Body-and-arm determines global position of end effectors
◦ Two or three degrees of freedom:
 Roll
 Pitch
 Yaw

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End Effectors
 The special tooling for a robot that enables it to perform a
specific task
 Two types:
 Grippers – to grasp and manipulate objects (e.g., parts) during work cycle
 Tools – to perform a process, e.g., spot welding, spray painting

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Minimum distances moved
 Spatial Accuracy – It refers to the smallest
increment of motion at the wrist that can be
controlled by the robot. It is sum of the control
resolution and mechanical accuracies. The arm
movement must be divided into its basic motions
and the resolution of each degree of freedom is
figured separately.

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Robot work volume

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Robot weight capacity

 Payload - The weight capacity of each robot

manipulator is its payload. This is a critical specification
and includes the tooling weight as well. You can rule out
a number of robots with this robot specification category
alone.
 Robot Mass - Every robot has a specific weight or
mass. This number only indicates how much the robot
manipulator weighs. It does not include the weight of
the robot's controller. This specification may not be
quite as important unless you are trying to install your
robot on a table or shelf.
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Accuracy and repeatability
 Accuracy – the accuracy of the robot is its
capability to position its wrist end at a given point
with in its work volume.
 Repeatability - Ability to return to an exact location
again and again, known as a robot's repeatability.
More precision-driven applications require tighter
repeatability figures. Repeatability is listed as a
millimetre of alteration i.e. plus or minus from the
point.

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Robot configuration

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Polar
 Used for handling at machine tools, spot welding,
die-casting, fettling machines, gas welding and arc
welding. It's a robot whose axes form a polar
coordinate system.
1. sliding arm (L - joint)
2. vertical axis (T - joint)
3. horizontal axis (R -joint)

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Cylindrical
 Used for assembly operations, handling at machine
tools, spot welding, and handling at die-casting
machines. It's a robot whose axes form a cylindrical
coordinate system.
1. Vertical column(T - joint)
2. Arm assembly(L - joint)
3. Arm(O - joint)

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Cartesian
 A type of robotic arm that has prismatic joints only.
 The linear movement of the joints gives the
Cartesian robot a highly rigid structure that allows it
to lift heavy objects.
 Three sliding joints
1. Z- (L - joint)
2. X- (O - joint)
3. Y- (O - joint)

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Jointed-arm robot
 Used for assembly operations, die-casting, fettling
machines, gas welding, arc welding and spray
painting.
 It's a robot whose arm has at least three rotary joints
1. T - joint
2. R - joint
3. R - joint

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SCARA
 SCARA - Selectively Compliant Assembly Robot
Arm
 Used for pick and place work, application of sealant,
assembly operations and handling machine tools.
 It's a robot which has two parallel rotary joints to
provide compliance in a plane.
1. V - joint
2. R - joint
3. O - joint
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