Lecture

Fundamentals of Robotics

Part E
Handling Systems

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 1

 Handling Systems: Manipulators / Robots

Introduction  Inspection / rescue manipulator

Kinematic
Robot Types

Coordinate
Transformations

Motion Control
& Path Planning

Handling Systems

Robot Programming

Safety

Sensors

Robot Hardware

Performance and


Accuracy Canadarm2

 Robot feeding press brake

Sources: wiki commons

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 2

 Handling System for Palletizing

Introduction

Kinematic
Robot Types

Coordinate
Transformations

Motion Control
& Path Planning

Handling Systems

Robot Programming

Safety

Sensors

Robot Hardware

Performance and
Accuracy

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 3

 Handling objects with different properties + different requirements concerning
handling processes

Introduction
Handling objects:
Kinematic
 Handling objects are geometrically
Robot Types defined items (more or less) which are
Coordinate
moved or kept by a handling device
Transformations

Motion Control  Handling objects can be:

& Path Planning
 Workpieces / components
Handling Systems
 Tools
Robot Programming  Also stones, concrete parts, food
(e.g. chocolate candy, animal carcases)
Safety
& agricultural products,
Sensors if they can be considered as
Robot Hardware
geometrically defined to some degree

Performance and
Accuracy

sources: Wolf/Steinmann (Hanser-Verlag), Grohe

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 4

 Workpiece Characteristics define Workpiece Behaviour

Workpiece properties

Workpiece characteristics Workpiece behaviour

workpiece characterizing physical static transport

geometry shape elements characteristics behaviour behaviour

 overall shape  drilled hole  material  stability of  sliding

(type of  collar / Bund  mass position properties
behaviour)  bulge / Wulst  center of gravity  stability of  rolling
 dimensions  slot / Schlitz  temperature orientation properties
 aspect ratio  recess / Aussparung  stiffness  preferred  directional
 symmetries.  chamfer / Fase (shape stability) orientation stability.
 hook / Haken  breaking  stackability
 notch / Kerbe. resistance  ability to
 processing state hang.
 surface
condition.

source: Wolf/Steinmann – Greifer in Bewegung

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 5

 Typical basic shapes of workpieces with different levels of handling difficulty

Introduction

Kinematic Mushroom
Robot Types Shape element Sphere Bar Flat part “Chaotic” part
shaped part
Coordinate
Transformations
Simple Parts with
Motion Control smooth outer surface
& Path Planning

Handling Systems

Robot Programming Feature in inner or outer

contour
Safety Holes, notches, slots

Sensors

Robot Hardware Work pieces with

eccentric elements
Performance and
Accuracy

Irregularly shaped
or assembled shapes

source: Hesse – Grundlagen der Handhabungstechnik

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 6

 Cause and Effect of Object Motions

Introduction
Classification of Object motions
Kinematic
Robot Types
by causative force by motion type
Coordinate
Transformations
Free motion by gravity force Falling
Motion Control (usually directed to centre of earth)
& Path Planning

Handling Systems

Robot Programming Forced motions by external Rolling (linearly or curve)

(or supporting) forces
Safety
Sliding (without rotational share)
Sensors

Robot Hardware Impulsive motions with a Rolling-sliding

continuously changing share (sliding with rotational share)
Performance and
Accuracy of free and forced motions, Tilting (as free or guided motion)
e.g. vibratory conveyor
Flipping (rotation of 180°)

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 7

 Cheese Roll Competition

Introduction

Kinematic
Robot Types

Coordinate
Transformations

Motion Control
& Path Planning

Handling Systems

Robot Programming

Safety

Sensors

Robot Hardware

Performance and
Accuracy

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 8

 Material Flow - Definitions

Introduction

Kinematic
Robot Types

Coordinate material flow

Transformations

Motion Control
& Path Planning

Handling Systems
components
Robot Programming

Safety

Sensors
transport storage industrial handling
Robot Hardware
VDI 2411 VDI 2411 VDI 2860
Performance and
Accuracy

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 9

 Time shares in production (typical example)

Introduction

Kinematic
Robot Types

Coordinate
Transformations

Motion Control
& Path Planning
processing time

Handling Systems auxiliary time

Robot Programming
material flow =
Safety transport, storage
and handling
Sensors

Robot Hardware

Performance and
Accuracy

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 10

 Levels of Material Flow

Introduction
1. level: Inter-factory transport
movements between different
Kinematic facilities
Robot Types

Coordinate
Transformations
2. level: Inter-department transport
Motion Control movements between different
& Path Planning
departments
Handling Systems

Robot Programming
3. level: Intra-department transport
Safety movements between different
Sensors
areas or work cells within a
department
Robot Hardware

Performance and
Accuracy 4. level: Workcell handling
moving objects
within a workcell

sources: CNN, Inbis, Spamer Schulz, Energy Information administration

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 11

 Industrial Handling, Definition in VDI 2860

Introduction

Kinematic
Robot Types
Industrial handling, definition in VDI 2860:
Coordinate
Transformations

Motion Control
& Path Planning "Industrial handling is the creation, changing or temporary
Handling Systems
upkeeping of a given
spatial position and orientation of geometrically defined
Robot Programming
objects in a reference coordinate system
Safety

Sensors
There may be given other conditions like time, quantity and
Robot Hardware trajectory (motion path)“.
Performance and
Accuracy

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 12

 Industrial Handling: Major Functions

Handling according to VDI 2860

Basic Change
Store Move Lock Check
functions quantity

Sub- sorted split rotate hold verify

functions storage join position release verify shape
partly sorted portion flip grip verify size
storage branch swivel detach verify presence
unsorted sort. arrange pick up count
storage. transport. clamp. measure.

source: VDI 2860

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 13

 Examples for Storage Devices

Introduction

Kinematic
Robot Types
Vertical linear axis with
horizontal telescope axis
Coordinate for loading and unloading
Transformations storage spaces

Vertical magazine
Motion Control
& Path Planning

Handling Systems Inward/outward

transfer device
e.g. rotary table Inward/outward
Robot Programming transfer device Tray conveyor storage
e.g. horizontal linear axis

Safety

Sensors

Robot Hardware

Performance and
Accuracy
Buffer: vertical storage

Batch storage for pallets

(moving stack)
sources: Fibro, Hermle, Winkel

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 14

 Storage Devices

Introduction
Bunker
Kinematic
 Unsorted storage of workpieces
Robot Types  Appropriate for
Coordinate  large quantities of small parts
Transformations
 short process cycle times
Motion Control  simultaneous supply of several workpieces to a machine.
& Path Planning

Handling Systems

Robot Programming

Safety

Sensors

Robot Hardware

Performance and
Accuracy
source:
Grimm 2009

Red: bunker control Disadvantage:

Blue: conveyor Damages possible by pressure,
friction, scratching of surfaces

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 15

 Bunker / Device for separating single parts

Introduction

Kinematic
Robot Types

Coordinate
Transformations

Motion Control
& Path Planning

Handling Systems

Robot Programming

Safety

Sensors

Robot Hardware

Performance and
Accuracy

Spiral vibratory conveyor

for separating single parts with a defined orientation
curtain hooks / rail

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 16

 Taking objects from a bunker with a robot (Vision based)

Introduction
Visual
recognition of
Kinematic
Robot Types
single rods
Coordinate
Transformations

Motion Control
& Path Planning

Handling Systems

Robot Programming

Safety
Bunker with rods
Sensors

Robot Hardware

Performance and
Accuracy
Aim of the project BinGrip:
 Make bin-picking process more
robust
 Speed up process
sources: ABB, Dynamis

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 17

 Arranging: Classification of Methods for arranging

Introduction  Arranging by selection

linear conveyor
Wendel, Linearförderer

Kinematic work piece

Werkstück
Robot Types

Coordinate
Transformations
chicane
Schikane

Motion Control
& Path Planning
 Arranging by adjustment
Handling Systems

Robot Programming

Safety

Sensors

Robot Hardware  Arranging by separation

Performance and
Accuracy

source: Hesse 2000

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 18

 Devices for Locking (Holding / Clamping)

Introduction

Kinematic
Robot Types

Coordinate
Hold:
Transformations  Hold position of a part
Motion Control
 Here: Tray for crankshafts
& Path Planning (form fit)
Handling Systems

Robot Programming

Safety

Sensors Clamp:
Robot Hardware  Hold position of a part by
force fit
Performance and
Accuracy  Here: work piece positioner
for an arc welding robot

sources: Bloksma, Schweisstechnik Schwalmbach

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 19

 Devices for Checking

Triplex position switch

Introduction

Kinematic
Robot Types

Coordinate
Transformations

Motion Control
& Path Planning

Handling Systems

Robot Programming

Safety

Sensors

Robot Hardware

Performance and
Accuracy

Tactile sensor for

checking position and
orientation of a part
source: Balluff

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 20

 Devices for Moving

Introduction

Kinematic
Robot Types

Coordinate
Transformations

Motion Control
& Path Planning

Handling Systems

Robot Programming

Safety

Sensors

Robot Hardware

Performance and
Accuracy

source: Celluveyor / DHL

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 21

 Assembly: Definition

Introduction

Kinematic
Robot Types

Coordinate Definition of Assembly:

Transformations

Motion Control
& Path Planning
Mounting components of a product
with all necessary supporting tasks
Handling Systems
during and after the workpiece manufacturing.
Robot Programming

Safety

Sensors

Robot Hardware

Performance and
Accuracy

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 22

 Assembly stations: Different Levels of Automation

Manual assembly
Introduction

Kinematic
Robot Types Automated assembly
Coordinate
Transformations
Modular
work-
Motion Control station
& Path Planning

Handling Systems

Robot Programming

Safety
Interlinking
Sensors
facility
Robot Hardware indexing
turntable/
Performance and
Accuracy rotary table

Source: Bosch
Partially automated assembly Ignition plugs

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 23

 Rotary Cycle Assembly Machine for Roller Shift Levers

Introduction

Kinematic
Robot Types

Coordinate
Transformations

Motion Control
& Path Planning

Handling Systems

Robot Programming

Safety

Sensors

Robot Hardware

Performance and
Accuracy

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 24

 Translational and Rotational Degrees of Freedom of an Object

Introduction

Kinematic
Robot Types

Coordinate
Transformations

Motion Control
& Path Planning

Handling Systems

Robot Programming

Safety

Sensors

Robot Hardware

Performance and
Accuracy

Translational degrees of Rotational degrees of freedom

freedom: (Orientation angles):
1, 2, 3 4, 5, 6

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 26

 Position and Orientation

Introduction

Kinematic
Spatial arrangement
Robot Types
…of a geometrically defined object is defined by:
Coordinate
Transformations

Motion Control
& Path Planning
Position
Handling Systems Distance between the origin of the object's own coordinate system
and the origin of the reference coordinate system
Robot Programming
3 lengths for 3 translational degrees of freedom.
Safety

Sensors

Robot Hardware Orientation

Performance and
Accuracy
Angular relationship between the axes of the object's own coordinate system
and the axes of the reference coordinate system
3 angles referring to the 3 rotational degrees of freedom.

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 27

 Degrees of Freedom of an Object in Space

object’s
Introduction coordinate system
Kinematic
Robot Types
object
Coordinate
Transformations

Motion Control
& Path Planning

Handling Systems

Robot Programming r
Safety reference
system
Sensors

Robot Hardware

Performance and
Accuracy

r = position vector

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 28

 State of Orientation (SO)

Introduction
= Number of rotational degrees of freedom that are known:
Kinematic
Robot Types

Coordinate orientation of the object is defined in all

Transformations SO=3
rotation axes
Motion Control
& Path Planning

Handling Systems orientation of the object is defined in two

SO=2 rotation axes
Robot Programming

Safety
orientation of the object is defined in one
SO=1
Sensors
rotation axis
Robot Hardware

Performance and
orientation of the object is undefined in all
Accuracy SO=0
rotation axes

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 29

 Degree of Positioning (DP)

Introduction
Number of translational degrees of freedom that are known:
Kinematic
Robot Types

Coordinate DP=3 origin of the object coordinate system is located at a

Transformations
defined point
Motion Control
& Path Planning
DP=2 origin of the object coordinate system is located at
Handling Systems
any point of a curve
Robot Programming
(e.g. straight line, circular path)

Safety
DP=1 origin of the object coordinate system is located at
Sensors any point of a surface
Robot Hardware
(e.g. plane, cylinder)

Performance and
Accuracy DP=0 object is found at any position in space

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 30

 Degree of Alignment

Introduction

Kinematic
Robot Types

Coordinate
Transformations

Motion Control
& Path Planning
Degree of Alignment:
Handling Systems

DA = SO | DP
Robot Programming

Safety

Sensors

Robot Hardware
Both values specified  not a quotient!
Performance and
Accuracy

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 31

 Alignment Task „Cuboid“ without axis of symmetry

Introduction
DA = 0 / 0 DA = 3 / 3
Kinematic
Robot Types

Coordinate
Transformations Object falling Object coordinate system aligned
with world coordinate system
Motion Control
& Path Planning
W Z
Handling Systems V
Robot Programming
Z Y
W‘‘ V‘‘
Safety Y
U
Sensors U‘‘ X
Robot Hardware X
Performance and
Accuracy X,Y,Z = world coordinate system
U,V,W = workpiece coordinate system
desired workpiece position: x = 0; y = 0; z = 0

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 32

 Alignment Task “Disc”

Introduction Object: disc, rotation-symmetry around W, both sides identical

Kinematic
Robot Types
Which degree of alignment does Which degree of alignment is
the disc have, necessary, if the disc has to be
Coordinate
Transformations
if it is thrown into a bunker gripped by a robot?
Motion Control
& Path Planning
Z
W
Handling Systems
V
Y
Robot Programming
Z
Safety
W‘‘
Sensors V‘‘
Y
Robot Hardware
U X
Performance and
Accuracy

U‘‘
X
Degree of alignment = 0 / 0 Degree of alignment = 2 / 3
To be gripped safely by a robot, the part may not
be rotated around the x or y axis!

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 33

 Example for Alignment

Introduction
I 2/1
Kinematic
Robot Types

Coordinate
Transformations
pick & place unit
II 0 / 0 with a gripper
Motion Control
& Path Planning
III 2 / 1
Handling Systems V 2/3
Robot Programming

Safety

Sensors

Robot Hardware conveyor baffle

IV 2 / 3
Performance and
Accuracy
end stop

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 34

 Assembly Example: Mobile Phones

Introduction

Kinematic
Robot Types

Coordinate Storing
Transformations

Motion Control
Gripping
& Path Planning
Moving
Handling Systems
Storing
Robot Programming

Positioning
Safety

Sensors
Joining

Robot Hardware Locking

Performance and
Accuracy

Source: Baumann

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 35

 Symbols for Basic Functions of Handling based on VDI 2860

Introduction

Kinematic
Robot Types
divide / separate
Coordinate
Transformations

Motion Control
& Path Planning
combine (join)
Handling Systems

Robot Programming

Safety

Sensors rotate
Robot Hardware

Performance and
Accuracy

displace

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 36

 Basic Functions of Handling based on VDI 2860

Introduction

Kinematic
Robot Types

Coordinate
hold
Transformations

Motion Control
& Path Planning

Handling Systems
release
Robot Programming

test / check
Safety

Sensors

Robot Hardware

Performance and
Accuracy

sources: Schunk, Sick

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 37

 Basic Symbols for Production and Handling Tasks

Introduction

Kinematic
Robot Types
Handling
Coordinate
Transformations symbols of sub-functions
Motion Control
& Path Planning

Handling Systems
Inspection
if not sub-function of a
Robot Programming
handling process
Safety

Sensors Production Stage

Robot Hardware
without a clearer
specification of the
Performance and
Accuracy
production process

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 38

 Functions of Handling based on VDI 2860

Introduction

Kinematic
Robot Types
Store Partially arranged storage
Coordinate Store Change quantity
Transformations
Change quantity

Motion Control
& Path Planning

Handling Systems

Robot Programming Merge

Safety
Rotate
Sensors

Robot Hardware
Move

Performance and
Accuracy
Move

19 Convey

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 39

 Functions of Handling based on VDI 2860

Introduction

Kinematic Hold
Robot Types
Lock
Coordinate
Transformations

Motion Control
& Path Planning Check

Handling Systems 27 Check shape

Robot Programming

Safety

Sensors

Robot Hardware

Performance and
Accuracy

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 40

 Dividing the Function “Arrange” into Elementary Functions

Introduction

Kinematic
Robot Types
Arrange

Coordinate
Transformations

Motion Control
Orientate: Position:
& Path Planning bring into a bring into a
defined orientation defined position
Handling Systems

Robot Programming

Safety

Sensors
Measure Rotate Measure Displace
Robot Hardware orientation position

Performance and
Accuracy

source: VDI 2860

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 41

 Combine Functions

Introduction process related sequence consisting of single

Kinematic production-, handling- and controlling steps:
Robot Types

Coordinate
Transformations

Motion Control
& Path Planning

Handling Systems concurrent functions:

Robot Programming

Safety

Sensors
device specific combined functions:
Robot Hardware

Performance and
Accuracy

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 42

 Exercise: Sketch a Handling Process

Introduction

Kinematic
Robot Types

Coordinate pick & place unit

Transformations
with a gripper
Motion Control
& Path Planning

Handling Systems

Robot Programming

Safety conveyor baffle

Sensors
end stop
Robot Hardware

Performance and
Accuracy

release hold transfer position guide convey check

availability

Please make a diagram of this handling process using the symbols shown on the slide

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 44

 Learning Objectives – Handling Systems

Introduction

Kinematic
 Please name the major workpiece properties with reference to
Robot Types handling tasks.
Coordinate  Please classify object motions with respect to causes and effects.
Transformations

 Please name the major functions of industrial handling according to

Motion Control
& Path Planning VDI 2860 and give examples for subfunctions.
Handling Systems  What is a bunker? How can you get single parts out of a bunker
with defined position and orientation?
Robot Programming

 Please name three major methods of arranging

Safety
and give examples with a sketch for each method.
Sensors
 Please explain the term “Degree of Alignment” and its components..
Robot Hardware

Performance and
Accuracy

PD Dr.-Ing Jobst Bickendorf Control and cyberphysical systems (RCS) FoR 47