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

2
 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. 3
 Introduction
Material handling is the essence of industrial robotics with most
robotic applications falling within this category.

Materialhandling 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.

4
 General Considerations
Ifa 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

5
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
6
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.
8
 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 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 11
 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.

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 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 14
 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. 17
 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 18
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.

22
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

23
 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 25
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. ……….
26
 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 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/Indust
rial-Robotics-Industry-Insights/Robotic-Material-H
andling/content_id/3767
https://www.robots.com/applications/material-ha
ndling
http://www.motoman.com/applications/robotic_p
ackaging.php
“Automated Wheel Assembly System Using PLC
Controlled Robot” by J. Dilipsingh, S. Jeyanthi, R.
S. Jagadeesh.
“An Overview of Robotics and Autonomous
29
Thank You

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 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)

38
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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