Automation & Robotics

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3 Tech-Design Automation & Robotics eseries Edition Q0

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5 FIRST EDITION First Printing, June 2010 Copyright 2010 Lab-Volt Systems, Inc All rights reserved No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopied, recorded, or otherwise, without prior written permission from Lab-Volt Systems, Inc Information in this document is subject to change without notice and does not represent a commitment on the part of Lab-Volt Systems, Inc The Lab-Volt software and other materials described in this document are furnished under a license agreement or a nondisclosure agreement The software may be used or copied only in accordance with the terms of the agreement ISBN Lab-Volt, Tech-Design and Mind-Sight logos are registered trademarks of Lab-Volt Systems, Inc Lab-Volt recognizes product names as trademarks or registered trademarks of their respective holders Certain clipart and images used within this course are used with permission from: Copyright 2003 Microsoft Corporation, One Microsoft Way, Redmond, Washington , USA All rights reserved wwwablestockcom Copyright 2003 Lab-Volt Systems, Inc and its licensors All rights reserved wwwcomstockcom All rights reserved Copyright 2009 JUPITERIMAGES, and its licensors CorelDRAW 9 All rights reserved All other trademarks are the property of their respective owners Other trademarks and trade names may be used in this document to refer to either the entity claiming the marks and names or their products Lab-Volt Systems, Inc disclaims any proprietary interest in trademarks and trade names other than its own

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7 Automation & Robotics Table of Contents Introduction1 The Ancestry of the Robot Arm3 To-Do List 3 Study Guide4 Video Response: Robot Arms and End-of-Arm Tooling6 Creating a Program7 To-Do List 7 Study Guide8 Video Response: Robot Systems10 Avoiding Obstacles11 To-Do List 11 Study Guide12 Changing Speeds13 To-Do List 13 Study Guide14 Impacts Video Response: Environmental Impacts 15 Capabilities and Limitations16 To-Do List 16 Study Guide17 Video Response: Advantages and Limitations of Robots18 Basic Robotics19 To-Do List 19 Study Guide20 Methods of Programming22 To-Do List 22 Study Guide23 Editing Programs25 To-Do List 25 Study Guide26 Robotics in Manufacturing27 To-Do List 27 Study Guide28 Using a Feeder29 To-Do List 29 Study Guide30 Working with a Rotary Carousel31 To-Do List 31 Study Guide32 Tech-Design by Lab-Volt vii

8 Table of Contents Automation & Robotics The Future of Robotics33 To-Do List 33 Study Guide34 Video Response: The Future of Robotics35 Video Response: Careers in Robotics36 Appendices37 Independent Study Project Proposal39 Topic Outline40 Bibliography41 Activities42 Drawings43 viii Tech-Design by Lab-Volt

9 Introduction Introduction This is organized by unit In each unit you may find: Unit Objectives New Terms and Words To-Do List Study Guide Data sheets (worksheets) Video response sheets The Unit Objectives are a summary of what you can expect to learn in the unit New Terms and Words provide the definitions for words you may not be familiar with If you come across any other words you do not understand, look them up in a dictionary, write the definitions, and add them to your Understanding vocabulary is the biggest key to understanding any information The To-Do List helps you keep track of all the work you do The Study Guide will help you to take notes as you read the unit You can use this to study for the unit test You can use all of the unit Study Guides to study for the course test Data sheets or worksheets provide space to record information or answer questions about activities Some also give you a place to write down the details of your projects Video response sheets are worksheets that go with the videos you will watch After you watch a video, answer the questions on the video response sheet You can save any other work you do for this course in this guide Use the to study what you have learned Your teacher may also ask to collect your work for a grade Tech-Design by Lab-Volt 1

10 Introduction 2 Tech-Design by Lab-Volt

11 Automation & Robotics Unit Details The Ancestry of the Robot Arm Objectives During this unit, you will: explore the history of robots be introduced to the basic components of a robot learn about the Lab-Volt Robot Arm review some of the significant historical events related to the field of Automation and Robotics and complete the Timeline Activity To-Do List Complete the following assignments Use this to-do list to keep track of each task To-Do Due Date Notes Study Guide Video Response: Robot Arms and End-of-Arm Tooling Timeline Activity Unit Test? New Terms and Words innovated introduced something new or differs from existing forms; originated, invented knurled having knurls or knots; having small ridges on the edge or surface Additional Equipment Required Lab-Volt Robot Arm Tech-Design by Lab-Volt 3

12 Unit Details Automation & Robotics Study Guide The Ancestry of the Robot Arm I A Brief History of Robotics A The name robot is derived from robota, which means in the language and appeared first in a play in B A robot is a machine that performs functions normally done by C There is evidence of mechanical devices that data as far back as in D During the current era, there are many examples of mechanical devices in and that predate the Industrial Revolution E During the Renaissance in Europe, designed numerous mechanical artifacts and weapons F In 1774, the Jacquet-Dronz father and son team built a doll named who could and play G One of the first examples of industrial automation is a in, which was controlled by a H Industrial automation grew at a very fast pace during the I Seiko, the Japanese watch-maker company, developed a robotic arm called in J The first American programmable industrial robot was invented and built by in II Here s The Lab-Volt Robot Arm 4 Tech-Design by Lab-Volt

13 Automation & Robotics Unit Details A The Lab-Volt Robot Arm contains the five basic components found in all industrial robot arms:,,,, and B The Robot Arm has three joints:,, and C The arm end effectors include:,, others,, and D The drives used are Tech-Design by Lab-Volt 5

14 Unit Details Automation & Robotics Video Response: Robot Arms and End-of-Arm Tooling How many components are typically found in robotic systems? What are the main components of a robotic system? What is good human analogy for a robotic end effector? Where is the robot s end effector generally found? What is the main function of the robot s arm What is a good human analogy for a robot s controller? What do controllers depend on for the performance of its functions? What is the main purpose of the robot s sensor(s)? What does the robot use to move from one position to the next? 6 Tech-Design by Lab-Volt

15 Automation & Robotics Unit Details Creating a Program Objectives During this unit, you will: learn the menus of the Teach Pendant create and store a program run a stored program practice editing a program To-Do List Complete the following assignments Use this to-do list to keep track of each task To-Do Due Date Notes Study Guide Video Response: Robot Systems Activity Guide: Saving Your Program Unit Test Additional Equipment Required Lab-Volt Robot Arm One 2x2x½ inch Square Part One Film Canister One Metallic Can Tech-Design by Lab-Volt 7

16 Unit Details Automation & Robotics Study Guide Creating a Program I A Robotics System A A robotics system has fundamentally two components: a and a B Typical robot components include: 1 A can execute anywhere within its 2 An, also known as, performs the actual function 3 A provides the input power 4 A contains all the instructions for the specific functions to be performed 5 A variety of equipment, such as a conveyor belt, is often used C The instructions to the robot need to be II Playing with Blocks A It must be to the robot and in order to control it B The four are used to manage the program development C The four are used to move through the menu options and to the programmed points III Getting with the Program A The series of instructions that the robot must follow is called a B The specific places recorded in the robot s memory are called 8 Tech-Design by Lab-Volt

17 Automation & Robotics Unit Details C The final program consists of a sequence of D The is the maximum distance the robot can reach in any direction E The robot has a if it hits anything due to in programming F You select from the in order to clear the robot of any earlier program G The various number and function keys are used to the robot and its parts to a desired point, which is then saved by using the key H After all robot points are programmed, the program can be saved in a computer using the software I The memory of the Teach Pendant is when the power is Tech-Design by Lab-Volt 9

18 Unit Details Automation & Robotics Video Response: Robot Systems What is the main characteristic of an industrial robot? What are the main applications of industrial robots? How is a robot often programmed? How are industrial robots adjusted to handle the wide variety of tasks required? How can an assembly line be equipped with robots? 10 Tech-Design by Lab-Volt

19 Automation & Robotics Unit Details Avoiding Obstacles Objectives During this unit, you will: practice moving the robot in its work envelope program the robot to avoid obstacles To-Do List Complete the following assignments Use this to-do list to keep track of each task To-Do Due Date Notes Study Guide Unit Test Additional Equipment Required Lab-Volt Robot Arm One Metallic Can One Film Canister Tech-Design by Lab-Volt 11

20 Unit Details Automation & Robotics Study Guide Avoiding Obstacles I An Obstacle A Anything within the of the robot could become an obstacle B Robots must be to obstacles C Avoiding obstacles is particularly important when the robot II Programming the Robot to Avoid Obstacles A Not accounting for all in a program can be very B Make sure all previous are before reprogramming a robot C Adjust the of the robot according to the of the object being moved D Before the program, test it by through the program at a time 12 Tech-Design by Lab-Volt

21 Automation & Robotics Unit Details Changing Speeds Objectives During this unit, you will: practice changing speeds for accuracy and timing examine why speeds change for different operations explore the impact of manufacturing on the environment To-Do List Complete the following assignments Use this to-do list to keep track of each task To-Do Due Date Notes Study Guide Activity Guide: Loading Your Program Impacts Video Response: Environmental Impacts Unit Test? New Terms and Words tolerances upper and lower limits allowed in manufacturing a part; the range of variation in a standard Additional Equipment Required Lab-Volt Robot Arm One 2x2x½ inch Square Block One Film Canister One Metallic Can Tech-Design by Lab-Volt 13

22 Unit Details Automation & Robotics Study Guide Changing Speeds I Speed Need A A speed is desirable when: 1 the robot is moving a object 2 are small B Programming speed is appropriate when: 1 the robot is anything, 2 the object being moved heavy, 3 and there are no C Most programs require speed from D The speed of an operation must be with all other automated procedures E Programming Speed Changes 1 The speed of the of the Robot Arm ranges from 2 The speed can be adjusted by using the key in the 3 Speed adjustments to an existing can be made using the function 4 Test the by stepping through the program 14 Tech-Design by Lab-Volt

23 Automation & Robotics Unit Details Impacts Video Response: Environmental Impacts Besides making products, what are other outputs of typical manufacturing facilities? What is the impact of robotics on the rate of pollution from factories? Are there other collateral pollution factors indirectly impacted by robotics? Tech-Design by Lab-Volt 15

24 Unit Details Automation & Robotics Capabilities and Limitations Objectives During this unit, you will: discover some of the advantages and limitations of using robots in industry create a program using a complete robotics system To-Do List Complete the following assignments Use this to-do list to keep track of each task To-Do Due Date Notes Study Guide Video Response: Advantages and Limitations of Robots Unit Test Additional Equipment Required Lab-Volt Robot Arm Two 2x2x1 inch Square Blocks One Gravity Feeder 16 Tech-Design by Lab-Volt

25 Automation & Robotics Unit Details Study Guide Capabilities and Limitations I Some Pluses and Minuses A Advantages of robots 1 Robots perform and tasks more than humans 2 They are able to handle from very to very payloads 3 They can be to perform new functions B Limitations of robots 1 Robots displace that then needs retraining 2 Robots are expensive to and 3 While they can be reprogrammed, they are typically limited to 4 Many robots work as systems which require every move be well specified II A Complete Automated System A A complete automated system consists of a working with B The peripheral tooling component used in the exercise was a C The robot arm and the peripheral tooling were synchronized by a that the robot when a part was ready D When the microswitch was by a part in the feeder, it sent a logic level 0 signal to E The robot until a is available in the feeder Tech-Design by Lab-Volt 17

26 Unit Details Automation & Robotics Video Response: Advantages and Limitations of Robots What are the main advantages of industrial robots? What are the main robot limitations in industrial applications? What is meant by robot accuracy? How is a robot s accuracy measured? What is meant by repeatability? What does payload measure? What is the range of typical industrial robot payloads? 18 Tech-Design by Lab-Volt

27 Automation & Robotics Unit Details Basic Robotics Objectives During this unit, you will: explore the different types of robots review the five basic components of a robotics system control the robot using RoboCIM To-Do List Complete the following assignments Use this to-do list to keep track of each task To-Do Due Date Notes Study Guide Activity Guide: Using RoboCIM Unit Test? New Terms and Words coordinates any one of a set of numbers used in marking the location of a point on a line, in space, or on a given plane or other surface; for example, latitude and longitude are coordinates of a point on the Earth s surface interim interval, in between, meantime Additional Equipment Required Lab-Volt Robot Arm One Square Block One Film Canister One Metallic Can RoboCIM Software Tech-Design by Lab-Volt 19

28 Unit Details Automation & Robotics Study Guide Basic Robotics I Four Types of Robots A There are four types of robots, distinguished by the used to specify their moves 1 Robots with a rectangular box work envelope are called Robots a A special case of a Cartesian robot is the, which is anchored 2 Robots with a cut-off cylindrical tube work envelope are called robots 3 Robots with a semi-spherical work envelope centered at its base are called robots 4 Robots that can rotate around their base, but less than a full circle, and can also move in the vertical direction are called or II Components of a Robotics System A Robot s five basic components: B A sixth component of a robotics system is a set of instructions that tells the robot what steps to take III Using RoboCIM A In addition to the, the Lab Volt Robot Arm can be programmed using the software B The RoboCIM software has a that allows developing and testing a program in a virtual environment 20 Tech-Design by Lab-Volt

29 Automation & Robotics Unit Details C The of the RoboCIM software sends the program to the robot Tech-Design by Lab-Volt 21

30 Unit Details Automation & Robotics Methods of Programming Objectives During this unit, you will: examine four methods used to program a robot demonstrate how to record points in RoboCIM create and test a program in RoboCIM to control the robot To-Do List Complete the following assignments Use this to-do list to keep track of each task To-Do Due Date Notes Study Guide Activity Guide: Introduction to Programming Unit Test Additional Equipment Required Lab-Volt Robot Arm One Film Canister One Metallic Can RoboCIM Software 22 Tech-Design by Lab-Volt

31 Automation & Robotics Unit Details Study Guide Methods of Programming I There are fundamentally methods for programming a robot A If the operator physically adjusts the required components and end stops, the programming is called 1 This requires great care to assure are set up 2 This method is usually used with robots B If the operator physically guides the end effector through all the steps, the programming is called 1 The program is saved in the by at each appropriate stop point 2 The robot arm must be by the operator 3 Examples of this type of programming include and C If the operator uses a teach pendant to lead the robot through its paces, the programming is called 1 As the end effector reaches an appropriate, it is recorded into the robot s 2 A good example is the Lab Volt Robot Arm with the or the D If the operator programs all required functions off-line and away from the robot, the approach is called 1 Many complex robots use this type of programming 2 Our example is the use of the Tech-Design by Lab-Volt 23

32 Unit Details Automation & Robotics II The RoboCIM software has two programming options: A One method uses icons and graphics tools, and is called B The other method allows the operator to enter text commands using the keyboard, and is called 24 Tech-Design by Lab-Volt

33 Automation & Robotics Unit Details Editing Programs Objectives During this unit, you will: explore some reasons for editing programs demonstrate how to modify points in a list in a program insert a delay command in a program modify the speed associated with a recorded programmed point To-Do List Complete the following assignments Use this to-do list to keep track of each task To-Do Due Date Notes Study Guide Activity Guide: Program Editing Unit Test Additional Equipment Required Lab-Volt Robot Arm One Film Canister One Metallic Can RoboCIM Software Tech-Design by Lab-Volt 25

34 Unit Details Automation & Robotics Study Guide Editing Programs I Program Editing A Possible reasons for editing a program: 1 You may need to, or commands 2 You may need to modify a that was saved 3 You may need to insert additional 4 You may need to account for obstacle B Editing a program 1 It is good practice to save the edited program with a using 2 If the coordinates are changed for an existing point, save it with the 3 In order to remove a command, you click on contains it and click on the 26 Tech-Design by Lab-Volt

35 Automation & Robotics Unit Details Robotics in Manufacturing Objectives During this unit, you will: explore types of robots used in manufacturing environments create and edit a program that simulates a spot welding robot create a program that simulates continuous welding To-Do List Complete the following assignments Use this to-do list to keep track of each task To-Do Due Date Notes Study Guide Activity Guide: Industrial Application Unit Test Additional Equipment Required Lab-Volt Robot Arm One Metallic Can Square Parts RoboCIM Software Tech-Design by Lab-Volt 27

36 Unit Details Automation & Robotics Study Guide Robotics in Manufacturing I Manufacturing Environment A Most robots in industry handle tasks that are, B Robots used in manufacturing environments are called,, or C They perform a wide variety of functions, including:, D Other Industrial Environments,,,, etc 1 Applications for robots are also found in:,,,,,, etc 2 Robots are also used in design and planning applications, such as: etc E Spot Welding Robots,,,, 1 They tend to be robots with multiple 2 They are flexible and a welding point from 3 They are able to handle a heavier than humans could 28 Tech-Design by Lab-Volt

37 Automation & Robotics Unit Details Using a Feeder Objectives During this unit, you will: demonstrate how to use a gravity feeder create a program to make a robot pick up parts from a feeder and drop them into a metallic can To-Do List Complete the following assignments Use this to-do list to keep track of each task To-Do Due Date Notes Study Guide Activity Guide: Gravity Feeder Unit Test Additional Equipment Required Lab-Volt Robot Arm Gravity Feeder One Metallic Can Square Parts RoboCIM Software Tech-Design by Lab-Volt 29

38 Unit Details Automation & Robotics Study Guide Using a Feeder I Lab-Volt Gravity Feeder A It feeds one part After the robot a part, another part ready to be picked up B It has a that can inform the C While the feeder can handle various parts, they must with the dimensions of the gravity feeder when a part is available D The gravity feeder must to the robot controller E If there are no parts in the feeder, the robot controller can be to: 1 until a part is available 2 with its execution of the program 30 Tech-Design by Lab-Volt

39 Automation & Robotics Unit Details Working with a Rotary Carousel Objectives During this unit, you will: demonstrate how to use a rotary carousel create a program that simulates a galvanizing process To-Do List Complete the following assignments Use this to-do list to keep track of each task To-Do Due Date Notes Study Guide Activity Guide: Rotary Carousel Unit Test Additional Equipment Required Lab-Volt Robot Arm Rotary Carousel One Metallic Can One Film Canister RoboCIM Software Tech-Design by Lab-Volt 31

40 Unit Details Automation & Robotics Study Guide Working with a Rotary Carousel I Lab-Volt Rotary Carousel A It must be connected to of the robot B It can rotate in the or direction C It is driven by a, which moves in D Carousels are used in industry to move from one to another II Robotic Operation A The robot controller can to operate the rotary carousel B The carousel can be made to,, and again 32 Tech-Design by Lab-Volt

41 Automation & Robotics Unit Details The Future of Robotics Objectives During this unit, you will: apply a simple formula for justifying the cost of switching to a robotics system be able to define the role of automation and robotics in today s society explore career opportunities in robotics To-Do List Complete the following assignments Use this to-do list to keep track of each task To-Do Due Date Notes Study Guide Video Response: The Future of Robotics Video Response: Careers in Robotics Career Activity Unit Test Additional Equipment Required Lab-Volt Robot Arm Tech-Design by Lab-Volt 33

42 Unit Details Automation & Robotics Study Guide The Future of Robotics I Investment Analysis A The most common analysis to justify an investment in robotics is to determine the or B The period where the investment the difference between labor savings and expenses is called the C The loss of value of new equipment due to age and use is called D The allows companies to deduct as a cost every year a percentage of the initial investment E Companies usually set their expected, which is generally less than the period allowed by F The main business driver for investments in robotics is II The Future of Robotics A The use of robotics in space is likely to increase, for example: 1 space stations 2 perform various tasks from Earth 3 transmit in addition to visual images back to Earth B The use of robots in homes and business will C Robots will be to program and test 34 Tech-Design by Lab-Volt

43 Automation & Robotics Unit Details Video Response: The Future of Robotics In what way are space probes considered robots? How were robots used in the space stations? What new functionality for robotic grippers is being investigated? Give some examples of the robots being developed by NASA Tech-Design by Lab-Volt 35

44 Unit Details Automation & Robotics Video Response: Careers in Robotics What are some of the responsibilities of industrial engineers? What can a computer programmer do in automation and robotics? What functions can technicians perform? What role can teacher and trainers have in the field of robotics? 36 Tech-Design by Lab-Volt

45 Automation & Robotics Ap p e n d i c e s

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47 Automation & Robotics Independent Study Project Proposal Course: Section: Topic State as specifically as possible the idea, question, and/or activity you have chosen Description State why you have chosen this topic, what you expect to learn, any previous experience you had with this topic, and the type of investigation you will conduct Materials State what materials, people, or activities will be involved in the completion of your project Due Instructor s Approval: Student s Signature: Submit this proposal with your completed project Tech-Design by Lab-Volt 39

48 Independent Study Automation & Robotics Topic Outline Course: Section: In the area provided, write the outline you will use for your independent study project Introduction Discussion Conclusion Due Instructor s Approval: Student s Signature: Submit this proposal with your completed project 40 Tech-Design by Lab-Volt

49 Automation & Robotics Independent Study Bibliography Course: Section: In the area provided, supply the name, author, publisher, and publication date of the references you plan to use for your independent study project Texts 1 2 Journals Others (Examples: work experience, interviews) 1 2 Due Instructor s Approval: Student s Signature: Submit this proposal with your completed project Tech-Design by Lab-Volt 41

50 Independent Study Automation & Robotics Activities Course: Section: In the area provided, give descriptions of the activities or exercises you plan to incorporate into your independent study project Include the materials and the time required for each of the activities or exercises Activities Exercises Due Instructor s Approval: Student s Signature: Submit this proposal with your completed project 42 Tech-Design by Lab-Volt

51 Automation & Robotics Independent Study Drawings Course: Section: In the area provided, supply rough sketches of any drawings you intend to use in your independent study project If you need additional worksheets, you may make additional copies Due Instructor s Approval: Student s Signature: Submit this proposal with your completed project Tech-Design by Lab-Volt 43

52 Independent Study Automation & Robotics 44 Tech-Design by Lab-Volt

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