Robotics Essay Research Paper ADVANCED MANUFACTURING TECHNOLOGY

Robotics Essay, Research Paper

ADVANCED MANUFACTURING

TECHNOLOGY & AUTOMATION

Coursework 2

Robotics

Summary

At present BL Cars Ltd manufacture a part of an automobile suspension assembly known as a Crosstube. They are considering moving from manual to robotic production in either a single cell/single robot or line/multi robot layout. The following report recommends the use of the Fanuc Arc Mate robot, which is a compact, six axis, modular-built, electric servo-driven robot which is controlled by the a R-J3 controller with ArcTool application software. All ancillary equipment options are considered.

The two layouts are considered and all health and safety implications are detailed. The report concludes with a discussion on the validity of each layout. For low volume manufacture it is recommended that a single-cell layout is utilised. For economic production of high volumes a line layout would be the primary choice.

Contents

1.0 Introduction

2.0 Robot Specification

2.1 Mechanical Characteristics

2.2 Performance Specifications

2.3 Programming & Control Methods

3.0 Specification Of Ancillary Equipment

3.1 Welding Tool

3.2 Gripper

4.0 Robotic Assembly

4.1 Cell Layout

4.1 Line Layout

5.0 Health and Safety

5.1 Cell Layout

6.2 Line Layout

6.0 Discussion

7.0 References

8.0 Appendix

1.0 Introduction

BL Cars Ltd manufactures a part of an automobile suspension assembly. It is known as a Crosstube. The complete part consists of four thin sheets of steel presswork. Two parts are identical and are positioned either end of the larger cross brace, which has been formed from two larger pieces of sheet steel..

The diagram below illustrates the complete assembly:

Presently the two parts making up the cross brace are secured using specific jigs. Once secure they are spot welded along the flange edges. The next step is to secure the two mounting plates to the presswork. The process is completed by arc welding the component to add extra strength to the spot welds and secure the mounting plates. N.B. When the parts are pressed from the sheet steel locating points are incorporated. This ensures each part is located in the correct position in the jig.

The use of industrial robots is ever increasing. The robot usually does a secondary machinery operation after a primary shaping operation. When performed manually, this secondary operation often requires the operator to work in an unpleasant environment, to carry out a repetitive and tiring task with bulky tools.

BL Cars Ltd is considering using robots to automate the Crosstube assembly process. The robots will be used for material handling, spot and arc welding in one of two contrasting layouts:

1. Single-cell, single robot – low volumes

2. Line-layout, multi-robot – high volumes

Compared to manual welds, robot welds provide the following benefits:

. A higher quality weld

. Greater consistency

. Increase arc on time as a proportion of total time

. Increased operator safety

. Automatic weld quality monitoring.

Compared to manual handling, robots handling provides the following benefits:

. Greater consistency

. Greater accuracy

. Increased repeatability

. Low running costs

2.0 Robot Specification

BL Cars Ltd have decided to use the Fanuc Arc Mate 50il. This robot is a compact, six axis, modular-built, electric servo-driven robot which is controlled by the R-J3 controller with ArcTool application software. The robot has been designed to maximise throughput and use of floor space by providing a compact, high speed design in a proven and reliable mechanical unit.

Fanuc Arc Mate 50il

. Price: Single robot .30,000

Mechanical Characteristics

. The robot has six axes of movement. The diagram below illustrates axis movement:

. The diagram below illustrates the floor space required for mounting:

. Physical dimensions

Performance Specifications

Programming & Control Methods

The majority of MIG welding jobs are conducted manually. It is relatively recently that machines have come on to the market with sufficient positional repeatability to automate the process reliably and flexibly. Arc welding using MIG is a complex multi-variable control task. Therefore is imperative that an effective controller is chosen.

The controller BL Cars LTD has chosen to use is the R-J3 shown below:

FANUC Robotics’ SYSTEM R-J3 Controller uses advanced technology packaged in a proven, reliable third generation controller design. Process capability and open architecture features improve application and motion performance while simplifying system integration.

SYSTEM R-J3 incorporates FANUC Robotics’ unique “plug-in-options” concept which allows the flexibility for applications specific configurations while maintaining a commonality for all users of the system.

Features:

. 32-bit main CPU with dual processor architecture permits fast calculations, reduces program execution times and increases path accuracy

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