Part 1
1.
a) Handling Sheets (Weight Between 10kg to 100kg)
Robot Type: Articulated Industrial Robot
Justification:
- Versatility: Articulated robots, such as those from KUKA or ABB, offer a high level of flexibility
and dexterity, which is crucial for handling various sheet sizes and weights.
- Payload Capability: These robots are available with payload capacities that can comfortably
handle weights between 10kg and 100kg.
- Precision: They provide precise control and are suitable for applications requiring accurate
positioning.
b) Holding Sheets for Welding
Robot Type: Collaborative Robot (Cobot)
Justification:
- Safety and Integration: Cobots are designed to work safely alongside human operators. Their
built-in safety features make them ideal for tasks where human intervention is required.
- Gentle Handling: Cobots can hold sheets securely while minimizing the risk of damage.
c) Spot and Continuous Welding of Side Panels to a Frame
Robot Type: Industrial Robot with Welding Tools
Justification:
- Welding Precision: Robots like the Fanuc ARC Mate series are specifically designed for welding
applications, providing high precision and consistency.
- Specialized Tools: They can be equipped with specialized welding torches and sensors to ensure
high-quality welds.
d) Painting
Robot Type: Articulated Robot with Painting Tool
Justification:
- Controlled Application: Articulated robots equipped with spray guns can ensure a uniform
application of paint on complex surfaces.
- Efficiency and Safety: They help reduce exposure to hazardous chemicals and optimize paint
usage.
2. Suitable End Effectors for Each Operation
a) Handling Sheets:
- End Effector: Vacuum or Magnetic Gripper
- Description: Vacuum grippers are ideal for handling flat sheets with a range of weights.
Magnetic grippers are suitable for ferrous materials.
b) Holding Sheets for Welding:
- End Effector: Pneumatic or Hydraulic Gripper
- Description: These grippers ensure secure holding of sheets, necessary for precise welding
operations.
c) Spot and Continuous Welding:
- End Effector: Welding Torch with Sensors
- Description: A welding torch integrated with sensors for real-time feedback on weld quality and
positioning.
d) Painting:
- End Effector: Spray Gun
- Description: A spray gun with adjustable atomizing capabilities for even paint distribution.
3. Quality Inspection System Improvements
a) Welding Cracks:
- Current System: Basic visual or ultrasonic inspection.
- Improvements:
- Ultrasonic Testing: Implement automated ultrasonic testing for more accurate detection of
internal defects.
- Laser Scanning: Use laser scanning for detailed surface inspection.
b) Component Alignment:
- Current System: Manual measurements.
- Improvements:
- Vision Systems: Integrate machine vision systems to automate alignment checks.
- Automated Fixtures: Use fixtures that can adjust in real-time to ensure correct alignment.
c) Electrical Testing:
- Current System: Manual testing tools.
- Improvements:
- Automated Electrical Testers: Deploy automated systems that can continuously monitor and
log electrical performance.
- Data Analysis: Utilize data analytics to detect potential issues early.
4. Arduino Uno Programs for Specific Tasks
I. Pick and Place
#include <Servo.h>
Servo gripper;
void setup() {
gripper.attach(9); // Attach servo to pin 9
pinMode(8, OUTPUT); // Motor control pin
pinMode(7, OUTPUT); // Sensor pin
}
void loop() {
// Move to pick position
moveToPosition(50, 100); // Example function call
delay(2000); // Wait for movement
// Activate gripper
gripper.write(90); // Close gripper
delay(1000);
// Move to place position
moveToPosition(150, 100); // Example function call
delay(2000);
// Release gripper
gripper.write(0); // Open gripper
delay(1000);
// Return to home position
moveToPosition(0, 0); // Example function call
delay(2000);
}
void moveToPosition(int x, int y) {
// Control motors to move to (x, y) position
digitalWrite(8, HIGH); // Example motor control
// Add code for motor movement
}
II. Spot Welding
#include <Servo.h>
Servo welder;
void setup() {
welder.attach(9); // Attach servo to pin 9
pinMode(8, OUTPUT); // Welding control pin
}
void loop() {
// Move to welding position
moveToWeldingPosition(50, 100); // Example function call
delay(2000);
// Start welding
digitalWrite(8, HIGH); // Activate welder
delay(2000); // Welding duration
// Stop welding
digitalWrite(8, LOW); // Deactivate welder
delay(2000);
// Move to next position
moveToWeldingPosition(150, 100); // Example function call
delay(2000);
}
void moveToWeldingPosition(int x, int y) {
// Control motors to move to (x, y) position
// Add code for motor movement
}
III. Continuous Welding
#include <Servo.h>
Servo welder;
void setup() {
welder.attach(9); // Attach servo to pin 9
pinMode(8, OUTPUT); // Welding control pin
}
void loop() {
// Move to welding start position
moveToWeldingStartPosition(50, 100); // Example function call
delay(2000);
// Start continuous welding
digitalWrite(8, HIGH); // Activate welder
moveInPath(); // Example function to follow a path
digitalWrite(8, LOW); // Deactivate welder
// Return to home position
moveToWeldingStartPosition(0, 0); // Example function call
delay(2000);
}
void moveToWeldingStartPosition(int x, int y) {
// Control motors to move to (x, y) position
// Add code for motor movement
}
void moveInPath() {
// Code to move along a predefined path
// Add code for continuous movement
}
5. Safety System for Shape Forming and Molding Robotic Cell
Safety System Proposal:
- Physical Barriers: Install barriers around the robot cell to prevent unauthorized access during
operations.
- Emergency Stop Buttons: Install multiple emergency stop buttons in accessible locations
around the cell.
- Safety Sensors: Use sensors to detect the presence of personnel and halt operations if someone
enters the safety zone.
- Warning Signals: Equip the cell with warning lights and alarms to signal when the robot is in
operation.
- Manual Inspection Protocol: Develop a procedure for safely performing manual inspections,
including the use of PPE and lockout/tagout practices.
Safety Requirements:
- Compliance: Adhere to safety standards such as ISO 10218 and ISO/TS 15066.
- Training: Provide training for all personnel on safety procedures and emergency protocols.
- Regular Maintenance: Perform regular checks and maintenance of safety systems to ensure
reliability.
6. Safe Working Plan for Inside Components Assembly Robotic Cell
Safe Working Plan:
- Robot Safety Features: Ensure that robots are equipped with collision detection and emergency
stop mechanisms.
- Guarding: Install physical barriers or safety enclosures to protect operators from moving parts.
- Operator Training: Ensure operators are trained in safe working practices and emergency
procedures.
- Risk Assessment: Conduct a detailed risk assessment to identify and mitigate potential hazards.
Risk Assessment:
- Identify Hazards: Recognize potential hazards such as mechanical failures or electrical issues.
- Analyze Risks: Evaluate the likelihood and severity of each hazard.
- Implement Controls: Introduce control measures, including safety interlocks and regular
maintenance.
- Monitor and Review: Continuously monitor safety performance and review risk assessments to
ensure ongoing safety.
