Calibration of Gantry-Tau Robot and Prototyping of Extruder for 3D Printing

This master thesis is about improving the accuracy of a Gantry-Tau robot by identifying the key parameters in the kinematics of the robot. This is done using a vision system and then estimating the parameters by minimizing the closure equation of the kinematics. The robot with improved control is then used for additive manufacturing. Furthermore, a prototype for a large plastic printer head is presented

Engineering Method and Tool for the Complete Virtual Commissioning of Robotic Cells

Intelligent robotic manufacturing cells must adapt to ever-varying operating conditions, developing autonomously optimal manufacturing strategies to achieve the best quality and overall productivity. Intelligent and cognitive behaviors are realized by using distributed controllers, in which complex control logics must interact and process a wide variety of input/output signals. In particular, programmable logic controllers (PLCs) and robot controllers must be coordinated and integrated. Then, there is the need to simulate the robotic cells’ behavior for performance verification and optimization by evaluating the effects of both PLC and robot control codes. In this context, this work proposes a method, and its implementation into an integrated tool, to exploit the potential of ABB RobotStudio software as a virtual prototyping platform for robotic cells, in which real robots control codes are executed on a virtual controller and integrated with Beckhoff PLC environment. For this purpose, a PLC Smart Component was conceived as an extension of RobotStudio functionalities to exchange signals with a TwinCAT instance. The new module allows the virtual commissioning of a complete robotic cell to be performed, assessing the control logics effects on the overall productivity. The solution is demonstrated on a robotic assembly cell, showing its feasibility and effectiveness in optimizing the final performance

Research on hybrid manufacturing using industrial robot

The applications of using industrial robots in hybrid manufacturing overcome many restrictions of the conventional manufacturing methods, such as small part building size, long building period, and limited material choices. However, some problems such as the uneven distribution of motion accuracy within robot working volume, the acceleration impact of robot under heavy external loads, few methods and facilities for increasing the efficiency of hybrid manufacturing process are still challenging. This dissertation aims to improve the applications of using industrial robot in hybrid manufacturing by addressing following three categories research issues. The first research issue proposed a novel concept view on robot accuracy and stiffness problem, for making the maximum usage of current manufacturing capability of robot system. Based on analyzing the robot forward/inverse kinematic, the angle error sensitivity of different joint and the stiffness matrix properties of robot, new evaluation formulations are established to help finding the best position and orientation to perform a specific trajectory within the robot\u27s working volume. The second research issue focus on the engineering improvements of robotic hybrid manufacturing. By adopting stereo vision, laser scanning technology and curved surface compensation algorithm, it enhances the automation level and adaptiveness of hybrid manufacturing process. The third research issue extends the robotic hybrid manufacturing process to the broader application area. A mini extruder with a variable pitch and progressive diameter screw is developed for large scale robotic deposition. The proposed robotic deposition system could increase the building efficiency and quality for large-size parts. Moreover, the research results of this dissertation can benefit a wide range of industries, such as automation manufacturing, robot design and 3D printing --Abstract, page iv

Implementation of a robotic flexible assembly system

As part of the Intelligent Task Automation program, a team developed enabling technologies for programmable, sensory controlled manipulation in unstructured environments. These technologies include 2-D/3-D vision sensing and understanding, force sensing and high speed force control, 2.5-D vision alignment and control, and multiple processor architectures. The subsequent design of a flexible, programmable, sensor controlled robotic assembly system for small electromechanical devices is described using these technologies and ongoing implementation and integration efforts. Using vision, the system picks parts dumped randomly in a tray. Using vision and force control, it performs high speed part mating, in-process monitoring/verification of expected results and autonomous recovery from some errors. It is programmed off line with semiautomatic action planning

An Integrated Design and Simulation Environment for Rapid Prototyping of Laminate Robotic Mechanisms

Laminate mechanisms are a reliable concept in producing lowcost robots for educational and commercial purposes. These mechanisms are produced using low-cost manufacturing techniques which have improved significantly during recent years and are more accessible to novices and hobbyists. However, iterating through the design space to come up with the best design for a robot is still a time consuming and rather expensive task and therefore, there is still a need for model-based analysis before manufacturing. Until now, there has been no integrated design and analysis software for laminate robots. This paper addresses some of the issues surrounding laminate analysis by introducing a companion to an existing laminate design tool that automates the generation of dynamic equations and produces simulation results via rendered plots and videos. We have validated the accuracy of the software by comparing the position, velocity and acceleration of the simulated mechanisms with the measurements taken from physical laminate prototypes using a motion capture system

MIRA Modular Interchangeable Robotic Arm

Low-cost robotic arms are becoming much more popular in educational settings. The goal of this project is to create a proof of concept for a modular robotic arm. To accomplish this, we have modified an existing arm to use our own modular control system, created a removable joint that can be connected to the end of the arm, and created an end-user interface which allows visualization of the arm’s movement in real time. Creating this arm will make robotics education accessible to a larger number of people, without compromising the potential for each person to gain a high quality understanding of the way robotic arms behave