Robots & Automation – MFET 445

Robots & CNC in Integrated

Manufacturing – MFET 685
 Agenda
• Motion Control
• Robot Programming
• Programming Methods
• Programming Languages
• Types of Programming

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Motion Control
 Robots can be classified according to their pattern of motion.
 The three classifications of motion are:
 Pick-and-place
 Point-to-point
 Continuous path
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Pick-and-Place Motion tube.com/watch?v
=QfbdVboVNUM
 Pick-and-Place motions is
often used in manufacturing
processes to perform work
that is repetitive and does not
require many complicated
movements to accomplish a
task.
 Such as picking up a part at
one location and placing it in
another location
 2 positions per axis
 Hard Automation
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e.com/watch?v=hCu
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Point-to-Point Motion
 PTP motion involves the movement of a robot through a
number of points in space.
 Point-to-point control means individual robot positions are
recorded in the memory.
 These positions include both mechanical stops for each joint,
and the set of values that represent locations in the range of
each joint.
 Feedback control is used to confirm that the individual joints
achieve the specified locations in the program.
 The path of motion is a series of straight lines between the
points. May also use speed control.
Point-to-Point Motion
Continuous-Path Motion
 CP motion is an extension of point to point motion.
 The difference is that continuous path motion can involve several
thousand points.
 Continuous path control refers to a control system capable of
continuous simultaneous control of two or more axes.
 The following advantages are noted with this type of playback
control: greater storage capacity—the number of locations that
can be stored is greater than in point-to-point; and interpolation
calculations may be used, especially linear and circular
interpolations.
 Since more points are used, the distance between each point can
be extremely close.
Continuous-Path Motion

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youtube.com/
watch?v=LKsE
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Robot programming
 Robot Programming is the defining of desired motions so
that the robot may perform them without human
intervention.
 Most industrial robot comes in different languages, however
all of them uses the same pseudo language.
Programming Methods
 Robots can be programmed manually, by means of a teach
pendant, by walking them through a tasks, or by means of a
computer terminal.
 The various programming methods are best suited for only
particular types of motion control.

 Four types of programming methods:

 Manual
 Teach Pendant
 Walk-Through
 Computer Terminal
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e.com/watch?v=K9y
Manual Programming 13ooQcCU

 Manual programming can be best described as a type of machine

setup.
 An operator adjusts the necessary end stops, switches, cams,
electric wires to setup the sequence.
 This type of programming is quite limited and are suited for pick-
and-place applications.
 Manual programming is simple and does not require an operator
skilled in the use of computers.
 Capital investment and maintenance costs for manually
programmed robots are low.
 Provides high operating speeds, good accuracy and repeatability.
 However, it lacks in flexibility since most manual robots are
limited to only two or three DOF.
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Using a Teach Pendant om/watch?v=T5hN0N4

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 In teach pendant programming, the operator leads the robot

through the various positions involved in an operation.
 The user moves the robot to the desired location using the teach
pendant to record the robot’s position. The recorded positions
are stored in the memory.
 The teach pendant is a popular method of programming
because it is convenient, simple to learn and suitable for
programming many tasks found in industry.
 However, complex tasks such as reaching extreme tight
tolerances may involve a lengthy programming time.
 The robot must be operation while programming (ON) as the
program cannot be entered into the teach pendant while robot
is off-line (OFF).
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tube.com/watch?v
Walk-Through Programming =mIlkWKciz68

 Walk-through programming is used for continuous path

robots.
 A skilled and experienced operator physically moves the end-
effector through the desired motions.
 Some robot manufacturers name it as the “Free” movement
of the robot while teaching points.
 Walk-through programming does not require computer
experience.
 However, the person programming the robot must be highly
skilled in the precise motion required by the task.
 The robot must be operating (ON) while programming using
the walk-through method.
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tube.com/watch?v
Walk-Through Programming =mIlkWKciz68
 Using a Computer Terminal
 Programming a robot using a computer can be done on-line (at
the robot’s console) or off-line (away from the robot).
 Testing the robot program is done at the job site.
 Computer programming provides greater flexibility. It is not
necessary to take a robot out of operation while the program is
being written and debugged, so productivity is not affected.
 High-level computer languages allow programming of more
complex operations.
 However, the operator must be experienced in the use of
computer, high level languages and programming logic.
Robot programming (IRL)
Programming Languages
 Different robot manufacturers offers different languages for
their equipment.
 Common programming Languages:
Robotics Programming Language Originator
SAIL (Stanford Artificial Intelligence Stanford University
Language)
AL (Assembly Language) Stanford University
MCL (Manufacturing Control Language) McDonnell Douglas Corp.
VAL (Variable Assembly Language) Unimation
V+ Adept Technology
Karel FANUC Robotics
AML (A Manufacturing Language) IBM
RAIL Automatrix
RPL Hewlett Packard
RobotBASIC Intelledex Inc.
Magik GE Energy
SCORBASE Intellitek
Ralph-3 CRS-Technology
Types of Programming
 The majority of robots in industry today use hierarchical
control programming.
 However, task-level programming simplifies the
programming task and is growing in popularity.
 Relationship

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 Gear Manufacturing

Fixed automation: Programmable automation:

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Hierarchical Control Programming
 Hierarchical control programming, each level accepts
commands from the level above and responds by generating
simplified commands for the level below.
 This system uses sensory feedback, to close control loops.
Hierarchical Control Programming
Task-Level Programming
 In task-level programming, the user specifies the goals of
each tasks rather than the motions required to achieve those
goals.
 Instructions are entered using simple English-like terms.
 (Next slide) Displays the architecture for a typical custom
work cell.
 Four separate controllers are used.
 A motion control system runs the robot, while the PLC
(Programmable Logic Controller) provides work cell logic.
 The vision system is for inspection and robot guidance.
 The computer is included for UI (User Interface).
Task-level Programming
Task-Level Programming
 Another example of task-level programming:
 One controller and one program system are needed to work
with multiple technologies.
 The operator can focus attention on the task instead of writing
programming code.
Task-level Programming
 CIM Wheel

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 Flexible Manufacturing System
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ube.com/watch?v=
8cr0nDBRt3c

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.youtube.com
/watch?v=iy
AWaIYDyZU

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 Robots and
CNC within the
CIM
Architecture

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Hierarchical Control Programming
KAREL

TP

BG
Fanuc TP Robot Programming
Fanuc Robot Programming
 Fanuc Robot Programming

Define work coordinate framework

 Fanuc Robot Programming

Define tool offsets

 Fanuc Robot Programming

P3: idle

P1:start

P2: finish

Use teach pendant to define operating points

Fanuc Robot Programming
CNT motion – no stopping
May be less precise

Larger number (CNT100 vs CNT1) means

less precision, less slowdown at each
point

FINE motion – pauses at each point exactly

OUTPUTS

Type of output dictates capacity

• Large Mechanical relay – LOTS

• Small mechanical relay – some
• SSR – quite a bit
• TTL – very little

Outputs may consist of a contact

closure, TTL/CMOS (logic high/low)
or transistor PNP (high signal) or NPN
(low signal).

Might also be set up for AC vs. DC

INPUTS

Type of input dictates robustness and current

draw

• relay – durable, high current

• TTL/CMOS – delicate but very little
current draw
• Optoisolated – durable, low current

Outputs may require high signal,

grounded wire, or AC or DC
Fanuc Robot Programming
 Fanuc Robot Programming
Program Flow
Control Label
 Fanuc Robot Programming
Work
Coordinate
System
 Fanuc Robot Programming
Tool
Coordinate
System
 Fanuc Robot Programming
Joint Motion
Control
 Fanuc Robot Programming

Digital Output
 Fanuc Robot Programming

Timeout for
Digital Input
Interrupt
 Fanuc Robot Programming

Digital Input
Interrupt
 Fanuc Robot Programming

Comment
 Fanuc Robot Programming

Register

Conditional
Branch
 Fanuc Robot Programming

Register

Conditional
Branch
 Fanuc Robot Programming

Program
Termination
 Fanuc Robot Programming

Macro Call
 Fanuc Robot Programming

Send Text
message to
pendant or
terminal output
 Fanuc Robot Programming

End of Program
Karel Programming
Fanuc Karel Programming
Fanuc Karel Programming
Fanuc Karel Programming
Fanuc Karel Programming
Fanuc Karel Programming
Fanuc Karel Programming