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Purpose: This paper aims to propose a hybrid force/position controller based on the adaptive variable impedance. Design/methodology/approach: First, the working space is divided into a force control subspace and a position subspace, the force control subspace adopts the position impedance control strategy. At the same time, the contact force model between the robot and the surface is analyzed in this space. Second, based on the traditional position impedance, the model reference adaptive control is introduced to provide an accurate reference position for the impedance controller. Then, the BP neural network is used to adjust the impedance parameters online. Findings: The experimental results show that compared with the traditional PI control method, the proposed method has a higher flexibility, the dynamic response accommodation time is reduced by 7.688 s and the steady-state error is reduced by 30.531%. The overshoot of the contact force between the end of robot and the workpiece is reduced by 34.325% comparing with the fixed impedance control method. Practical implications: The proposed control method compares with a hybrid force/position based on PI control method and a position fixed impedance control method by simulation and experiment. Originality/value: The adaptive variable impedance control method improves accuracy of force tracking and solves the problem of the large surfaces with robot grinding often over-polished at the protrusion and under-polished at the concave. [ABSTRACT FROM AUTHOR]

Purpose: This research paper aims to optimize the calibration process for an ABB IRB 120 robot, specifically for robotic orbital milling applications, by introducing and validating the use of the observability index and telescopic ballbar for accuracy enhancement. Design/methodology/approach: The study uses the telescopic ballbar and an observability index for the calibration of an ABB IRB 120 robot, focusing on robotic orbital milling. Comparative simulation analysis selects the O3 index. Experimental tests, both static and dynamic, evaluate the proposed calibration approach within the robot's workspace. Findings: The proposed calibration approach significantly reduces circularity errors, particularly in robotic orbital milling, showcasing effectiveness in both static and dynamic modes at various tool center point speeds. Research limitations/implications: The study focuses on a specific robot model and application (robotic orbital milling), limiting generalizability. Further research could explore diverse robot models and applications. Practical implications: The findings offer practical benefits by enhancing the accuracy of robotic systems, particularly in precision tasks like orbital milling, providing a valuable calibration method. Social implications: While primarily technological, improved robotic precision can have social implications, potentially influencing fields where robotic applications are crucial, such as manufacturing and automation. Originality/value: This study's distinctiveness lies in advancing the accuracy and precision of industrial robots during circular motions, specifically tailored for orbital milling applications. The innovative approach synergistically uses the observability index and telescopic ballbar to achieve these objectives. [ABSTRACT FROM AUTHOR]

Purpose: Because of the key role of joint torque in industrial robots (IRs) motion performance control and energy consumption calculation and efficiency optimization, the purpose of this paper is to propose a deep learning torque prediction method based on long short-term memory (LSTM) recurrent neural networks optimized by particle swarm optimization (PSO), which can accurately predict the the joint torque. Design/methodology/approach: The proposed model optimized the LSTM with PSO algorithm to accurately predict the IRs joint torque. The authors design an excitation trajectory for ABB 1600–10/145 experimental robot and collect its relative dynamic data. The LSTM model was trained with the experimental data, and PSO was used to find optimal number of LSTM nodes and learning rate, then a torque prediction model is established based on PSO-LSTM deep learning method. The novel model is used to predict the robot's six joint torque and the root mean error squares of the predicted data together with least squares (LS) method were comparably studied. Findings: The predicted joint torque value by PSO-LSTM deep learning approach is highly overlapped with those from real experiment robot, and the error is quite small. The average square error between the predicted joint torque data and experiment data is 2.31 N.m smaller than that with the LS method. The accuracy of the novel PSO-LSTM learning method for joint torque prediction of IR is proved. Originality/value: PSO and LSTM model are deeply integrated for the first time to predict the joint torque of IR and the prediction accuracy is verified. [ABSTRACT FROM AUTHOR]

Purpose This paper aims to conduct a comprehensive fault tree analysis (FTA) on the critical components of industrial robots. This analysis is integrated with the reliability block diagram (RBD) approach to investigate the robot system reliability.Design/methodology/approach For practical implementation, a particular autonomous guided vehicle (AGV) system was first modeled. Then, FTA was adopted to model the causes of failures, enabling the probability of success to be determined. In addition, RBD was used to simplify the complex system of the AGV for reliability evaluation purpose.Findings Hazard decision tree (HDT) was configured to compute the hazards of each component and the whole AGV robot system. Through this research, a promising technical approach was established, allowing decision-makers to identify the critical components of AGVs along with their crucial hazard phases at the design stage.Originality/value As complex systems have become global and essential in today’s society, their reliable design and determination of their availability have turned into very important tasks for managers and engineers. Industrial robots are examples of these complex systems that are being increasingly used for intelligent transportation, production and distribution of materials in warehouses and automated production lines. [ABSTRACT FROM AUTHOR]

Purpose The purpose of this paper is to propose an on-line iterative compensation method combining with a feed-forward compensation method to enhance the assembly accuracy of a metrology-integrated robot system (MIRS).Design/methodology/approach By the integration of a six degrees of freedom (6DoF) measurement system (T-Mac), the robot’ movement can be tracked with real-time measurement. With the on-line measured data, the proposed iterative compensation for absolute positioning and the feed-forward compensation for relative linear motion are integrated into the assembly process to improve the assembly accuracy.Findings It is found that the MIRS exhibits good performance in both accuracy and efficiency with the application of the proposed compensation method. With the proposed assembly process, a component can be automatically aligned to the target in seconds, and the assembly error can be decreased to 0.021 mm for position and 0.008° for orientation on average.Originality/value This paper presents a 6DoF MIRS for high-precision assembly. Based on the system, a novel on-line compensation method is proposed to enhance the assembly accuracy. In this paper, the assembly accuracy and the corresponding distance parameter are given by a series of experiments as reference for assembly applications. [ABSTRACT FROM AUTHOR]

Purpose – The purpose of this paper is to compare the quality and efficiency of five methods for solving the path planning problem of industrial robots in complex environments. Design/methodology/approach – In total, five methods are presented for solving the path planning problem and certain working parameters have been monitored using each method. These working parameters are the distance travelled by the robot and the computational time needed to find a solution. A comparison of results has been analyzed. Findings – After this study, it could be easy to know which of the proposed methods is most suitable for application in each case, depending on the parameter the user wants to optimize. The findings have been summarized in the conclusion section. Research limitations/implications – The five techniques which have been developed yield good results in general. Practical implications – The algorithms introduced are able to solve the path planning problem for any industrial robot working with obstacles. Social implications – The path planning algorithms help robots perform their tasks in a more efficient way because the path followed has been optimized and therefore they help human beings work together with the robots in order to obtain the best results from them. Originality/value – The paper shows which algorithm offers the best results, depending on the example the user has to solve and the parameter to be optimized. [ABSTRACT FROM AUTHOR]

Jaguar Cars, the luxury UK automaker, is developing a new car, the X350. For the first time, the company is to use aluminium body panels for the body shell. Aluminium can be difficult to weld so self-piercing rivets are used for metal joining. The rivets are used in place of spot welding, but are applied by rivet setters attached to robots. [ABSTRACT FROM AUTHOR]

This case study describes the application of robots to an agricultural depalletizing operation. Discusses the reasons for adopting robotics, the requirements of the application and the resulting system performance. [ABSTRACT FROM AUTHOR]

Improvements in both robot manufacture and robot controller technology have resulted in greater robot accuracy. A trial has been conducted to highlight the improvements brought by this evolution. By measuring the accuracy of the velocity profiles of two generations of the Fanuc Hexapod robot (the Flextool), these evolutionary developments are illustrated. The results from the trial show that although both generations of robot exhibit good accuracy, the later robot is superior both in terms of mechanical design and in controller processing capability. [ABSTRACT FROM AUTHOR]

The paper discusses the new emerging technology of “gastrobotics”, or food-powered mobile robots. The concept of self-sufficiency is examined, and it is postulated that robots with stomachs offer the promise of sustained autonomous operation in an unstructured outdoor environment, which is not possible with existing alternative methods. Data is presented that compares the energy density of various foods, with that of common chemical batteries and gasoline. The various food groups are discussed as regards their suitability as fuel for gastrobots, and a variety of potential applications are presented. The basic operation of a microbial fuel cell is described in its role as an artificial stomach, thereby demonstrating how this biotechnology can efficiently convert food into electricity. [ABSTRACT FROM AUTHOR]

Robots have been used on plastic injection moulding machines for many years. Linear robots account for the vast majority of applications but there is a small increase in use of six-axis articulated arm types for certain applications. This paper discusses the pros and cons for the various types being used and describes the downstream processes that can be incorporated within the automated cell. [ABSTRACT FROM AUTHOR]

Describes the benefits of using robots to unload injection moulding machines and the various robot configurations that can be applied. The use of robots to assist in the manufacture of injection moulded loading doors for domestic washing machines is given as an example. [ABSTRACT FROM AUTHOR]

A new application for the industrial robot has emerged, inspection, with two players emerging, Stäubli and Amatec Robotics of the Kuka Roboter Group. Both companies’ systems and their competing benefits are discussed. Until this new development, car bodies were inspected on-line with arrays of laser sensors fixed in position over the production line. Using a robot to manipulate the same type of sensor gives more flexibility in the areas of the car to be measured and also reduces the number of sensors needed. It emerges that virtually all of the applications to date are to be found in European car plants, and some of these are described. The increasing demand for quality assurance is forcing many manufacturers to look to in-line inspection to solve the problem. As in many instances, it is the automotive industry that is taking the lead with systems able to check on every body built. Gone has hard fixturing as too slow and inflexible, and even the programmable CMM that has the flexibility but cannot “keep up”, as well as being less robust for production line applications. The answer until now has been banks of laser triangulation sensors mounted in tunnels spanning the production line. But now there is an alternative, using robots to manipulate the same type of sensor, still allowing inspection within the line cycle time but with the flexibility to cater for variants, design changes and even the introduction of new models. Two companies are now offering in-line measurement systems based on robots, Stäubli with flexible robotic absolute measuring system (FRAMS), and Amatec Robotics, a subsidiary of, and the robot sensor applications specialist in, Kuka Roboter GmbH, who has developed flexible in-line measurement system (FIMS). Both employ the same type of 3D vision sensor that is used in the fixed sensor tunnel system, but attached to the end of the robot arm so that it may be manipulated within a large working envelope. One ro... [ABSTRACT FROM AUTHOR]

This paper deals with the problem of developing a low cost remote supervisory control system with multimedia features of distributed robotic cells. The distributed robotic cells are locally controlled by different vendor systems. In the automated factories, a low cost and not isochronous backbone network is usually installed to transfer process data from the production level to the other ones. The proposed architectural prototype makes possible on different remote platforms a supervisory control with full process database access and field audio/video signal. The case of field vocal messages and animated plant synoptic using the low cost factory backbone network has been considered. On the remote station it is possible to use commercial supervisory control applications. A first case study, the remote supervision of a robotic cell, installed in the University of Naples, has given satisfying results. In addition, this application has shown the possibility of using the prototype for educational and research purposes, making available remote access to laboratories. [ABSTRACT FROM AUTHOR]

An extremely high-pressure jet of water is an efficient method of cutting soft materials, and combining the waterjet process with industrial robots is an economic alternative to the traditional punch tool method of producing complex-shaped components for car interiors, such as floor carpets, headliners and door trims. Applications are given of robotic waterjet systems installed in the USA, France and Iran as well as news of a new cutting box introduced by ABB-IR Waterjet Systems. A further development of the waterjet process is described in which the addition of abrasives enables aluminium castings to be fettled and cleaned. Waterjet cutting is one of those technologies, like laser welding and even robotics itself, to have been discovered before its time. But, today it has found a strong niche application in the automotive industry, just like the other “solutions in search of a problem”, in its case for the three-dimensional trimming of vehicle interior components made from soft materials. These include materials such as polyurethane foam, moulded fibres, sandwich materials and composites. More than 80 per cent of the European market for waterjet cutting is taken up by suppliers of internal car components to the major automotive OEMs such as Audi, BMW, Ford, Mercedes, Vauxhall, Volkswagen, Saab and Volvo. Waterjet has also paralleled the laser in its affinity with robotics, which provides the flexibility of operation demanded by the automotive manufacturers. The programmability of the robot enables complex shapes to be readily generated and easily changed to accommodate complete new designs, component modifications or another product or variant. Manufacturing runs for an entirely new component may be established in less than 40 hours, according to ABB I-R Waterjet Systems, a joint venture between ABB Flexible Automation and Ingersoll-Rand and the market leader in robotic waterjet cutting. A design modification needs only simple revision... [ABSTRACT FROM AUTHOR]

It has been an ultimate long-term dream in robotics and AI fields to build robotic systems with life-like appearance, behaviours and intelligence, reflected by many science fiction books and films. This is also an extremely challenging task. This paper introduces our current research efforts to build a multi-agent system for cooperation and learning of multiple life-like robots in the RoboCup domain. A behaviour-based hierarchy is proposed for the Essex Rovers robot football team to achieve intelligent actions in real time, which includes both a neural network-based color detection algorithm and a fuzzy logic controller. Preliminary results based on legged locomotion experiments of Sony walking robots are presented. [ABSTRACT FROM AUTHOR]

A compliance device combining passive and active compliance has been tested and developed for an anthropomorphic robot for use during assembly operations. The device has the ability to correct for angular and lateral misalignments between mating parts, resulting in no equipment or part damage. The method of control, the design features of the device and the modifications made to enable the device to be used by an anthropomorphic robot are described and future modifications which will enable the device to operate more effectively are discussed. [ABSTRACT FROM AUTHOR]

Proposes a navigation algorithmn for the position estimation of mobile industrial robots. Navigation methods used to estimate the position of mobile robots; Features of the proposed navigation system; How the Kohonen neural network can detect robot position.

Describes the image processing controls used by Volvo Car Corp. in the assembly of automotive front wheel components. Features of vision technology supplied by Cognex company; How the vision technology was applied to the automotive parts assembly line; Advantages of vision system technology in robotic assembly line.

Presents a study which assessed and compared the accuracy of modern industrial robots. Advantages and drawbacks of offline robot programming; Benefits of calibration tools for robots; Methodology; Results and discussion.

Presents news briefs on the robotics industry as of June 2000. Plastic moulding applications of robots presented at the National Plastics Exposition 2000 at McCormick Place in Chicago, Illinois; Number of robots sold in Great Britain in 1999; Move of Sertec Group Holdings Ltd. to purchase the company Contour Cutting Technologies; Features of the intelligent cleaning robots which use navigation technology from the company Siemens.

Presents an outline of the robot system promoted by Kyushu Electric Power Co. Inc. in an all-out effort to introduce outage-free maintenance techniques. Discussion on the development of a robot simulator; Information on the development of a hybrid robot; Conclusion.

Presents a novel drive mechanism for a robotic tractor for transversing pipelines, including sewers, in a poor condition. Basic mechanism of the brush tractor; Description on the sewer tractor design; Conclusions.

Describes the development and application of the ABB IRB 140 industrial robot. Characteristics; Applications.

Presents several products released by the robotics industry in Great Britain as of 2000. Rho4 robot handling and machine control from Bosch; RE40 ironless winding system from Maxon Motor UK Ltd.; Grippers for automated assembly equipment from Leader Grippers; IRB 580 coating robot from ABB Flexible Automation.

Features a study that examined the design and construction of the Pallet Handling Device robot system of Stewart-Glapat Corp. for autonomous loading of pallets into semi-truck trailers. Use of programmable logic controller and sensors; System description and control architecture; Results and conclusion.

Reports on the 2000 Hanover Factory Automation show held in Hanover Messe, Germany. Review of robots and automation systems; Applications with the use of vision; Identifications of trends for off-line programming software from robot makers.

Presents news briefs about the robotics industry as of 2000. Increase in the 1999 worldwide sales of robots; Agreement between Adept Technology Inc. and Sony Corp.; Publication of the book `The Extended Arm of Man,' by Lars Westerlund; Portable Welders to supply integrated manual and robot spot welding guns to Chrysler's Saltillo, Mexico plant.

Focuses on the use of piezoelectric actuators for use in robot gripping systems. Discussion on electrostrictive and piezoelectric actuation; Explanation of the application of piezoelectric elements in robot gripping systems; Technology of microrobotics and their associated microgrippers.

Demonstrates that present technologies in year 2000 are sufficient to produce a household robot, like Isaac, for the elderly or disabled. Typical day with Isaac; Technology references.

Provides information on industrial robots released in February 2000. Details on the Epson robots designed for use in dust-proof and wash down areas; Description of the Durr Ecopaint robot, a cab painting system used by Airflow Streamlines; Features of the gantry robot manufactured by Afma Robots for industrial production.

Presents a study which suggested that robots be provided with an ability to reason, enabling them to autonomously carry out task and path planning within the context of production. Essential role of standardization within production processes; Details on simplification, an alternative to standardization; Significance of simplification approach to the adoption of robotic assembly.

Presents a study which described the experience of setting up a cooperative arm system based on individual open-architecture controllers. Description of the systems' components; Overview of the main issues related to the coordination and the control of cooperative robots; Problems related to the implementation of a cooperative system.

Discusses the benefits of using robots for advanced composite lay-up procedures. Details on the use of composites in aerospace applications; Impact of the use of industrial robots and robotic systems; Information on precision tooling.

Proposes a computer-assisted robotic fettling technique using visual feedback. Process parameters associated with high-speed fettling operations; Principle of visual servoing technique; Conclusion.

Presents information on Loctite Corp. One-Pass robotic flange cleaning system. Purpose and design of the robotic flange cleaning system; Details of two complementary Loctite formed-in-place gasket sealant dispensing systems.

Provides statistical data on the sales and profitability of the robot market around the world as of January 2000. Growth of the European robot market in 1998; Decline in the value of the world robot market in 1998; Projected sales of robots worldwide by 2002.

Offers information on SIRIUS, a modular climbing robot system. Design requirements for the robot system; Main points of the development of a modular robot system; Details on the control system of the robot.

Offers information on SINAS, a navigation system which functions to clean robot applications, developed by Siemens company. Structure and main feature of the SINAS system; Technical requirements of the robot; Details on some main navigation modules.

Provides information on a study which focused on automating the welding process for the ship building industry. Why conventional robotic welding are seldom used in shipyards; Features of a Ship Welding Robot System; Information on walk-through teaching method.

Focuses on the implementation of a high-speed welding system with an arc welding robot. Past methods for welding control; Ideas for welding control; Features of MOTOPAC-WH200 arc welding robot.

Discusses the application of low cost laser based seam tracking systems to welding robots in the automotive industry. Reasons for using vision seam-tracking systems in automotive application; How a robot produces welds; Problems that a Meta laser vision system solves.

Evaluates the applications of robots in the automotive industry. Description of compact robot designs; Pioneering applications of robots for machining and laser welding; Evolution of paint shop technology to make greater use of robots.

Highlights the investment made by Rover for the launch of its executive car, the Rover 75. Reason behind the building of a factory on the existing Oxford site; Capabilities of the factory particularly for its body-in-white facility; Standards in robot automation.

Explains the collaborative robots (cobots) as one approach to a class of materials handling equipment called Intelligent Assist Devices (IASDs). How cobots use transmissions to create virtual surfaces; Other applications of cobots; Effects of cobots to ergonomics.

Provides information on a study which examined the features of lamb and sheep dressing robots. Criteria to follow when designing robots; Details on the lamb automation of the slaughterline; Handling challenges in the meat processing, beef automation, technology transfer and commercialization; Conclusion.

Deals with the MOTOMAN-SV035 robot designed for the food industry by the Motoman Robotics Division of Yaskawa Electric Corp. in Japan. Information on the package of the food handling robot; Explanation on the actual production line system.

Focuses on the IRB 340 FlexPicker robot from ABB Flexible Automation designed for the food and beverage industry. Speed and cost as the two principal criteria in designing FlexPicker; Description of the robot's cylindrical working envelope; How the vision guidance system developed by Cognex work with FlexPicker.

Presents information on several products for use in manufacturing plants. Heavy duty assembly manipulator from Expert UK Ltd; Alignment compensator for positioning tools on robots and similar automated assembly machines from Leader Grippers; Access safety solutions for hazardous robot cells from Fortress Interlocks.

Describes the development of the Advanced Robotic Manipulator (ARM) system for use in weld inspection. Industrial applications of the robotic system; ARM philosophy; Details of the system's hardware and software.