Modular industrial robotics: New kinematic simplicity for plant engineers

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Now a totally modular and easy-to-program robotics know-how lets engineers and different plant personnel shortly choose and join kinematic modules to create industrial robotic arms.

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Sponsored content material ⚙️ Conventional six-axis serial robotics and selective compliance meeting robotic arms (SCARAs) have prebuilt constructions and rigidly outlined motions and levels of freedom (DOFs). In distinction, now a completely new sequence of field-assemblable robots is each programmatically and bodily configurable (and reconfigurable) by engineers and plant workers alike. Referred to as Automation Technology for Robotics or ATRO, every accomplished meeting consists of a base module and a singular mixture of different modules (every acknowledged as separate EtherCAT gadgets by controls) to make functioning robotic tables, arms, or delta assemblies.

Extra particularly, ATRO kinematics are constructed of modules from 4 classes.

ATRO base modules (the primary upon which different modules are stacked) embrace a ruggedized base with mounting flanges, energy and networking connectivity ports, and an output media feed that begins the inner run of media by means of the meeting’s inside to permit limitless joint rotations. (Extra on this shortly.)

Energetic motorized modules are open-ended arm sections containing a planetary gearmotor, brake, servodrive, and management electronics in a ruggedized cylindrical housing. Ends are threaded and studded with mechanical locking Hirth joints to shortly safe to different modules within the sequence.

These subsystems are available in a wide range of diameters, lengths, and shapes; each straight I-shape and angled L-shape motorized modules are available in 5 energy sizes. As a result of every lively module kinds an entire drive system for one robotic axis, the one exterior elements wanted are an influence provide and controller. It’s a construction that considerably reduces the quantity of control-cabinet actual property consumed by {hardware} to command the robotic’s DOFs.

After programming, ATRO robotics use EtherCAT for direct integration into PC-based controls for routinely optimized workcells. In actual fact, one industrial PC can command a number of ATRO robots. In addition to simplifying set up, that may additionally trim value.

Connection or linkage modules are available in I, L, and Y shapes and permit additional customization of the robotic morphology. That includes the identical ruggedized housings and mechanical end-connection geometries because the ATRO system’s motorized modules, these function the movable joints of ATRO assemblies.

Lastly, user-specified system modules combine application-specific gripping or different end-effector features. With these core module choices, an unlimited array of robotics is feasible, together with:

• Single-axis rotary indexing tables and two-axis trackers
• Three-axis delta robots (with supporting {hardware}) and four-axis pick-and-place robots
• 5-axis palletizing arms
• Six-axis serial arms
• Seven-axis robotics able to specialty articulation for machine tending and comparable duties necessitating extension into hard-to-reach areas inside equipment.

In some instances, the automation resolution’s mechanics and half rely will be decreased. ATRO’s extraordinarily versatile construction lets it fulfill a wide range of purposes — even these involving payloads to 10 kg and reaches to 1.3 m.

Programming and controlling ATRO robots

ATRO options EtherCAT connectivity that enhances the way in which wherein the robotic modules are commissioned and programmed through TwinCAT software program. The latter contains a huge mannequin library to assist normal in addition to customized industrial kinematics for simpler integration of robotic handlers into machine workcells. In distinction, conventional off-the-shelf SCARA and glued serial robots are not often an ideal match for pre-existing or finalized workcell components … thus complicating the setup of real-world purposes.

The ATRO interface inside TwinCAT helps 3D simulation of single robots to let finish customers construct robots themselves utilizing the bottom, lively, and linkage modules simply described. From there, digital workpieces, trays, tables, baskets, machine entry home windows, imported machine CAD information, and obstacles (similar to pillars, partitions, and workcell fencing) within the TwinCAT GUI will be modeled to let the person outline how the robotic ought to work together with or keep away from them.

Decide, flip, place, and myriad different strikes will be set within the desired sequence after which exported.

As soon as the controller receives the exported file, it builds the complete PLC code. Then customers merely log into the controller through the GUI and click on an allow button to run the robotic by means of its motions. Coordination with superior conveying methods and even levitating motor installations is feasible, as are expansive configurations with as many as 16 ATRO robots.

Constructions are merely scanned by the management software program, and the TwinCAT robotic features routinely create the corresponding management utility — together with a digital twin. (The place wanted, the digital twin inside TwinCAT can outline stresses on ATRO’s mechanical elements.) In-the-field instructing of ATRO methods is equally straightforward; customers merely seize the robotic, transfer its linked modules by means of desired positions, and set the trail and factors through a linked HMI.

To be clear, customers with totally different skillsets can select from three programming choices — primary routines (for handbook robotic instructing), reasonably subtle routines (for customers who really feel comfy constructing, importing, and defining machine components), and superior routines for TwinCAT consultants with proficiency in 3D simulation, coding operations, and line-by-line tweaking of routinely generated programming (as IEC 61131-3 structured textual content, ladder logic, or function-block diagrams — FBDs).

Bodily system connections and communications

ATRO’s tight TwinCAT integration permits management of a number of robots through one controller. Even machine-vision picture processing, machine studying, purposeful security, and direct cloud integration (to assist enterprise-level evaluation and predictive upkeep routines) are doable. Synchronization of ATRO methods with XTS and XPlanar adaptive product dealing with methods inside this widespread atmosphere minimizes communication delays. As talked about, ATRO methods can even endlessly rotate at every joint. That’s attributable to:

• The gearmotor design in lively modules
• Multi-turn servo-axis monitoring of place
• Routing of energy, communications, and different fluid media by means of the middle of every robotic module through rotary unions and Hirth joints.

The latter is especially considerably distinctive — particularly as connections embrace 4 for compressed air, vacuums, water, and different fluids; EtherCAT and Gbit Ethernet; and 48-V in addition to high-voltage AC energy. All these connections render the ATRO able to accepting varied distributors’ finish effectors and grippers (whether or not electromagnetic or pneumatic) which by definition are exceptionally job particular.

The place may limitless joint rotation show helpful? Properly, this provides ATRO methods most reachability in addition to the flexibility to take particularly quick (learn: quick) paths to achieve given positions in 3D area. What’s extra, it eliminates the bulkiness of cables run alongside the robotic’s exterior in addition to interfering torques so widespread in robots and collaborative robots (cobots).

The usage of EtherCAT-standard LED communications (within the type of illuminated bands on each ATRO module) gives native diagnostics data. A module glowing blue signifies the ATRO is in instructing mode. Inexperienced signifies the module has a dependable connection and is able to function. Yellow signifies that an operation is being processed; crimson signifies the presence of a difficulty.

What prompted ATRO improvement — and rising purposes

ATRO satisfies a necessity for easy-to-assemble customized machine-tending choices, particularly these requiring arms able to reaching round obstacles inside massive gear. Its customizable kinematics can even deal with variable payloads and execute notably sophisticated motions. Think about an utility from the machine-tool business — that of milling. Right here, ATRO controls can nimbly interpolate the movement wanted from the top effector to understand, orient, and cargo workpieces into the machine … after which nimbly reverse the method as soon as milling is full.

Although ATRO methods aren’t but licensed to be used as cobots, they do embrace 17 totally different drive-based security modes, together with restricted pace and protected acceleration settings. The primary cutting-edge ATRO permutations have taken the type of so-called octo-robots for superior meeting and materials dealing with purposes.

Beckhoff Automation | www.beckhoff.com