IBDP Design Technology - 4.6 Robots in Automated Production

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Robots in Automated Production

The development of increasingly sophisticated robotic manufacturing systems is transforming the way products are made. Designers should consider the benefits of increased efficiency and consistency when using robots in production and be able to explore the latest advances in technology to ensure the optimum manufacturing process is used. However, a good designer will also understand their responsibility to consider the moral and ethical issues surrounding increased use of automation, and the historical impact of lost jobs.

The first commercially available robots were the Versatrane and Unimate 2000, which went on sale in 1962. These robots were capable of being programmed to undertake complex movements and lifting heavy loads repeatedly. You also need to bare in mind that computers were at the very early stages of commercial development, and very rare outside of the academic world. Remember the birth of the internet as we know it now wasn’t for another 41 year - January 1st 1983.

4.6.1 | Work envelope and load capacity

A traditional robot has two primary characteristics: Work envelope and load capacity.

A robot’s work envelope is its range of motion, or theoretical space needed for safe operation. These distances are determined by the length of the robot's arm and the distance of its axes. Each axis contributes to its own range of motion.

A fixed robot can only perform within the confines of its work envelope. However, many robots are designed with considerable flexibility in mind. Some have the ability to reach behind themselves. Robots can be restricted within their maximum work envelope if physical space or specific hazards are an issue.

Gantry robots defy the traditional constraints of work envelopes, they move along track systems to create a large workspace. This track system can easily be adjusted or enlarged.

Load capacity is the maximum weight a robot can lift, manoeuvre, or manipulate.

4.6.2 | Single-task robots

1st generation robots are single-task machines programmed and manufactured to do one task. They were generally mechanical arms with the ability to make precise motions at high speed, many times, for prolonged periods of time. Such robots still have widespread applications in industrial and manufacturing today. First-Gen robots can work in groups, such as in the automated integrated manufacturing system (AIMS) if their actions are synchronised - We see this for instance in an automated car production line.

However, these robots are “dumb” and can not sense the world around them and respond to it. The operations of First-Gen robots must be constantly supervised, because if they get out of alignment and are allowed to keep working, the results can be a whole series of bad production runs or errors.

Most single task robots are designed to imitate skilled labour. They perform a specific job or task repeatedly. This can be painting, welding, packing, or moving components. They have fixed inputs and outputs, therefore can not easily be changed, or quickly given another task to perform.

4.6.3 | Multi-task robots

2nd Gen Robots are Multi-task or adaptive robots. The inputs and outputs can be varied to allow the robot to perform a range of tasks. A second-generation robot has rudimentary machine intelligence. It is equipped with sensors that provide feedback from the outside world. These could include pressure sensors, proximity sensors, tactile sensors, radar, sonar, lidar, and vision systems.

A controller processes the data from the sensors and adjusts the operation of the robot accordingly. These devices came into common use around 1980. 2nd-Gen can stay synchronised with each other without having to be constantly supervised by a human operator.

Period checks are required for any machines because things can always go wrong. The more complex the system, the more ways things can malfunction. While 2nd Gen robots were a big advancement from 1st Gen, the development of robotics has significantly moved on. Some of this technology of 2nd gen is now used in children’s toys, vacuum cleaners and other everyday objects.

3rd generation robots are autonomous robots, that can work on their own without supervision - they often watch and learn from humans and replicate tasks. The concept of third-generation robots encompasses two major avenues of evolving smart robot technology; the autonomous robot and the autonomous insect. There are situations where autonomous robots do not perform efficiently. In these cases, simple insect robots, under the control of one centralised computer can be employed. These simple robots work collectively and collaboratively like ants or bees. The individual machine will lack artificial intelligence (AI), but the group as a whole will be intelligent.

Multi task robots will, as the name suggest, will have multiple tasks to carry out. While each of these individual tasks may not be complex, it is possible to build up a number of functions to perform an overall complex task. They have flexible inputs and outputs so they can be programmed to react to different stimuli, and respond accordingly.

4.6.4 | Teams of robots

4.6.5 | Machine to machine (M2M)

Machine to machine (M2M) is a broad label that can be used to describe any technology that enables networked devices to exchange information and perform actions without the assistance of humans and is a part of the Internet of Things (IoT).

M2M communication is often used for remote monitoring. For example, a vending machine can message the distributor when a particular item runs low. M2M is an important part of warehouse management, traffic control, logistic services, supply chain management, fleet management, and telemedicine.

Key components of an M2M system include sensors, a networked communications link and computer software programmed to help a networked device interpret data, make decisions and navigate the system.

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