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There is evidence that the worldwide demand for industrial robots has yet to reach the numbers predicted by industrial experts and visionaries
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some twenty years ago. The early industrial robots were expensive and temperamental, and they required a lot of maintenance. Moreover, the software was frequently inadequate for the assigned tasks, and many industrial robots were ill-suited to the tasks assigned them. Many early industrial customers in the 1970s and 1980s were disappointed because their expectations had been unrealistic; they had underestimated the costs involved in operator training, the preparation of applications software, and the integration of the industrial robots with other machines and processes in the workplace. By the late 1980s, the decline in orders for industrial robots drove most American companies producing them to go out of business, leaving only a few small, generally unrecognized manufacturers. Such industrial giants as General Motors, Cincinnati Milacron, General Electric, International Business Machines, and Westinghouse entered and left the field. However, the Japanese electrical equipment manufacturer Fanuc Robotics North America and the Swedish-Swiss corporation Asea Brown Boveri (ABB) remain active in the U.S. robotics market today. However, sales are now booming for less expensive industrial robots that are stronger, faster, and smarter than their predecessors. Industrial robots are now spot-welding car bodies, installing windshields, and doing spray painting on automobile assembly lines. They also place and remove parts from annealing furnaces and punch presses, and they assemble and test electrical and mechanical products. Benchtop industrial robots pick and place electronic components on circuit boards in electronics plants, while mobile industrial robots on tracks store and retrieve merchandise in warehouses. The dire predictions that industrial robots would replace workers in record numbers have never been realized. It turns out that the most costeffective industrial robots are those that have replaced human beings in dangerous, monotonous, or strenuous tasks that humans do not want to do. These activities frequently take place in spaces that are poorly ventilated, poorly lighted, or filled with noxious or toxic fumes. They might also take place in areas with high relative humidity or temperatures that are either excessively hot or cold. Such places would include mines, foundries, chemical processing plants, or paint-spray facilities. Management in factories where industrial robots were purchased and installed for the first time gave many reasons why they did this despite the disappointments of the past twenty years. The most frequent reasons were the decreasing cost of powerful computers as well as the simplification of both the controls and methods for programming the computers. This has been due, in large measure, to the declining costs of more pow-
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erful microprocessors, solid-state and disk memory, and applications software. However, overall system costs have not declined, and there have been no significant changes in the mechanical design of industrial robots during the industrial robot s twenty-year learning curve and maturation period. The shakeout of American industrial robot manufacturers has led to the near domination of the world market for industrial robots by the Japanese manufacturers who have been in the market for most of the past twenty years. However, this has led to de facto standardization in industrial robot geometry and philosophy along the lines established by the Japanese manufacturers. Nevertheless, industrial robots are still available in the same configurations that were available fifteen to twenty years ago, and there have been few changes in the design of the end-use tools that mount on the industrial robot s hand for the performance of specific tasks (e.g., parts handling, welding, painting).
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Load-handling capability is one of the most important factors in an industrial robot purchasing decision. Some can now handle payloads of as much as 200 pounds. However, most applications do not require the handling of parts that are as heavy as 200 pounds. High on the list of other requirements are stiffness the ability of the industrial robot to perform the task without flexing or shifting; accuracy the ability to perform repetitive tasks without deviating from the programmed dimensional tolerances; and high rates of acceleration and deceleration. The size of the manipulator or arm influences accessibility to the assigned floor space. Movement is a key consideration in choosing an industrial robot. The industrial robot must be able to reach all the parts or tools needed for its application. Thus the industrial robot s working range or envelope is a critical factor in determining industrial robot size. Most versatile industrial robots are capable of moving in at least five degrees of freedom, which means they have five axes. Although most tasks suitable for industrial robots today can be performed by industrial robots with at least five axes, industrial robots with six axes (or degrees of freedom) are quite common. Rotary base movement and both radial and vertical arm movement are universal. Rotary wrist movement and wrist bend are also widely available. These movements have been designated as roll and pitch by some industrial robot manufacturers. Wrist yaw is another available degree of freedom.
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