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In order to pick up an object, a robot must be able to sense the strength of the object being gripped so as not to crush the object. Accordingly, the robot gripper is equipped with sensing devices to regulate the amount of pressure applied to the object being retrieved. Several industrial sensing devices enable the robot to place objects at desired locations or perform various manufacturing processes: Transducers. Sensors that convert nonelectrical signals into electrical energy Contact sensors (limit switches). Switches designed to be turned ON or OFF by an object exerting pressure on a lever or roller that operates the switch Noncontact sensors. Devices that sense through changes in pressure, temperature, or electromagnetic field
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Proximity sensors. Devices that sense the presence of a nearby object by inductance, capacitance, light reflection, or eddy currents Range sensors. Devices such as laser-interferometric gauges that provide a precise distance measurement Tactile sensors. Devices that rely on touch to detect the presence of an object; strain gauges can be used as tactile sensors Displacement sensors. Provide the exact location of a gripper or manipulator. Resistive sensors are often used usually wire-wound resistors with a slider contact; as force is applied to the slider arm, it changes the circuit resistance Speed sensors: devices such as tachometers that detect the motor shaft speed Torque sensors. Measure the turning effort required to rotate a mass through an angle Vision sensors. Enable a robot to see an object and generate adjustments suitable for object manipulation; include dissectors, flying-spot scanners, vidicons, orthicons, plumbicons, and charge-coupled devices
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Multisensor-Controlled Robot Assembly
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Most assembly tasks are based on experience and are achieved manually. Only when high volume permits are special-purpose machines used. Products manufactured in low-volume batches or with a short design life can be assembled profitably only by general-purpose flexible assembly systems that are adaptable and programmable. A computer-controlled multisensor assembly station responds to these demands for general-purpose assembly. The multisensor feedback provides the information by which a robot arm can adapt easily to different parts and accommodate relative position errors. The assembly task may be viewed as an intended sequence of elementary operations able to accept an originally disordered and disorganized set of parts and to increase gradually their order and mating degrees to arrive finally at the organization level required by the definition of the assembly. In these terms, it may be considered that assembly tasks perform two main functions: (1) ordering of parts and (2) mating of parts in the final assembly. The ordering function reduces uncertainty regarding assembly parts by supplying information about their parameters, type, and position/orientation. The performance criterion of this function may be expressed as an entropy. The final goal of ordering is to minimize the relative entropy sum of the components of the assembly. In an assembly station, the ordering is performed either in a passive way
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by sensors or in an active way by mechanical means such as containerization, feeding, fixturing, or gripping. The part mating function imposes successive modifications of the positions of the parts in such a way as to mate them finally in the required assembly pattern. The modification of the position of the parts is carried out by manipulating them by transport systems and robot arms. The part mating function requires a priori information about the parts to be manipulated and the present state of the assembly. During this manipulation, the part entropy may increase because of errors in the robot position or by accidental changes in the manipulated parts. An example of a multisensor system is a test bed for research on sensor control of robotic assembly and inspection, particularly comparisons of passive entropy reduction to active mechanical means. Programs for the system must be easy to develop and must perform in real time. Commercially available systems and sensors had to be used as much as possible. The system had to be very flexible in interfacing with different subsystems and their protocols. The flexible assembly system (Fig. 8.32) consists of three main parts: Robot equipped with a transport system Vision sensors, force-torque sensors, and ultrasound sensors Control system The system was built with a variable transport system (VTS) (Fig. 8.33). It is a modular system in which product carriers are transported to the system. Two docking stations that can clamp the product carriers are included in the system. Some of the product carriers have translucent windows to allow backlighting of the vision system. The VTS system has its own controller operated by parallel input/output lines. The robot is equipped with six degrees of freedom and a payload capacity of 4 kg. The absolute accuracy is 0.2 mm. The robot controller consists of two 68000 microprocessors. The standard way of programming the robot is through a teach pendant. Three different interfaces can connect the robot and control system: (1) computer link at 9600 baud (RS-232), (2) adaptive control, and (3) parallel interrupt lines. The computer link lets the control computer give commands to the robot such as: Load programs from disk Start programs Set position registers Read out robot positions Take direct control of robot movement Up- and download robot programs
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