Robotic Manufacturing Cell

The Integration of two robotic entities into a miniature assembly line, in order to make a product involving operations of barcode scanning, part manipulation, fixture design, and supervisory control.

=Problem Definition= In past projects, teams have not been able to integrate the two robots into one process. Our goal this year is to ensure this happens. A new end effector will be necessarily designed in order to assemble the products. The final process, put simply, will be to sort through various male and female pieces using the scanner. Once the two are separated into their respective destinations, the arm will grab the male piece and place it into the construction zone, then grab the female piece and place it on top of the male one. The other robot will then push the pieces together using the constructed end effector. This way, the two robots will be working together in one manufacturing process.

Background
2013-2014 In Spring 2013 The Boeing Company donated DENSO robotic arms to The University of Idaho College of Engineering. That fall Mechanical and Electrical Engineering students, as a part of Team Roboshow, were tasked to learn basic programming of the robotic arms and create a work-cell for the arms. Their work-cell incorporated multiple safety features as well as a clear poly-carbonate enclosure for public demonstration. The team was able to successfully program the robot to use a dry-erase marker to create logos and patterns on a white board.

2014-2015 The following year another design team, known as Team Vandalbot, was formed to design a manufacturing process which could assemble various rivet and nut-plate assemblies in order to automate a repetitive task currently done by factory workers. The team was able to demonstrate this process and provide documentation for future teams.

Summer-Fall 2016 During the Summer and Fall of 2016 Team Vandalbot completely redesigned the robotic manufacturing cell. They made the cell larger which allowed for operators to have easier access to the robots for things like maintenance or changing end effectors. They also made the work cell fully modular allowing future teams to rearrange the cell for their specific needs. New pedestals for the robots were also designed because the originals were very unsteady. The team also performed stress analysis on the new pedestals to ensure they wouldn't break or fall over during operation. The team also programmed the robots to do tasks such as stack cups and write with a marker on a board. Finally the team also created a simple beginners manual that included all the basics needed to run the robot.

Summer-Fall 2017 The next year, the design team for the Robotic Arm Manufacturing Cell, Team CSRM, integrated a simple vision system involving a scanner, so that the arms could sort through two varied parts. These parts, a rectangle and a hexagon, were created by the team members, as well as the fixtures these parts were based in. Their process involved one of the robotic arms picking up pieces from a randomized mixture, then scanning the object to sort between the two. To pick the objects up, the robot used a pneumatic gripping mechanism.

Client Needs
Our client is Ankit Gupta, the professor for the industrial automation class. Working on this project could inspire future assignments for the class, as well as requests for perhaps even more progression for students to learn about these robotic arms. This will enable enhancements to improve the class. As the request for this specific project, we are tasked to integrate the two arms into one manufacturing process. Other requirements involve using the scanner to “see” which part is which: male or female. In order to perform this process, unique end effectors and fixtures will need to be designed, which will be available for future class use as well.

Deliverables

 * Incorporate two robots in one manufacturing process
 * Design and construct male and female parts
 * Design and construct an end effector to assemble the parts
 * Design and construct an incoming queue ramp
 * Design and construct fixtures the assembled part
 * Use the scanner to sort through various pieces

Design Specifications/Constrains

 * Robotic arm should not hold more than 5-7 kg
 * The operating air pressure must be between .1 and .39 MPa, while the max is .49 MPa
 * Due to limitations on the arm with University of Idaho serial number 196-549, the negative X-Axis must not exceed a length of 762 mm
 * End Effectors must be inserted using a round base of 2.25” with 4 screws in a square shape having a 1.266” diagonal
 * In order to be picked up, the parts must have a max width of 2”, with a rectangular ridge of .25”

=Project Learning=
 * 1 step: Load queue (operator loads queue into the ramp)
 * 2 step: Exit Cell (start loop)
 * '''3 step: Start Program
 * 4 step: Scan Part (the first part out of the ramp is scanned with bar code scanner)
 * 5 step: Move 1st part to intermediate storage (R1 will move female to intermediate storage as a base of assembly)
 * 6 step: Move 2nd part to intermediate storage (R1 will move and place a male part right on top of the female )
 * 7 step: Assembly (R2 will push over male part with designed "Finger Push" end effector, and clamp creating assembly
 * 8 step: Sorting Process (if there are two consecutive same type of parts, the second one goes back to ramp)
 * 9 step: Storage Product (final assembly will be placed in a box and good to go)
 * 10 step: Repeat the loop (if scanner has a bar code in front, than loop will be repeated, if there is no bar code read action, theh the hole cell go to initial position after step 7 will be done.

Manufacturing Flow Chart


After operator manually loaded the assembly parts into the ramp and exits the cell, he needs to start the program. The first part is scanned and if computer recognize a female part than Robot Arm nr.1 will pick it and will place into intermediate storage as a base of an assembly, if next part will be female again, than Robot Arm will pick current part and put it back to ramp that way sorting operation will be realized. If Next part will be male than Robot Arm nr.1 will pick it and will move it to the intermediate storage over the female part as a top of an assembly. Robot nr. 2 will push over male part that way clamp connection between two parts will be realized. Robot Nr.1 will pick the whole assembly and deposit into the storage. After The assembly was deposited the next scanned part repeat the loop, if there is no scanned parts than robots arms comes back to their initial position to waiting mode

Parts Design
The manufacturing cell will operate with two unique types of parts: Male and Female. During the process, Female parts will serve as a bottom base of the whole assembly and the Male part will be inserted into the top of the Female part, creating the final assembled product.

The preliminary Prototype of the Male part has: The preliminary Prototype of Female part has:
 * Design Software: 3D SolidWorks
 * 1" height
 * 2" outer diameter
 * 1" inner diameter of rod
 * 0.5" rod height
 * Design Software: 3D SolidWorks
 * 1" height
 * 2" outer diameter
 * 1" inner diameter
 * 0.5" hole height


 * Manufactured: Eiger 3D Printer
 * Material: 100% Onyx with radial infill

Both parts have a channel for the o-ring which serves the function of clamping the two parts together.

SubProblems
=Final Design=

=Validation=

=Team Members=

=Additional Documentation=


 * [[Media:2018 CyberCrew Team Contract.pdf|Team Contract]]
 * [[Media:2018 CyberCrew Interview Questions.pdf|Client Interview Question]]
 * [[Media:2018 CyberCrew Product Requirements.pdf|Product Requirements]]
 * [[Media:2018 CyberCrew Gant Chart.pdf|Project Schedule]]
 * [[Media:2018 CyberCrew Agendas.pdf|Agendas]]
 * [[Media:2018 CyberCrew Minutes.pdf|Meeting Minutes]]

Presentations