Synthesized robotic manufacturing cell

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Welcome to Robo-shop

[[File:
P 20190703 130955 vHDR Auto.jpg
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Current State of Cell
Sponsors
  • BOEING
Team Name RoboShop
Duration Summer-Fall 2019
Lead Instructor
  • Dr. Steven Beyerlein
Faculty Adviser
  • Dr. Matthew Swenson
Mentor
  • Mentor Names
Client
  • Ankit Gupta
Team Members
  • Salem Alhajri
  • Brad Hummel
  • Joshua Kohl
  • Mohamed Alessa

The goal of the project is to incorporate two robots in one miniature assembly line, in order to make a product involving operations that include part manipulation, barcode scanning, and fastening a screw.


Problem Definition[edit]

Background[edit]

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.

Summer-Fall 2016 During the Summer and Fall of 2016 Do All Robotics 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.

Summer 2018-Fall 2018 The group that worked on this period were made of four Mechanical Engineering, and the name of the group is CyberCrew. There goals for there project is to integrate the two robots to work together in one assembly line, and create an assembly line that combine two female and male parts together. they made the two robotic arms work together in one assembly line, their assembly line were to make the first arm grab the part, and then scan that part. after the scanning, the arm will put female part first in a specific area, and then the same arm grabs the male part and put it above the female part. the Second arm will use pressure power to combine the two parts together.

Picture Description
Cell.jpg
Current State of the cell.
Robots equipped with past groups end effectors for their task.

Client Needs[edit]

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 a scanner to determine the shape of the object being scanned. In order to perform the required manufacturing process, unique end effectors and fixtures will be designed, which will be available for future students.

Deliverables[edit]

  • Incorporate two robots in one manufacturing process
  • Design and construct different shaped parts
  • Design and construct an end effector to grab and move all the different shaped parts
  • Design and construct an end effector to hold a torque screwdriver
  • Use torque screwdriver to fasten a screw into all parts
  • Use a scanner to sort different shaped parts
Flow Chart
Code FlowChart.png
  • User does set-up tasks
  • Robot #1 will pick-up an object
  • Robot #1 will scan picked object
  • Robot #1 will place object in its specific spot in the template
  • Robot #2 will pick-up screw from yet to be designed place with magnetic tipped drill bit on torque screwdriver
  • Robot #2 use torque screwdriver to fasten screw into object
  • Robot #1 will pick-up object
  • Robot #1 will place object onto conveyor belt
  • Repeat for next 2 objects

Specifications[edit]

User Interface Requirements: The assembly must be self-functioning, or automated. The only user involvement shall be to start the process. In case of malfunction, emergency stop switches are in place: one on each controller and one on the outside of the cell.


What it should do: This is an automated assembly line, where the two robotic arms communicate with each other via TCP/IP protocols to complete a task. The first robot utilizes a gripper to grab objects and scans them over the bar code to identify their shapes. Once identified, the objects will be placed in their specific location, the same robot will also grab screws and place them on the objects. The other robot will utilize a screwdriver to fasten the screws.

for further specifications, see Product Requirements: [[ http://images.shoutwiki.com/mindworks/2/29/RoboShop_Product_Requirements.pdf]]

Device Specification Variable limit
Robot arm #1 Fixture Mass 5 kg
Robot arm #1 Gripper Pressure .39 MPa
Robot arm #2 Fixture Mass 5 kg
Robot arm #2 Screwdriver Pressure Applied 2.5 kg

Design Elements[edit]

FIXTURES:

Picture Discription
SquareTemplate.jpg

SqrTemp4.0.png
The template is 2" x 2" and 1/2" thick.
The extruded part is 2" tall and a 1/4" x 1/4" square.
There is a 1/4" x 1/4" x 1/4" square cut out of the bottom to place on a peg so we can guarantee screw hole locations.
AlSqrMockPart.jpg
We changed to using Aluminum parts instead of plastic. We were having an issue with the parts being picked up after the screw was inserted. Using Aluminum significantly increased the weight of the part and has helped eliminate the part being lifted. Also, Using a metal part has allowed us to tap the part and eliminate the need of metal inserts.
CircleTemplate.jpg

CirTemp4.0.png
The Circle is a 3" Diameter with the extruded part being 2" tall and a 1/4" x 1/4" square.
There is a 1/4" x 1/4" x 1/4" square cut out of the bottom to place on a peg so we can guarantee screw hole locations.
OctagonTemplate.jpg


OctTemp4.0.png
The octagon has a side length of 1 1/4".
The extruded part is 2" tall and a 1/4" x 1/4" square.
There is a 1/4" x 1/4" x 1/4" square cut out of the bottom to place on a peg so we can guarantee screw hole locations.
SlideJigTop.jpg

SlideJigSide.jpg
This is our slide jig to hold the screws for robot #2 to come pick screws up out of.
SpringJig.jpg
This is a Spring loaded screw holder. The user will pull back on the handle and load the screws, the spring will then push the screws in place for robot #2 to come with the screwdriver and pick up the screws.

END EFFECTORS:

Picture Description
GripperLipsWhite.jpg
End effector for robot#1. These grippers are air pressurized so they can open and close.
They are used for the handling of mock parts.
Robot2Endeffector.jpg
This is the end effector for Robot #2. This end effector is used to hold the torque screwdriver.
It has two thumb screws on opposite sides to hold the screwdriver in place.
Clamp end effector.jpg
Updated end effector for for Robot #2. We changed to a clamping end effector because the thumb screws were tearing the rubber on the torque screwdriver and therefore moving the screwdrivers location. Using a clamp fixes this problem.

TOOLING:

Picture Description
41kgbmqawNL. SL500 AC SS350 .jpg
Bosch Electric Screwdriver, Autoday 3.6V Smart 6 Modes Adjustable Torques
Cordless Rechargeable Screwdriver Tool Kits
(picture from amazon)
   Screwdriver was going to ship 3-4 weeks late so we canceled the order and are going with the Dremel. 
DremelScrewdriver.jpg
GO 4-Volt Max Lithium-Ion Cordless Screwdriver
with USB Charger and Insert Bits

TEMPLATE:

Picture Description
Template.jpg
Current template design to hold 3 different shaped objects.
Template used so objects are in specific orientation for robot #2 screwdriver.
The cut outs are 1/8" of an inch bigger than the actual objects to allow for easier drop locations.

FASTENER/ACCESSORIES:

Picture Description
Screw.jpg
The screw we have chosen to use is a M6 x 1 with a threaded length of 1/2".
It is a Socket head cap screw (SHCS).
We chose a SHCS so that there were more orientations the screw could be in to be picked up.
BrassInsert.jpg
Brass Screw-to-Expand insert for plastic, M6x1 Thread, 12.7 mm installed length. Metal inserts will be used to make the plastic parts last longer.
AlInsert.jpg
Aluminum Screw-to-Expand insert for plastic, M6x1 Thread, 12.7 mm installed length. Metal inserts will be used to make the plastic parts last longer.

Validation[edit]

Requirement Test Test Subject Target Date Result Recommendation
Torque We will need test/calculate of much torque we will need to fasten the screw into the objects. Torque Screwdriver/Mock Part 7/24/19 -Screwdriver needs to be set at about 1.5 No further action necessary
Torque screwdriver Pressure We will need to test how much pressure is needed to apply to the screwdriver in order to achieve the calculated torque. Torque Screwdriver 7/12/19 took 2.5 kg of pressure to activate the screwdriver No further action necessary
Robot Arm #2 We will need to calculate the total weight we are putting on the end of Robot Arm #2 in order to ensure that the 5 Kg weight limit is being met. All objects 8/30/19
Robot # 1 must be able to grab templates and move them to scanner Set up templates and command the robot to move them Robot #1 7/15/19 Able to pick up and move mock part to scanner Move along and get three starting points.
Robot #2 must be able to move screws without them falling out Place the screws into the drill bit and manually move robot #2 around with various speeds Robot #2 7/15/19 -Screws did not stay in drill bit
-Able to move screws around
-Add magnets to hold screw in place
-No further work needed
Robot #1 must be able to move templates from scanner to jigs Code route from scanner to jigs. Robot #1 7/17/19 Able to move mock parts to jigs No further action necessary
Robot #1 must be able to place mock parts in their specific location in the jig Code positions and see if they work Robot #1 7/17/19 - Going in at an angle and drop is not consistent
-Dropping in perfectly
-Can move tool with a different axis
-Square dropping in perfect. Start on other parts.
Robot #1 must pick up templates from jig and move to conveyor belt Robot#1 must be able to grip templates and move accurately Robot #1 7/18/19
Scanner must be able to read bar-code on each template Tape bar-code onto bottom of templates and see if scanner can identify them Scanner 7/18/19 - Scanner not working
-Scanner working
-Ask Ankit
-No further work needed
Robot #2 be able to screw in fasteners into templates Set up templates in jigs. Install fasteners into screw-gun and move into holes. Apply pressure until screws in Robot #2 7/22/19 -Does not screw in all the way
-Screws in desirable distance
-Adjust end position height
-Get more screw hole locations
Robot#2 must be able to collect screws from holder Move robot#2 to collect screws Robot #2 7/25/19

TESTING: File:Robot2ScrewinginTest.pdf

Robot -2.gif
Robot-1 .gif

Final Design[edit]

Team Members[edit]

Picture Info
JoshKohlpic.jpg

Name:Josh Kohl
Major:Mechanical Engineer
Hometown:Carreywood, Idaho
Responsibility:Team Member
Email:Kohl1461@vandals.uidaho.edu

MX Pic.jpg

Name:Brad Hummel
Major:Mechanical Engineer
Hometown:Pasco, Washington
Responsibility:Team Member
Email:humm7394@vandals.uidaho.edu

41cb2377-b7cf-4cfd-b6a4-3d063be1e218.jpg

Name:Salem Alhajri
Major:Mechanical Engineer
Hometown: Kuwait
Responsibility:Team Member
Email:alha3966@vandals.uidaho.edu

20190703 131036.jpg
Name:Mohammed Alessa

Major:Mechanical Engineer
Hometown: Dammam, Saudi Arabia
Responsibility:Team Member
Email:ales9576@vandals.uidaho.edu

Additional Documentation[edit]

Project Schedule
Gantt Chart: File:GanttRoboshop.pdf
Product Requirements: images.shoutwiki.com/mindworks/5/54/Product_Requirements_RoboShop.pdf

Meeting Minutes

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Presentations

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Client Interview

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Resources[edit]

https://www.denso-wave.com/en/robot/product/five-six/vs.html