Where is the Russian market of industrial robotics heading? Industrial robots in modern production.

Today, industrial robots have become widespread in human production activities. They serve as one of the most effective means of mechanization and automation of transport and loading operations, as well as many technological processes.

The positive effect of the introduction of industrial robots is usually noticeable simultaneously from several sides: labor productivity increases, the quality of the final product improves, production costs decrease, working conditions for a person improve, and finally, the transition of an enterprise from the production of one type of product to another is greatly facilitated.

However, in order to achieve such an extensive and multifaceted positive effect from the introduction of industrial robots on already operating manual production, it is necessary to first calculate the planned costs for the implementation process itself, for the cost of the robot, and also weigh whether the complexity of your production and technological process is adequate at all - the modernization plan with assistance in the installation of industrial robots.

After all, sometimes production is so simplified initially that the installation of robots is simply impractical and even harmful. In addition, for adjustment, maintenance, programming of robots, qualified personnel will be required, and in the process of work, auxiliary devices, etc., it is important to take this into account in advance.

One way or another, robotic unmanned solutions in production are becoming increasingly important today, if only because the harmful effect on human health is minimized. Let's add here the understanding that the full cycle of processing and installation is carried out faster, without breaks for a smoke break and without errors inherent in any production where a living person acts instead of a robot. The human factor, after setting up the robots and starting the technological process, is practically eliminated.

To date, manual labor in most cases is replaced by the labor of a robotic manipulator: tool gripping, tool fixing, holding the workpiece, feeding it into working area. Restrictions are imposed only by: load capacity, limited working area, pre-programmed movements.

An industrial robot can, however, provide:

high productivity due to fast and accurate positioning; better economy, since you do not need to pay a salary to the people he replaces, one operator is enough;

high quality - accuracy of the order of 0.05 mm, low probability of marriage;

safety for human health, for example, due to the fact that when painting, contact of people with paintwork materials is now excluded;

finally, the working area of ​​the robot is strictly limited, and its maintenance is minimal, even if the working environment is chemically aggressive, the material of the robot will withstand this impact.

Historically, the first industrial robot made under a patent was produced in 1961 by Unimation Inc for a General Motors plant in New Jersey. The sequence of robot actions was recorded as a code on a magnetic drum and performed in generalized coordinates. To carry out the actions, the robot used hydraulic boosters. This technology was then transferred to the Japanese Kawasaki Heavy Industries and the English Guest, Keen and Nettlefolds. So the production of robots from Unimation Inc has expanded somewhat.

By 1970, Stanford University had developed the first robot, resembling the capabilities of a human hand with 6 degrees of freedom, which was controlled from a computer and had electric drives. At the same time, the Japanese Nachi is developing. The German KUKA Robotics will demonstrate the Famulus six-axis robot in 1973, and the Swiss ABB Robotics will already begin selling the ASEA robot, also a six-axis and electromechanically driven.

In 1974 the Japanese company Fanuc establishes own production. In 1977, the first Yaskawa robot is produced. With development computer technology robots are increasingly being introduced into the automotive industry: in the early 80s, General Motors invested forty billion dollars in the formation of its own factory automation system.

In 1984, the domestic Avtovaz will acquire a license from KUKA Robotics and begin to produce robots for its own production lines. Almost 70% of all robots in the world, as of 1995, will be in Japan, in its domestic market. So industrial robots will finally gain a foothold in the automotive industry.

How will automotive production do without welding? No way. So it turns out that everything automotive production world are equipped with hundreds of robotic welding systems. Every fifth industrial robot is engaged in welding. Next in demand is a robot loader, but argon-arc and spot welding are in first place.

No manual welding can match the quality of the seam and the degree of control over the process with a specialized robot. What can we say about laser welding, where from a distance of up to 2 meters a focused laser process is carried out with an accuracy of 0.2 mm - this is simply irreplaceable in aircraft engineering and medicine. Add here integration with CAD / CAM digital systems.

The welding robot has three main operating units: a working body, a computer that controls the working body and memory. The working body is equipped with a grip similar to a hand. The organ has freedom of movement along three axes (X, Y, Z), and the grip itself is able to rotate around these axes. The robot itself can move along the guides.

Not a single modern production can do without unloading and loading, regardless of the dimensions and weight of the products. The robot will independently install the workpiece into the machine, and then unload and stack it. One robot is able to interact with several machines at once. Of course, it is impossible not to mention in this context the loading of luggage at the airport.

Robots are already making it possible to minimize staff costs. It's not just about those simple functions like working with a die or operating a furnace. Robots are able to lift more weight, in much more difficult conditions, while not getting tired and spending significantly less time than a living person would need.

In foundries and forges, for example, conditions are traditionally very difficult for people. This type of production is in third place after unloading and loading in terms of robotization. It is not for nothing that almost all European foundries are now equipped with automated systems with industrial robots. The cost of implementing a robot costs an enterprise hundreds of thousands of dollars, but a very flexible complex that pays off with interest appears at its disposal.

Robotic laser and allow you to improve the traditional lines with plasma torches. Three-dimensional cutting and cutting of angles and I-beams, preparation for further processing, welding, drilling. In the automotive industry, this technology is simply indispensable, because the edges of the products must be accurately and quickly trimmed after stamping and molding.

One such robot can combine both welding and cutting. Productivity is increased by the introduction of waterjet cutting, which eliminates unnecessary thermal effects on the material. Thus, in two and a half minutes, all the small holes are cut in the metal of the Renault Espace bodies at the Renault robotic plant in France.

In the production of furniture, automobiles and other products, robotic pipe bending with the participation of a working head is useful, when the pipe is positioned by the robot and bent very quickly. Such a pipe may already be equipped various elements, which will not interfere with the process of mandrelless bending by the robot.

Finishing edges, drilling holes, as well as milling - what could be easier for a robot, whether it's metal, wood or plastic. Precise and durable manipulators cope with these tasks with a bang. The working area is not limited, it is enough to install an extended axle, or several steered axles, which will give excellent flexibility plus high speed. Man cannot do that.

The rotational speeds of the milling tool here reach tens of thousands of revolutions per minute, and the grinding of seams turns into a series of simple repeatable movements. But before, grinding and abrasive surface treatment were considered something dirty and heavy, and also very harmful. Paste is now fed automatically during felting after the abrasive belt has passed. Fast and harmless to the operator.

The prospects for industrial robotics are enormous, because robots can in principle be introduced into almost any production process, and in unlimited quantities. The quality of automatic work is sometimes so high that it is simply unattainable for human hands. There are entire large industries where mistakes and errors are unacceptable: aircraft manufacturing, precision medical equipment, ultra-precise weapons, etc. Not to mention the increase in the competitiveness of individual enterprises and the positive effect on their economy.

The Russian market of robotic technologies is still very young and is at the initial stage of development. In the next ten years, the demand for industrial robots will depend entirely on the interest shown in them by business owners. Only then will the robotization of our industry become the same irreversible process as the modernization of domestic enterprises is already irreversible today. The benefits of the transition to robotic technologies will inevitably bring many of our enterprises to a new technological level, improve the quality of their products, productivity and flexibility of production processes.

In everyday life, the word "robot" is often interpreted ambiguously. If you do not touch on the area of ​​science fiction, then “robots” are usually called machines that partially or completely replace a person in various fields its activities, mainly related to the production of industrial products.
Speaking about the classification of industrial robots, we note that they differ most significantly from each other:

• by areas of application: there are industrial robots, robots for special applications, etc.;
• by location in space: these are stationary, with a linear axis, portal;
• according to the principles of control: robots with software or with remote control.

Although under the general term "robot" a lot of different machines are combined, often having nothing in common with each other, at present, according to the criterion of the main directions of technological development, it has been combined into one subject area - robotics.

Industrial robotics includes auxiliary and technological robots. Auxiliary robots are used as additional technological equipment - these are, for example, loading robots servicing metal-cutting machines, presses, etc. Technological robots are used in production as the main technological equipment for spot and contour (laser, plasma) welding, waterjet cutting, dimensionless abrasive processing (polishing, cleaning), for product assembly, etc.
Industrial robots and robots for special applications are fundamentally different types of machines that differ significantly from each other in terms of application, design, and control methods.
Structurally, industrial robots are performed as machines based on a stationary arm, as a rule, with six degrees of mobility (hinges), similar in kinematic structure to a human arm. The main requirement for the design of industrial robots is reliability under conditions of many years of operation in repetitive operations, as well as positioning accuracy, load capacity, and speed of programmatically specified movements.

Robotics for special (non-production) applications is represented by machines for performing work in places where the presence of a person is difficult or completely excluded. First of all, these are remote-controlled mobile robots based on autonomous vehicles, controlled by an operator via wired or radio communication, from a safe place. Such robots are used, in particular, to neutralize dangerous objects (for example, mines - see the figure), to perform work in an airless space, under water, when clearing rubble, etc.

Some technological operations, for example, dimensionless finishing of complex-profile parts, can be implemented both using technological robots and using machine tools of the “machining center” type. In the general case, the task of both the machine tool and the robot is to implement the relative motion of the tool and the workpiece according to a given law with a given accuracy. The law of relative motion is described in the technological program. However, two classification features can be noted that distinguish technological robots in a special group of machines. The first is the ratio of the working area (the area in which the tool moves) to the dimensions of the machine. The working area of ​​the machine is usually significantly smaller than the machine itself and is located inside it, while the working area of ​​the robot is larger than the robot and surrounds it. Thus, the robot is inside its working area. The second difference is in the programming method. The law of tool movement is programmed in CNC machines in an absolute coordinate system. In robots, the base points of the trajectory are programmed by the method of learning with respect to a special calibrating tool.

Majority modern technologies processing of products, such as spot contact, seam arc welding, laser welding; laser, microplasma and waterjet cutting; assembly and finishing abrasive processing of spatially complex products require the movement of the tool along complex trajectories with high accuracy and a fixed speed. Previously, these operations were performed manually, but the tool used was often too heavy for a person. In addition, it is not always possible to provide the required quality of tool movement along the path, for example, accuracy and speed constancy. It is in such operations that technological robots are mainly used today.
Due to the relatively small volumes of the global market for industrial robots (when compared, for example, with the production of metal-cutting machine tools) and the difficulty of entering this market, a rather narrow circle of companies has developed that have the competencies and resources necessary for the production of industrial robots. These are, for example, Japanese Fanuc, Motoman, Kawasaki, Yaskawa, Swedish ABB, German KUKA Roboter GMBH, Reis, Italian COMAU, etc. All these companies produce robots of their own design and have original system software and mathematical software for their robot control systems. Complex technical means, included in the arsenal of robot manufacturers, also includes such components, the maximum efficiency of which is achieved only in the aggregate of a number of systems:

• model range of universal manipulators;
• contour control system;
• sensor systems for robot adaptation;
• mounted peripheral and technological equipment;
• manipulator calibration system;
• systems for technological preparation of production, design of devices and autonomous programming of the robot.

Against the background of the analysis of global trends in the development of robotic devices, it can be concluded that automation is the dominant means in achieving success in the context of the globalization of international economic relations, although not the only way to win the competition. Of course, considerable opportunities are hidden both in the stimulating role of personnel wages and in attracting workers to manage production and improve product quality. Suffice it to recall the Japanese "quality circles" that have spread throughout the world. The focus of their activities now affects not only quality issues, but also reducing the cost of products, ensuring safety and other important aspects. Automation creates fundamental opportunities for improving production conditions and increasing labor productivity, increasing product quality, reducing the need for labor and systematically increasing profits, which makes it possible to change the development trend, maintain developed markets and conquer new ones.
However, there are a number of factors that stand in the way of automation that must be considered. First of all, it should be understood that dealing with automation problems must begin with a preliminary study of products, technology and the enterprise as a whole. Only a thorough preparation of the product design, an assessment of the stability of the technology and the reliability of the equipment available in production will make it possible to derive the greatest benefit from the use of industrial robots.

A striking example of how robotic production lines form the basis of production is today's automotive industry. In this regard, all industrialized countries that produce cars also have firms involved in the development and production of robots. This allows them to stay ahead of competitors when introducing new technologies into automotive production.
Western robot manufacturing firms often use their right to regulate the development of robotic technologies through pricing policy and directive actions in their own interests and in the interests of the most promising customers, up to selective blocking of the development of some of them. It is no secret that they work closely with a number of leading foreign automotive concerns and are associated with them by numerous agreements on the non-distribution of know-how.
Mostly, the development of technological robots in the global industry occurred during the period of decline in the domestic industry, as a result of which the scope of robots in Russia was limited to a few enterprises. And today, the pace of introduction of robotization into the production capacities of domestic enterprises lags far behind foreign ones. In most cases, our enterprises, proceeding mainly from economic considerations, are limited to the mechanization of manual labor. Of course, with this approach, they are unable to seriously compete with high-tech industries, and even more so to compete with them in a dynamically developing market.

If earlier automation consisted in the replacement of physical labor through the mechanization of the main and auxiliary operations of the production process, today the deep automation of industry consists in the development of machine production, in which the functions of control and control, previously performed by a person, are transferred to instruments and automatic devices. Therefore, the well-established idea in our country of industrial robots solely as auxiliary loading and unloading devices serving machine tools or presses does not at all correspond to the current level of development of industrial robotics and the practice of using robots in production.
And yet today, many leading Russian manufacturing enterprises, whose leaders got acquainted with the capabilities of robots at foreign exhibitions and enterprises, are increasingly beginning to think about their application at home. But, in order to successfully introduce robotics into the Russian industry, it is not enough just to find suitable equipment suppliers. Contrary to our common opinion that any technology (including robotic) and any equipment can be freely bought and used today, this is not true for at least two reasons:

• leading concerns pay great attention to the development of key technologies, maintaining control over their distribution and preventing their flow to competitors;
• in technologically developed countries, there are overt and covert restrictions on the supply of unique advanced technologies to Russia, which are exacerbated by the still fairly widespread wary attitude of foreign developers and suppliers towards Russian enterprises.

Other unfavorable factors that objectively constrain the use of industrial robots in Russia are internal problems:

• Russian enterprises lack not only their own experience in the use of robots, but even a general idea of ​​technical and economic fundamentals robotic technologies;
• lack of qualified personnel capable of ensuring the operation of robots;
• the extreme insufficiency of specialists capable of designing robotic cells and lines, introducing robots and carrying out technological preparation for robotic production.

From the solution of these key issues and the introduction and development of robotics in production should begin.
Cadres, as you know, decide if not everything, then a lot. What are the qualification requirements for the personnel of an enterprise managing a robotic technological complex? It must be understood that industrial robots are not space technologies, the knowledge of which will require decades of hard work. Modern industrial robots are convenient and easy to use. A standard training course for working with them takes about three days and allows you to gain enough knowledge to independently control a robot or a section of machines with a robot loader, and operational experience in the future will allow you to fully master all the possibilities and features of robotic technologies.
Thus, without much exaggeration, it can be argued that almost any technically competent specialist will be able to control robots, even without higher education, and it does not require people with unique knowledge and experience. As a rule, one person is enough to service the robotic complex. His work is reduced to the "installation / removal" of the workpieces and pressing the "Start" button to start the system.
If we talk about people who create work programs for robots, train them, and provide elementary services, then such specialists must undergo special training without fail. It is necessary to select people for such training with higher technical education, preferably in conjunction with programming skills.
An example of a non-standard approach to solving problems of production automation is the introduction of a production site with several industrial robots, unique for our country, which is now being carried out at the Perm enterprise of OJSC Aviadvigatel by specialists from the Solver company. The main task of the ongoing project is to organize the production of samples at the newly created site for the study of the strength properties of materials. The goal is to create and develop a stable technology for their production. The level of robotization of the site should ensure the release of samples in the amount of 600 pieces per month.

Solver specialists, together with the factory workers, developed an electronic model of future production, outlined the range of tasks solved by the robotic complex, assessed its performance, efficiency and payback. As a result, the customer received a virtual picture of the future production, which at this stage is successfully translated into reality. The requirements for equipment, personnel, organization of technological preparation for production and production itself were more clearly understood, realized and subsequently adjusted. Thus, when tied to a specific result, a course was taken to build an effective production and its subsequent support.
When developing the concept of the complex, its basis was the methodology of "three projects", developed and successfully applied by the specialists of the "Solver" company. Four industrial robots as part of a robotic complex have been introduced into the production facility created from scratch.
Here are the most important benefits that have already been partially achieved by our specialists at this stage of the project at Aviadvigatel:

• reducing the labor intensity of production;
• increase its throughput;
• significant improvement in the quality of sample products;
• reducing the need for production space;
• reduction of qualification requirements for operators, who are mainly engaged in the maintenance of robotic technologies;
• flexibility in reconfiguring the system. Robotic complex can cut parts various forms and sizes, the operator only needs to modify the library of control programs;
• technological flexibility. One robot can cut samples, another robot can position workpieces, and a third robot can move them to different parts of the shop. And the time to re-equip them can be minimized by using additional equipment for tool change;
• reduction of harmful effects on people.

It should be noted that robot manufacturers are not engaged in the creation of technologies for the end customer, these tasks are performed only by qualified system integrators who have partnerships or dealerships with equipment manufacturers. And, of course, projects of this magnitude cannot be implemented without the close work of the plant's staff and the specialists of the consulting company, who are able to work together to develop non-trivial solutions.

SUMMARY

1. Improving the quality of products simultaneously with a decrease in serial production and frequent changes in manufactured product models is a trend in the modern market. The fulfillment of these conditions is impossible without the development of automation of technological production processes. In a number of key technologies, for example, in welding, laser processing, thermal cutting, painting, further development is possible only with the use of technological robots.
2. An alternative to technological dependence on foreign know-how holders could be the development of first experimental and then serial samples of domestic universal technological robots, including their own control system. As the experience of introducing and operating industrial robots has shown, the assimilation of advanced robotic technologies is impossible, first of all, without know-how on the software of the robots themselves.
3. The most high-tech tasks that arise in the preparation for the production of new parts special purpose, it is not possible to decide precisely because of the lack of such know-how. For example, coordinated automatic operation of several robots from different manufacturers cannot be carried out on the basis of a standard controller. The reason is the lack of access to sensor options and some interfaces in the robot control system, which are not manufactured, but bought in ready-made, as a "closed system". The prices for the required special control system software installed by firms are very high.
4. To create an alternative to such technologies, it is necessary to constantly work on the creation and development of our own control system for technological robots. The control system is the most science-intensive part of any robotic technological cell or line. Without a control system, the production of its own technological robots and the development of its own robotic technologies are impossible; without the development of its own know-how in the field of key technologies, in particular robotic ones, Russia will remain in the role of catching up with respect to foreign competitors.
5. Ideas about robotics and the role of industrial robots in modern domestic production have not yet been fully formed. The need for the development of industrial robotics as a means of ensuring the competitiveness of many types of machine-building production is not sufficiently recognized by the state authorities responsible for industrial policy.
6. Russia will inevitably enter a qualitative period of its development, when the demand for robotic technologies will be no less than in developed countries, and the number of qualified companies involved in the design and manufacture of robotic systems will grow significantly.
8. Realities today are such that if we do not reduce the software and design and technological gap in the introduction of robotic complexes into production processes in the next 10-15 years, then we will lag behind the leaders of the world industry forever.

The RBR50 list is familiar to many who specialize in the field of robotics - these are 50 companies selected by the editors of roboticsbusinessreview.com. The selection principle is as follows - the list includes companies that have had the most significant impact in the field of robotics in 2015. I am sure you are familiar with most of these companies. And if not all, then it is worth paying attention not to those that are not yet familiar - they are moving forward the development of robotics on the planet. I note that, unfortunately, there are still no Russian companies among them.

Other countries are represented in the following proportions: Germany - 1 (2%), Denmark - 1 (2%), India - 1 (2%), Canada - 3 (6%), China - 2 (4%), United Kingdom - 2 (4%), USA - 32 (64%), Taiwan - 1 (2%), Switzerland - 2 (4%), South Korea- 1 (2%), Japan - 4 (8%).

It remains to be seen when Russia will finally stop doing what it is doing now, concentrate its efforts in the development of modern technologies, and try to become a full-fledged participant in the international technological competition again. Unless, of course, it's too late by then.

, USA

Private company focusing on robotics. USA, Berkeley, CA. 3drobotics.com Develops innovative, flexible and reliable personal drones and UAV technologies for private and business use. The Solo platform is designed for aerial photography with subsequent data analysis for mapping and research, 3D modeling and so on. Market segments: agriculture, construction, security, research.

, Switzerland

A public company specializing in the field of industrial robots and manipulators. Headquarters in Zurich, Switzerland. Leading manufacturer of industrial robots, modular manufacturing systems and services. The company pays special attention to the performance of solutions, the quality of products and the safety of workers. ABB is expanding its activities into new markets and is also actively working in the field of traditional production to increase its flexibility and competitiveness. Market segments: energy, industrial automation, supply chains and retail, industry, manipulators. new.abb.com/products/robotics

, USA

One of the leaders in the supply of mobile robots for couriers. The robot automates internal logistics tasks by autonomously navigating in a dynamic and complex work environment, such as delivering medicines and supplies to hospitals and clinics.

, USA

A public company with a focus on medical robotics, assistive robotics, androids, industrial robots, manipulators, mobile robotics. The headquarters is in the USA.
The basis of the robotics directions of the company were the companies acquired in 2013: Boston Dynamics, Bot & Dolly, Holomni, Industrial Perception, Meka Robotics, Redwood Robotics, Schaft, Inc.

, USA

The company is an online retailer. The company serves customers in the US and around the world. To do this, Amazon uses robotics in its supply chains, in particular, KIVA robots in the company's warehouses.

, USA

ASI, Autonomous Solutions, Inc. develops hardware and software unmanned systems for use in extractive industries, farming, automation, industrial robotics, security systems and for the military.

, USA

Startup in the field of industrial robotics, which combines specialization in the field of image recognition systems and autonomous mobile robots. The goal is to increase the efficiency, "transparency" and security of enterprises and warehouses.

Carbon Robotics, USA

, Canada

The company specializes in the design and manufacture of unmanned solutions for scientific, industrial and military applications.

Cyberdyne, Japan

Exoskeletons HAL3, HAL5, Cyberdyne for Labor Support

, USA

Development of solutions for unmanned and robotic vehicles.

, China

Designs and manufactures unmanned systems and cameras for unmanned systems for use in the hobby sector, motion picture production, agriculture, search and rescue, energy, and so on.

Ekso Bionics, USA

Exoskeletons Ekso (eLEGs), ExoClimber, ExoHiker, Energid Technologies, USA

EPSON Robots USA

, Japan

Development and production of industrial robots.

Fetch Robotics, USA

, USA

iRobot Corporation designs and builds robots for private consumers, government agencies and industrial enterprises.

, USA

Home family robot. social robot.

Kawasaki Robotics, USA

Knightscope, USA

KUKA Robotics, USA

Industrial robots, development and production

, USA

The corporation specializes in the creation of global security systems, develops, manufactures and integrates products and services. The company does business in a wide range industries - space, telecom, electronics. information, aeronautics, energy, systems integration. Known for its development of drones and passive exoskeleton Fortis.

, USA

A private company specializing in the field of mobile robots. Offers solutions for use in warehouses that can increase labor productivity by 5-8 times compared to using traditional methods based on the use of electric cars.

, USA

It specializes in the development, production and sales of robots for use in industries such as electronics, telecommunications, utilities, pharmaceuticals, food processing, and the production of automation components.

Open Bionics, United Kingdom

ReWalk Robotics, USA

ReWalk medical exoskeletons

Robotiq, Canada

Samsung South Korea

Development and production of military robots, interest in other market segments, such as exoskeletons.

, USA

The company is developing service autonomous robots for use in the service industry. The flagship product is the Relay robot, which is already in use in a number of US hotels.

Schunk, Germany

, USA

Private company focusing on mobile robotics. Founded in 2003, it is engaged in the introduction of technologies based on computer vision in the industry of moving goods (goods in warehouses). The main product is robocars (robotic loaders).

Siasun Robot & Automation Co.Ltd., China

SoftBank Robotics Corporation, Japan

Subsidiary of Aldebaran Robotics, android type Pepper robots

Soil Machine Dynamics Ltd., United Kingdom

Swisslog, Switzerland

Logistics systems, warehouse robots, courier robots, e.g. Transcar

Titan Medical, Canada

Toyota Japan

ULC Robotics, USA

developer and manufacturer of crawler robots for repairing and sealing pipelines (from the inside), for example, the CISBOT robot

Universal Robotics, Inc., Denmark

industrial collaborative robots of the UR series, such as UR-10 and UR-5

Vecna ​​Technologies, USA

, USA

robot assisted surgical systems, simpler and cheaper compared to da Vinci

, USA

constructors for self-assembly of robots, for example, VEX Classroom & Competition Super Kit 276-3000, VEX Dual Control Starter Kit, VEX IQ Super Kit

, USA

manufacturer of industrial robots.

manufacturer of drones, including UAVs for use in agriculture

, USA

Development and production of industrial robots

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In this regard, solutions for industrial automation based on industrial robots are gaining particular popularity, allowing for a complete processing cycle with high productivity and accuracy, avoiding interruptions and production errors inherent in humans.

History of industrial robots

The history of the industrial robotics market goes back over 50 years. The first robot patent was obtained in 1961 (filed in 1954) by inventor George Devol, who founded Unimation Inc (from Universal Automatic) in 1956 with engineer Joseph F. Engelberger. – universal automation). Engelberg raised additional funding for the company, spread the idea of ​​robotics to potential customers, and popularized the idea of ​​industrial automation. Despite the fact that the patent was assigned to Devol, Engelberg is considered to be the "father of robotics".

Automakers were the first to take advantage of automation, and as early as 1961, deliveries of Unimate robots to the General Motors plant in New Jersey began. Unimate robots were built using hydraulic boosters and programmed in generalized coordinates, reproducing the sequence of actions recorded on a magnetic drum.

Later, Unimation donated its technology to Kawasaki Heavy Industries and GuestNettlefolds, thus opening the production of Unimate robots in Japan and England.

The main development of industrial robots began in the late 60s and early 70s, when in 1969 at Stanford University, a mechanical engineering student, Victor Scheinman, developed a prototype of a modern robot that remotely reproduces the capabilities of a human hand, the Stanford arm with six degrees of freedom, electric drives and computer control.

In 1969, there are developments in the field of robotics company Nachi. In 1973, the German company KUKA Robotics demonstrates its first Famulus robot, and almost simultaneously the Swiss company ABB Robotics introduces the ASEA robot to the market. Both robots have six controlled axes with an electromechanical drive.

In 1974, industrial robots are developed and installed in their own production at Fanuc, and in 1977 the first Yaskawa robot appears at Motoman.

The further growth of industrial robotics was due to the development of computers, electronics and the large-scale expansion of companies in the automotive market - the main customers of robots. General Motors spent more than $40 billion on automation in the 1980s. The main market for robots is the domestic market of Japan, where most of the companies producing them are located: Fuji, Denso, Epson, Fanuc, Intelligent Actuator, Kawasaki, Nachi, Yaskawa (Motoman), Nidec, Kawada. In 1995, out of 700,000 robots in use worldwide, 500,000 were in Japan.

Avtovaz became the largest integrator of robotics in the Soviet Union. In 1984, it acquired a license from the KUKA company, developing car production capacities and adopting the experience of world car manufacturers. On the basis of a separate machine tool division of the Avtovaz concern, the production of domestic robots used on the production lines of the enterprise began. To date, JSC Avtovaz, together with MSTU Stankin, is implementing a program for the production of a line of robots for industrial production up to 1000 units annually.

Benefits of using industrial robots in production

A modern industrial robotic arm is in most cases used to replace manual labor. So, the robot can use a tool gripper to fix the tool and process the part, or hold the workpiece itself in order to feed it into the work area for further processing.

The robot has a number of limitations, such as reach, payload, the need to avoid collision with an obstacle, the need to pre-program each movement. But with its proper application and preliminary analysis of the system, the robot is able to provide production with a number of advantages, improve the quality and efficiency of the workflow.

To assess the relevance of introducing a robot into the processing process, we present a number of advantages and disadvantages of using robotics in an enterprise:

1. Performance

When using a robot, productivity usually increases. First of all, this is due to faster movement and positioning during processing, and such a factor as the possibility of automatic operation 24 hours a day without interruptions and downtime also plays a role. In the case of a correctly chosen application of the robotic system, the performance compared to manual production increases by several times or even an order of magnitude.

It should be noted that with a wide range of products, constant readjustments, the need a large number peripheral equipment for different parts, productivity can also decrease, making the process inefficient and difficult.

2. Improved economic performance

By replacing a human, the robot effectively reduces the cost of paying specialists. This factor is especially important in economically developed countries with high salaries workers and the need for large allowances for processing, night time, etc. In the case of using a robot or an automated system, the workshop only needs an operator to control the process, while the operator can control several systems at once.

At the initial purchase, a robotic cell is a fairly serious financial investment, and the company is interested in its quick payback. Incorrect use of equipment and errors in its assembly and arrangement can lead to an increase in processing time or labor intensity of work, thereby reducing the profitability of production.

3. Processing quality

Often the reason for the introduction of a technological system based on an industrial robot is the need to ensure the quality of processing specified in the documentation for the product.

High positioning accuracy of industrial robots (0.1 0.05 mm) and repeatability ensure proper product quality and eliminate the possibility of manufacturing defects. The elimination of the human factor leads to the minimization of operating errors and the maintenance of constant repeatability throughout the production program.

4. Security

The use of the robot is quite effective in hazardous production that has an adverse effect on humans, for example, in the foundry industry, when cleaning welds, painting, welding processes, etc. In cases where the use of manual labor is limited by law, the introduction of a robot may be the only solution.

When working in the workshop, the perimeter of the working area is fenced with various devices to prevent a person from entering the robot's area of ​​operation. The presence of protective systems is the main and indispensable condition for the safe operation of robotic systems around the world.

5. Minimize workspace

A properly configured industrial robot cell is more compact than a manual work area. This is achieved by a more ergonomic design of the assembly jigs, the small size of the space occupied by the robot, the possibility of placing it in a suspended state, etc.

6. Minimum maintenance

Modern industrial robots, thanks to the use of asynchronous motors and high-quality gearboxes, are practically maintenance-free. Special models of robots are made of stainless steel, for example, for work in the medical and food industries, at high and low temperatures and in aggressive environments. This makes them less susceptible to the environment and increases the wear resistance of the equipment.

Application of robots in individual production processes

Welding

Welding is considered the most typical process for introducing robots. Historically, robotic welding has been widely used in the automotive industry, and now almost all automotive industries in the world are equipped with conveyors, which can consist of several hundred robotic complexes.

According to research, about 20% of all industrial robots are used in welding processes (in the US, about half). The second most important application is the palletizing of goods used in enterprises with a high volume of production, especially in the food industry.

Argon arc welding (TIG, MIG, MAG) or spot welding (RWS) using a robot provides higher quality products compared to the conventional manual or semi-automatic welding process. The capabilities of peripheral equipment allow for full process control, for example, to implement the function of non-contact tracking of the weld.

Currently, the use of robotic laser welding (LBW) is actively developing, which allows the laser to focus on a point with a variation of 0.2 mm, minimizing the thermal effect on the product and high welding accuracy and quality. The ability to withstand ultra-high focusing lengths (up to 2 meters) and thereby ensure remote welding significantly expands the limits of applicability of the welding process and increases the productivity of the product. Laser welding is actively used in aircraft, automotive, instrumentation, medicine, etc.

The transition to automatic welding using robots minimizes the cycle time by several times. This is achieved by ergonomic design or modernization of welding equipment to ensure a fast assembly cycle of the product, high speeds of movement of the robot and the organization of flow production with a one-time assembly of welding products. It should be noted that robotic systems are the only way to combine processing operations, for example, providing plasma or laser cutting, and subsequent welding by changing the torch or welding modes without reinstalling the part.

Also, the robotization of the welding process allows you to integrate welding programs into the CAD / CAM systems used at the enterprise to ensure the digital production process.

Automation of loading and unloading of products is a process that is important in any modern production with high productivity or large weight and dimensions of products. Thus, robots are used to load workpieces into metalworking machines, unload finished products and stack them on appropriate pallets. Moreover, quite often one robot serves several machines at once and works with different products, which reduces the cost of investments in such automation and expands the functionality of the implemented robot.

In Europe, there is a trend towards maximizing productivity through non-stop work around the clock, a philosophy of unmanned production is being introduced, associated with the desire to minimize personnel costs.

In the USSR, the task of reducing manual labor was not set, robotics was used to automate technological machines, where there may be restrictions on human labor - stamps, presses, plating baths, heating furnaces, etc. In addition, a person may be limited by the weight of the products. So, for parts from 2030 kilograms, the use of additional lifting equipment is required.

The introduction of automation in foundries and forging shops is driven by the need to eliminate difficult conditions for workers and improve production quality: unloading heavy forgings, casting blanks, subsequent cooling, loading into press dies, etc. It is no coincidence that the third place of application of robots after loading and unloading is occupied by the combination with forging and casting equipment. Almost all injection molding processes in Europe are automated using robots.

The use of technological systems based on robots can become an alternative to the use of conventional equipment specialized in any technological process.

On average, the cost of implementing a robot with an installation and the necessary package for interacting with equipment will cost an enterprise 5 million rubles, representing a truly flexible solution that can be used in the future for other tasks or implement auxiliary operations, for example, sorting various products, deburring, assembly operations, etc.

Metalworking processes using robots

In addition to welding and auxiliary operations, robots can be used in the machining processes themselves, acting as an alternative to machining equipment.

cutting material

Industrial robots are actively used for metal cutting operations using plasma, laser and waterjet cutting. Unlike the traditional plasma cutting machine, plasma torches using a robot can perform three-dimensional cutting, which is important for processing metal structures, rolled metal (tees, I-beams, angles, etc.), as well as preparing surfaces at an angle for further welding, cutting various holes etc.

Cutting metal using laser cutting is an alternative to a three-dimensional laser complex, allowing you to perform any cutting in three-dimensional space. This technology is widely used in the automotive industry, and is also quite effective for trimming the edges of products after stamping and forming operations. The robotic cell for laser cutting can also be used for laser welding, as well as in the future to combine two robots using the same source.

Robotic waterjet or waterjet cutting expands your cutting options to any 3D part, increasing productivity. Waterjet cutting is characterized by the absence of thermal effects and the ability to process almost any material. For example, waterjet cutting by a robot is used to cut all holes in steel 3 mm thick on the body of a Renault Espace car at a factory in France (Romorantin, France). A complete hole cutting cycle takes 2 minutes 30 seconds.

Pipe bending

Robotic tube bending is used in a limited way, being mandrelless bending by robotic workpiece positioning and the use of an accompanying bending head. The advantage of this processing is the high speed of production, the possibility of processing products with existing connecting elements and the simultaneous combination with the loading and unloading of products by the same robot. Such systems are used in the automotive industry, the manufacture of metal furniture and other goods. consumer goods where mandrelless bending is used.

Milling, drilling, deburring and removing welds

The use of robots for milling, drilling and edging of metals, plastics, wood and stone is a new, dynamically developing technology. It became possible primarily due to the increase in rigidity and accuracy of modern manipulators. The main advantages are the practically unlimited working area of ​​the robot (the system can be equipped with a linear axis of several tens of meters), high processing speed and a large number of controlled axes. For example, a typical milling cell based on an industrial robot has 8 to 10 controlled axes and allows for maximum machining flexibility.

It is possible to use a wide variety of powered tools, pneumatic and electric, air-cooled and liquid-cooled. For deburring the edges of parts after milling, a pneumatic driven tool with a rotation speed of 35,000 rpm is used, and for milling metals, a water-cooled electric spindle with a power of 24 kW is used.

Separately, it is worth mentioning such a difficult, laborious process for a person as cleaning a weld on a product. The use of automation can reduce the impact of harmful production factors and significantly reduce the time for stripping.

Polishing and grinding

Grinding metal parts is a complex and dirty process, extremely harmful to humans. At the same time, its automation is quite simple and does not present a problem for modern industrial manipulators. The robot will always be able to follow the path of the grinder, while ensuring consistent repeatability and excellent processing quality.

The processes of abrasive surface treatment can be divided into two main classes - grinding and polishing. When grinding, abrasive wheels or belts are used, material removal can be significant, and a lot of dust is generated. Polishing is a more subtle process, for which felt wheels with abrasive paste are used, with virtually no material removal. As a rule, these processes are combined. The advantage of the robot is that it can process a part on several abrasive tools in turn, in one setup. For example, first the surface layer is removed on an abrasive belt, and then the part is polished on a felt wheel with automatic paste supply.

Prospects for the use of robots

The advantage of robotics is the flexibility of application and the possibility of using it in an almost unlimited number of processes. So, for example, in the aircraft industry, in order to improve quality while reducing manual labor, robots are beginning to be used in the processes of riveting, fuselage skin, laying out composite materials, and in various works in confined spaces. The use of robots in measuring systems is actively spreading. In the US and Europe, robots are used in high-pressure cleaning chambers.

In Russia, the use of robots is still limited. So, in the pre-crisis year of 2007, up to 200 robotic systems were introduced with a total number of about 8,000 industrial robots in the country. For example, during the same year, about 34 thousand robotic systems were introduced in the USA, 43 thousand in Europe, and 59 thousand in Japan. The reasons for the lag are the lack of awareness of Russian technical specialists and enterprise management, the desire to avoid high costs for their implementation, and the low cost of manual labor.

At the same time, unlike stationary CNC equipment, the robot is a more versatile system focused on improving the quality and productivity of production and minimizing manual labor, ultimately leading to a positive economic effect and increasing the competitiveness of the enterprise. That is why more and more Russian integrators are ready to solve the problems of applied implementation of robots in technological processes. We hope that over the next few years the concept of "unmanned production" in Russia will rapidly gain momentum.

Igor Protsenko, Boris Ivanov

New Line Engineering LLC

Industrial robots in the cultural sector

Introduction:

The economy of many countries develops primarily due to industry. Industrial enterprises, such as metallurgical plants, machine-building plants, oil refineries and light industry factories annually bring more than 40% of the profitability of states. And since most of the industrial enterprises of our country have been privatized, we are talking about a very profitable business.

In industrial business, quality and productivity are business card when dealing with suppliers and customers. The higher the requirements for the quality of manufactured products, the more relevant the introduction of modern technologies becomes.

Enterprises are introducing robotic systems into production primarily to increase profits by reducing the workforce. In Japan, China and the USA, almost all industrial plants are equipped with "the latest technology". They employ a minimum of workers, which ensures a low cost of products. In Russia and Ukraine, the use of robotic devices is still limited. Outdated equipment in enterprises leads to a decrease in efficiency and quantity of production. And besides, it harms the environment. To increase production and product quality, companies need to take care of upgrading equipment.

Nowadays, automated devices for working in factories are presented in a wide range. Robots are successfully used in metallurgy, mechanical engineering, light and food industries. They are able to replace a person in difficult and dangerous working conditions. They provide speed, accuracy, quality, as well as high payback. This is achievable by the fact that robots do not need to pay salaries, pay for vacations and provide social benefits.

We invite you to find out useful information about automated systems and industrial robots, as well as about the beneficial use of these devices in industrial enterprises.

Automated production lines:

Enterprises of mass and small-scale production need to install automated production lines. These mechanisms are machines of continuous operation in the form of interconnected machines. Automatic lines are produced in many countries of the world, including Russia and Ukraine, and are supplied at a price of $10,000. assemblies.

The mechanisms are controlled by a computer and allow the processing of parts using dynamic technology. In accordance with the requirement for optimal loading of machines, the order and route of processing parts are partially changed. The computer plans the launch and release of parts, performs planned, dispatching calculations and calculates processing modes in accordance with the selected algorithm.

Production lines include automatic continuous casting machines (CCM). Modern continuous casting machines are a whole complex of sophisticated equipment: mechanical, hydraulic, cooling and lubrication systems, as well as electric drives with an automated control system technological process. The installation of this device provides a significant reduction in metal loss, improved working conditions, constancy of production conditions and increased productivity of the plant.

Open-hearth furnaces and oxygen converters are no longer relevant in the production of steel at metallurgical plants. Serious capital investments for implementation the latest technologies(ladle furnaces, electric furnaces, electrometallurgical mini-plants and continuous steel casting) at plants in Ukraine and Russia, will guarantee a capacity of 1 million 320 thousand tons of high-quality steel billets per year.

Universal robotic manipulators:

Manipulators have been used in factories since the middle of the 20th century. These devices are an automated mechanism equipped with a special distinctive tool - the so-called "hand" of the manipulator. This "hand" serves as the main acting body for various purposes. If it is a robot for welding, the manipulator arm performs welding operations, if it is a stacker robot, the arm is used for stacking and packaging products. Naturally, the principle of operation of the manipulator depends on its programming and equipment.

A variety of robotic manipulators is rapidly gaining momentum. Today there are 30 types of manipulators. Industrial robotics companies present their inventions, ranging from universal manipulators to molders of finished products. These devices are much more affordable than they seem, and today even the average business can afford to buy a couple of these devices a year for an average price of $ 2,500 apiece.

Start with versatile robotic arms. Universal industrial robots are high-tech devices that serve to solve problems related to production automation. They are mainly used in mechanical engineering and metallurgy for welding, cutting, machine maintenance, painting, polishing, surfacing, machining, glue and filler distribution, plasma spraying, cargo handling and palletizing.

Companies ABB, Kawasaki and FANUC supply universal industrial robots at prices ranging from $2,000 to $4,000 depending on the functionality of the device. These devices are able to increase the speed and quality of processing parts, but the main disadvantages of these devices are the incomplete interaction of all components and the impossibility of carrying out the most accurate operations.

At modern machine-building and metallurgical plants, "highly specialized" robotic manipulators are widely used. The most common are welding robots. Industries with a limited number of products can benefit from the introduction of automated welding systems. This process reduces the number of skilled welders, as the robot is 8 times more efficient than a human.

Welding robots:

Welding manipulators are a set of advanced technologies and components programmed to perform arc and spot welding of objects. Manipulators are used for welding tanks, cranes, beams and tanks. The devices perform welding of butt and fillet welds, welding of straight and circumferential seams and other work requiring extreme precision. The advantages of automated welding are obvious: manipulators provide high quality welding and the identity of the finished product; reduce defects in the processing of parts; increase the speed of production. The introduction of welding robots into production allows enterprises to reduce the time for manufacturing products, including assembly in a welding jig and the welding process, from 30 to 7 minutes.

When choosing suppliers of welding equipment, it is worth considering which manufacturing companies can guarantee the quality of their devices. The most qualified specialists in the field of automated welding are companies Kuka and Kawasaki. They supply welding manipulators priced at an average of $2,300, and according to industrialists who have already implemented robots from these companies, the devices are really reliable, efficient and easy to operate.

Assembly robots:

Next, consider manipulators for automatic assembly of parts. As the economic studies of the Moscow state university, up to 25% of the total production time is spent on assembly operations. Assembly robots are mainly 6-axis devices with 6 degrees of freedom, which are driven by a servo system.

Assembly robots of companies iRobot and MOTOMAN are some of the best mechanisms for automated builds. They are available on the industrial automation market at an average price of $2,000. Robots offer high-quality assembly of products, raising labor productivity by 10-20% and reducing scrap by 30-40%. The greatest effect from the use of assembly robots is achieved when full automation the entire production line.

Cutter robots:

The enterprises of the metallurgical industry also often use manipulators for cutting metal - independent anthropomorphic mechanisms. Modern cutting robots are available with a tracking system for the current position of the workpiece. By design, a manipulator for cutting metal is one of the most complex mechanisms. An important element of the robot is the contact sensor of the tool head with a metal surface. The on-board computer provides positioning accuracy up to 0.05 mm, which is sufficient for processing even small parts, as well as workpieces that require particularly precise cutting. When choosing these devices, it is worth considering that the manipulator must have a high degree of mobility, which leads to the presence of a large number of axes and drives. Such machines can be offered by Daihen and Kawasaki for ~ $1300 each. Along with low cost, these devices provide stable and accurate metal cutting.

Robot painters:

Painting equipment is an important element of machine-building enterprises. Robotics has managed to achieve significant advances in the field of these devices. For example, companies Adept and Triton supply painting robot arms starting at $2,500. These machines are equipped with special spray guns for painting parts and have increased flexibility to protect hoses when supplying paint to the working area from mechanical stress, twisting and breaking, pollution and dusting, which is simply impossible for people to do manually.

Bending robots:

An innovation in heavy industry is the use of bending robots. A bending robot is a simple automated machine, usually hydraulically or electrically driven. Both a conventional manipulator and pneumatic suction cups can be used as a gripping device of the device. The main supplier of bending manipulators is the company ROBOMAC, which provides modern devices at a price of $3165. The devices are capable of loading the object into the bending head, feeding, turning the object and unloading after bending. As a rule, the result is a flexible system that does not require any additional devices to work.

Loader robots:

In heavy and light industry, lifting equipment is indispensable. Companies ABB, KUKA, FANUC and Epson provide solutions for lifting heavy loads weighing more than a ton and transporting them from the mill to the warehouse. The most powerful systems handle the receipt and dispatch of cargo with incredible speed and efficiency. The cost of these "lifts" depends on the number and speed of lifting the load and ranges between 1900 and 4000 US dollars.

Packing robots:

The need to reduce the time of intralogistics, unhealthy environment, heavy human labor causes the need to automate palletizing processes. The speed and accuracy of palletizing robots are incomparable with human labor, and the efficiency and versatility is much higher than a standard palletizing machine. The cost of these robots is quite high. For example, renting a palletizer from OKURA for four months costs $80,000.

Light and food industry enterprises are interested in fast and high-quality packaging of products from the conveyor. Companies Komatec, Packmore and Epson offer cost-effective solutions for automated packaging of finished products. The machines are equipped with a flexible manipulator arm, which allows them to pack even the most fragile items with dexterity and care, without breaking them, unlike human packers. For example, a KOMATEC packing robot priced at $3,700 operates in the following way: it scans the movement of the conveyor, having identified the product, receives a signal to the electronic control unit, which, in turn, gives the command mechanical arm take the item. As you can see, all the movements of the robot are made according to the program. This contributes to a high-quality and fast process of packing objects.

Sorting robots:

Next, we will consider sorting manipulators similar to robopackers. These devices are also equipped with a working tool and a number of product detection sensors for accurate sorting. The main manufacturers of "sorters" include MOTOMAN and LEGO. Buying their devices has become more profitable than ever - from $ 2,800.

It should be noted that the variety of manipulators is not limited to the above devices. Manufacturing companies are actively engaged in the development and implementation of robotic systems for surfacing, forming, polishing and machining products, which are becoming more accessible to industrial enterprises every day.

Robots for handling hazardous substances:

If you own a chemical plant or refinery, you should consider filtering your workspace. Modern filtration devices are various gas and dust collectors, as well as devices for working with radioactive substances. Gas traps are particularly well represented in Blitz's $700 range.

Working with radioactive substances is extremely dangerous for humans, so scientists are actively working on the development of robots for service at chemical enterprises. Gas and dust collectors are used to dispose of substances hazardous to human health, gases and dust and help to purify the air. Installing one such device, such as a Torit dust collector, costs about $3,200. In a large enterprise, it is enough to install one dust collector in each workshop, and clean air and a safe working environment are guaranteed.

Oil refineries often need a quality inspection of pipelines for corrosion. This check is very important, because due to pipe failure, dangerous toxic substances can enter the environment and cause detrimental harm to it. Checking pipelines from the inside by people is possible, but it is better to shift this process to robots. A “tiny robot patrol” is used to check pipelines for corrosion. Laboratories and robotics companies such as SoCalGas are developing miniature robots equipped with cameras and sensors that move independently through pipes and transmit video footage in real time. On the this moment it is not yet known when the robots will be available for sale and at what price, but the researchers assure that the cost of these amazing devices will not be sky-high.

Software for industrial automation:

Software, as a rule, for industrial robots is written from scratch and developed separately for each robot. The principle of operation of the robot depends on its programmed intelligence. Leading manufacturers of industrial robotics KUKA, FANUC, MOTOMAN and ABB this issue special attention and invest decent funds in the development software for your devices.

Highly intelligent robots are able to perform all their movements in accordance with the required manipulation operation. At the same time, a program with the necessary coordinates and technological information is recorded in the memory of the control device. Distinctive features of industrial machines endowed with high intellectual abilities are:
lack of electric drive
high positioning accuracy of the part due to the location of the controls
independently maintained mechanisms and parts.
Equipped with independent drives and high-efficiency mechanisms, intelligent robots are the best choice for any precision engineering work, suitable for lifting loads, and also used in road and rail transport.

Currently fully automated, endowed with artificial intelligence cars are expensive. For example, MOTOMAN rents out its highly intelligent manipulators for a month for $280,000.

Conclusion:

Thus, we see how rapidly robots are developing in the industrial sector. Advanced technologies are increasingly freeing a person from performing complex and routine work. The introduction of robotics in factories can save energy, reduce pollution environment, reduce labor costs and increase the efficiency of the production process. The use of robotic technologies provides enterprises with a unique opportunity to take an evolutionary leap and break away from competitors. After all, the cost recovery for robots has already been proven in practice. So, take care of your future and the future of your country now.