Frontiers of assembly and manufacturing

Frontiers of Assembly and Manufacturing

Sukhan Lee, Raúl Suárez, and

Byung-Wook Choi

Frontiers of Assembly and

Manufacturing

Selected Papers from ISAM 2009

ABC

Prof. Sukhan Lee

School of Information and

Communication

Sungkyunkwan University

300 Chunchun-Dong, Jangan-Ku

Kyunggi-Do 440-746 Korea

E-mail: [email protected]

Dr. Raúl Suárez Feijóo

Researcher

IOC-UPC

Av. Diagonal 647, planta 11

08028 Barcelona, Spain

E-mail: [email protected]

Dr. Byung-Wook Choi

International Affairs Center and

Principal Researcher

Div. of Advanced Robot Technology

and Director, Korea IMS Center

Korea Institute of Industrial Technology

(KITECH)

1271-18, Sa-1-dong, Sangrok-gu

Ansan-si 426-791 Korea

Email: [email protected]

ISBN 978-3-642-14115-7 e-ISBN 978-3-642-14116-4

DOI 10.1007/978-3-642-14116-4

Library of Congress Control Number: 2010929749

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Preface

The technologies for product assembly and manufacturing evolve along with the

advancement of enabling technologies such as material science, robotics, machine

intelligence as well as information and communication. Furthermore, they may be

subject to fundamental changes due to the shift in key product features and/or en￾gineering requirements.

The enabling technologies emerging offer new opportunities for moving up the

level of automation, optimization and reliability in product assembly and manu￾facturing beyond what have been possible. We see assembly and manufacturing

becoming more Intelligent with the perception-driven robotic autonomy, more

flexible with the human-robot coupled collaboration in work cells, and more inte￾grated in scale and complexity under the distributed and networked frameworks.

On the other hand, the shift in key product features and engineering requirements

dictates the new technologies and tools for assembly and manufacturing to be de￾veloped. This may be exemplified by a high complexity of micro/nano system

products integrated and packaged in 3D with various heterogeneous parts, compo￾nents, and interconnections, including electrical, optical, mechanical as well as

fluidic means.

The objective of this volume is to show how the assembly and manufacturing

technologies evolve along with the advancement of enabling technologies and

how the emergence of a high complexity of micro/nano system products dictate

the development of new technologies and tools for their assembly and manufactur￾ing. To this end, we have chosen 19 papers, top-rated yet relevant, out of the 76

papers accepted to present at the 8th IEEE International Symposium on Assembly

and Manufacturing. The 19 papers chosen are further revised into the final manu￾scripts for book chapters that are organized into three parts: Part I: Fixture, Grasp￾ing and Manipulation in Assembly and Manufacturing, Part II: Micro/Macro As￾sembly and Disassembly, and Par III: Manufacturing System Scheduling and

Control. Part I, II and III are reviewed and organized by the co-editors of this vol￾ume, Prof. Raul Suarez, Prof. Sukhan Lee and Dr. Byungwook Choi, respectively.

Wishing that readers find this volume stimulating and informative …

Sukhan Lee

Raúl Suárez

Byungwook Choi

Contents

Chapter I: Fixturing, Grasping and Manipulation in

Assembly and Manufacturing ................................ 1

Summary by Ra´ul Su´arez

Dual Arm Robot Manipulator and Its Easy Teaching

System ...................................................... 5

Chanhun Park, Kyoungtaik Park, Dong IL Park, Jin-Ho Kyung

Calibration of Relative Position between Manipulator and

Work by Point-to-Face Touching Method .................... 21

Toru Kubota, Yasumichi Aiyama

Cutter Accessibility Analysis of a Part with Geometric

Uncertainties ................................................ 35

Masatomo Inui, Kazuhiro Maida, Yuji Hasegawa

Automatic Determination of Fixturing Points: Quality

Analysis for Different Number of Points and Friction

Values ....................................................... 53

Jan Rosell, Ra´ul Su´arez, Francesc Penalba

Contact Trajectories for Regrasp Planning on Discrete

Objects ...................................................... 69

M´aximo A. Roa, Ra´ul Su´arez

Modeling of Two-Fingered Pivoting Skill Based on CPG..... 85

Yusuke Maeda, Tatsuya Ushioda

Chapter II: Micro/Macro Assembly and Disassembly ........ 97

Summary by Sukhan Lee

VIII Contents

Assembly of 3D Reconfigurable Hybrid MOEMS through

Microrobotic Approach ...................................... 99

Kanty Rabenorosoa, Sylwester Bargiel, C´edric Cl´ecy, Philippe Lutz,

Christophe Gorecki

Modified Assembly Systems and Processes for the

Mounting of Electro-Optical Components .................... 113

J. Franke, D. Craiovan

Factory Level Logistics and Control Aspects for Flexible

and Reactive Microfactory Concept .......................... 127

Eeva J¨arvenp¨a¨a, Riku Heikkil¨a, Reijo Tuokko

Development of Structured Light Based Bin–Picking

System Using Primitive Models ............................. 141

Jong-Kyu Oh, KyeongKeun Baek, Daesik Kim, Sukhan Lee

Airframe Dismantling Optimization for Aerospace

Aluminum Valorization ...................................... 157

Julie Latremouille-Viau, Pierre Baptiste, Christian Mascle

A Monitoring Concept for Co–operative Assembly Tasks .... 171

Jukka Koskinen, Tapio Heikkil¨a, Topi Pulkkinen

Chapter III: Manufacturing System Scheduling and

Controlling .................................................. 185

Summary by Byung-Wook Choi

Printing Pressure Control Algorithm of Roll-to-Roll Web

System for Printed Electronics .............................. 187

Kyung-Hyun Choi, Tran Trung Thanh, Yang Bong Su,

Dong-Soo Kim

Adding Diversity to Two Multiobjective Constructive

Metaheuristics for Time and Space Assembly Line

Balancing .................................................... 211

Manuel Chica, Oscar Cord´ ´ on, Sergio Damas, Joaqu´ın Bautista

Construction and Application of a Digital Factory for

Automotive Paint Shops ..................................... 227

Yang Ho Park, Eon Lee, Seon Hwa Jeong, Gun Yeon Kim,

Sang Do Noh, Cheol-woong Hwang, Sangil Youn, Hyeonnam Kim,

Hyunshik Shin

Resource Efficiency in Bodywork Parts Production .......... 239

Reimund Neugebauer, Andreas Sterzing

Contents IX

Self-Tracking Order Release for Changing Bottleneck

Resources ................................................... 253

Matthias H¨usig

Integrated Operational Techniques for Robotic Batch

Manufacturing Systems ...................................... 265

Satoshi Hoshino, Hiroya Seki, Yuji Naka, Jun Ota

A Mathematical Model for Cyclic Scheduling with

Assembly Tasks and Work-In-Process Minimization ......... 279

Mohamed Amin Ben Amar, Herv´e Camus, Ouajdi Korbaa

Author Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

Chapter I

Fixturing, Grasping and Manipulation in

Assembly and Manufacturing

Summary by Raúl Su<rez

Assembly and manufacturing automation involves different problems, most of

them derived from the physical interaction between parts, where any imprecision

could produce important failures and consequently an increasing of the manufac￾turing costs. Properly task planning and programming, as well as the calibration of

the involved systems, are quite frequently more complex than the task execution

itself, and this is somehow strengthened by the continuous development of more

and more versatile tools, with sophisticated features and high flexibility in their

capabilities.

Typical robotized tasks as manipulating an object or making some action on it

require an appropriated constraint of the object degrees of freedom, either with re￾spect to a gripper or to a specific static reference system, and this implies, for

instance, the correct positioning of the object, the determination of the proper fix￾turing points, the calibration of the involved hardware and the planning and pro￾gramming of the tool movements, problems that may be really time consuming

and that usually demand high skill and practice from the human operator. Then,

solving these problems in an automatic way is quite relevant in order to fully

automate and optimize several assembly and manufacturing tasks, not only regard￾ing their execution but also their planning and programming as well.

This chapter includes some contribution in this line. It consists of six papers

dealing with: a teaching system to simplify the robot programming, a calibration

procedure to reduce position uncertainties, an approach to analyze object manu￾facturability in front of shape uncertainties with respect to the CAD model, a

software tool to find and analyze the quality of fixturing points, a procedure to de￾termine contact trajectories for object regrasping, and a model for two finger gras￾pless manipulation of an object. A brief presentation of each paper is given below.

The first paper, with title Dual Arm Robot Manipulator and Its Easy Teaching

System by Chanhun Park, Kyoungtaik Park, Dong IL Park and Jin-Ho Kyung,

presents a dual arm robot manipulator composed of two arms with six degrees of

freedom each one mounted on a torso with two additional degrees of freedom and

a teaching system to program it. The dual arm robot manipulator was designed for

precision assembly of mechanical parts, but programming it with traditional teach￾ing systems becomes a complex task, thus, the authors propose a more practical

2 R. Suarez

teaching system based on the guidance of one of the arms and making the other to

follow the proper trajectories in accordance with the manipulated object.

The second paper, with title Calibration of Relative Position between Manipu￾lator and Work by Point-to-Face Touching Method by T. Kubota and Y. Aiyama,

introduces a calibration procedure that estimates the relative position error be￾tween a manipulator and a workpiece. The procedure is based on a set of touching

actions between a point of an arm tip tool and a face of the workpiece, the touch￾ing information obtained from each contact is iteratively processed to reduce the

error in the estimation of the object position and orientation, with a limit imposed

by the existing uncertainty in the position of robot end effector, which is assumed

to be known. The approach needs to solve a linear programming problem in each

iteration, but it requires neither advance tool calibrations nor a skilled operator for

high precision calibration, thus it could reduce the calibration time and reduce

production costs.

The third paper, with title Cutter Accessibility Analysis of a Part with Geomet￾ric Uncertainties by Masatomo Inui, Kazuhiro Maida and Yuji Hasegawa, pro￾poses a methodology to analyze the manufacturability of a holder part produced

by working on a raw cast object, which usually has some shape differences with

respect to the corresponding CAD model. This shape uncertainty may result in un￾machinable features due to, for instance, collision between the cutter and the raw

cast object. Detecting these problems at the design stage can strongly reduce the

cost and waste time due to a later redesigning of a new holder part. The proposed

approach has two basic steps, first, the CAD model is properly modified expand￾ing it according to potential shape errors and, second, the un-machinable regions

are detected with a cutter accessibility analysis that looks for possible interfer￾ences between the cutter and the non-ideal holder part model.

The fourth paper, with title Automatic Determination of Fixturing Points: Qual￾ity Analysis for Different Number of Points and Friction Values by Jan Rosell,

Raúl Suárez and Francesc Penalba, presents a software tool that implements a pro￾cedure to search for fixturing points on an object surface and also allows a quality

analysis of any given set of fixturing points. The automatic search procedure can

be applied to 2D and 3D free-form objects, respectively represented by a sequence

of points or a triangular mesh, considering any number of fixturing points and a

variable friction coefficient at the contacts; the procedure is based on a uniform

exploration of the object boundary to identify contact points that iteratively in￾creases the quality of the fixturing. The quality analysis allows to determine, for

instance, how many points are necessary for a given friction coefficient in order to

fix the object with a given desired quality, or, whether increasing the number of

contact points means a significant improvement of the quality.

The fifth paper, with title Contact Trajectories for Regrasp Planning on Discrete

Objects by Máximo A. Roa and Raúl Suárez, provides a procedure that, given an

initial and a final desired grasps characterized by a set of contact points on the ob￾ject boundary, returns a path for each contact ensuring that the current grasp can re￾sist external disturbances at any time during the regrasp motion. The approach can

be applied to the regrasp planning of 2D and 3D objects whose boundaries are rep￾resented by a finite, but large, number of points. A sampling-based method together

Fixturing, Grasping and Manipulation in Assembly and Manufacturing 3

with the concepts of Independent Contact Regions and Non-Graspable Regions are

used to speed up the search of the grasp space for a continuous path between the

initial and the final grasp. Grasp changes are critical in manipulation tasks, there￾fore the proposed approach is an interesting step towards its automation.

The sixth and last paper of the chapter, with title Modeling of Two-Fingered

Pivoting Skill Based on CPG by Yusuke Maeda and Tatsuya Ushioda, deals with a

particular problem of graspless manipulation: the translation of a cuboid by pivot￾ing it using two fingers. This skill is modeled using Central Pattern Generators to

obtain the commands for the index finger and the thumb of a virtual hand such

that they push the cuboid producing a periodic pivoting. The results obtained with

dynamic simulation are promising, and motivates the study and potential devel￾opments of other skills as well as their physical validation.

Dual Arm Robot Manipulator and Its Easy

Teaching System

Chanhun Park, Kyoungtaik Park, Dong IL Park, and Jin-Ho Kyung*

Abstract. The dual arm robot manipulator has been developed and it easy teach￾ing system has been developed also. The manipulator consists of two industrial 6-

DOF arms and one 2-DOF torso and it was designed for the assembly automation

of the automotive parts. Two-arm robot system has more advantageous than the

traditional single arm robot system. But it is more difficult to teach the dual arm

robot system. In this paper, the research results on the dual arm robot manipulator

and its easy teaching system will be introduced.

1 Introduction

Traditional single arm robot has just one arm to handle the object so it can’t per￾form its role in the workplace where the human worker does his jobs with his two

arms. The robot manipulator needs to have two arms to have the function of coop￾eration to assembly mechanical parts. Recently, this is motivating some robot

company to develop the robot system with two arms on one torso. With the same

reason, industrial dual arm robot manipulator for precision assembly of mechani￾cal parts has been developed by the authors and its research results have been al￾ready introduced [1]. The developed manipulator has two industrial 6-DOF arms

and one 2-DOF torso. Left-arm and right-arm can be used to manipulate the work￾piece in the cooperation task and each single arm can be used as a stand-alone 6-

DOF manipulator at the same time.

The robot manipulator is very accurate and has enough power to lift up big and

heavy workpiece. But it is difficult to make the manipulator understand the

*Chanhun Park .

Kyoungtaik Park .

Dong IL Park .

Jin-Ho Kyung

Department of robotics and intelligent machinery,

Korea Institute of Machinery & Materials, 104 Sinseongno, Yuseong-gu,

Daejeon, 305-343, Korea

e-mail: [email protected], [email protected],

[email protected], [email protected]

6 C. Park et al.

operator’s intention because it does not have enough intelligence. Usually, teach￾ing pedants are used to teach the manipulator. But it is not easy to use them for the

naive operators. So, the intuitive teaching methods have been introduced by many

researchers and the direct teaching is one of the good candidates [2-6].

Two-arm robot system has more advantageous than the traditional single arm

robot system as mentioned above. But it is more difficult to teach the dual arm ro￾bot system because the left arm and the right arm and the torso have to be taught

separately. Furthermore it is very difficult the relative motion between the left arm

and the right arm using the traditional teaching pendants. With the traditional

teaching pendant system, the operator has to define the motion of the left arm.

And then he has to teach the motion of the right arm. If the torso is worked while

the two arms are working, the teaching process gets more complicated. So the

easy teaching system for the developed dual arm robot manipulator has to be de￾veloped. For this reason, the industrial dual robot manipulator that it is possible to

easily teach using easy teaching system has been developed. In this paper, the re￾search results and experimental results will be introduced.

2 Robot Design and Analysis

The developed dual arm manipulator has been developed for the automation of the

mechanical parts. Transmission assembly and constant velocity joint assembly

(Fig 1) are the first application target of the developed dual arm robot manipulator.

The assembly is composed of the parts of Table 1. The major parts of the assem￾bly are shown in Fig. 2.

Fig. 1 Transmission assembly line(left) and constant velocity joint assembly line (right)

Dual Arm Robot Manipulator and Its Easy Teaching System 7

Fig. 2 Transmission drawings and important parts

Table 1 Part list of transmission assembly line

Part Number Unit

1 PINION ASS’Y-MAIN DRIVE SUB - 1EA

2 BEARING-NEEDLE ROLLER(M/D) 43229-4A060 1EA

3 RING-SYNCHRO(4&5) 43384-4D000 1EA

4 SHAFT-MAIN SUB ASS’Y - 1SET

5 GEAR-COUNT SHAFT CLUSTER SUB - 1SET

6 PLATE ASS’Y-INTERMEDIATE - 1SET

7 BEARING-DOUBLE ANGULAR BALL 43226-4A040 1EA

8 SLEEVE REVERSE GEAR BEARING 43234-4A010 1EA

9 BEARING-ROLLER(SPACER) 43295-4D040 1EA

10 RETAINER-BEARING RR. 43144-4A001 1EA

8 C. Park et al.

Table 2 Requirement specification of developed dual arm robot manipulator

specification values

Out-reach 1.5m

Payload 10kg/arm

Max Speed 150deg/s

Repeatability 0.1mm

DOF 6/Arm, 2/Torso

For the consideration of assembly process and the layout of the transmission

assembly line (Fig. 3), the kinematic parameters of the manipulator are defined

following Table II. Out-reach of the robot manipulator is 1.5m, the payload is

10kgf. The repeatability is 0.1mm.

Fig. 3 Brief layout of transmission assembly line

The kinematic structure of the developed manipulator is shown in Fig 4. The

developed manipulator has two industrial 6-DOF arms and one 2-DOF torso. The

kinematic structure of the left/right arm has the same as one of the traditional in￾dustrial 6-DOF robots.

Fig. 4 Kinematic structure of developed dual arm robot manipulator