Index

Note: Page numbers followed by f indicate figures.

A

AC servo 21, 24
Application parameters 66–67, 104–106
Arc welding system 77f
benefits 77–78
equipment, automation systems 51–56
fixture design 110
guarding 69, 110–111
H-style positioner 109
multiaxis positioners and vision tracking 77
orientation 107–108
process equipment 51–56
selections 111
single-axis positioners 108–109
swing radius 109
turntable 107
two-axis positioners 109
unloading and reloading operations 76–77
Articulated/jointed arm 22–24, 23f
Assembly system 101f
bowl feeders 65–66
conveyor systems 65
delta robots 100–101
feeding 102
goal post test 101
joining functions 102
payload 101
positional repeatability 102
reach and size 101
rotary table systems 65
SCARA robots 65, 100–101
six-axis machines 100–101
testing 64
Automated guided vehicles (AGVs) 42–43
Automation 
application parameters 
cycle time 106
operators 105–106
benefits 189
competitiveness 191
concept refining 
changeover time 128
costing 130
downtime 129
efficiency 130
flexibility 128
product input and output 129
controls and safety 
human machine interfaces 124–125
loading and unloading 125
maintenance operations 125–126
programmable logic controller 126
sheet metal 125
cost benefits 186
definition 4
discrete/factory 5
external resources 188
finance issue 190
financial justification 187, 190
future aspects 191
applications 191
benefits 192–193
flexible 192
significant developments 191–192
system pricing 191
handling equipment 40–46
automated guided vehicles 42–43
conveyor systems 41–42
feeding system 43–46
objectives 40–41
self-guided vehicles 42–43
hard and soft 5–6
manufacturing operation 190–191
material removal 124
painting and dispensing 123–124
process equipment 
adhesives/sealants 57
arc welding 51–56
cutting and material removal techniques 57–58
painting 56–57
spot welding 50–51
Robot software 185–186
safety system 69, 186
spot and laser welding 123
system controls 
HMI 66–67
MAP 67–68
networks 68
PLC 66
technical risks 187
testing and simulation 
discrete event simulation 127–128
kinematic simulation 127
tooling/fixturing 62–64
Automation project 
clarifications 219
contacts 218–219
environment 219
implementation 182
installation and commissioning 
complexity 173
documentation 174
issues 173
safety 173
operation and maintenance 182
further capacity 174–175
performance investigation 183
service 175
standards specification 174
training 182
planning 
delivery dates 165
factory acceptance tests 166
site acceptance test 166
start of production 164–165
timing plans 165, 166, 167
training 166
preferred vendors 219
staff and supplier selection 
experience and expertise 168
financial stability 169
maintenance 177–178
production 176–177
review meeting 168
service support 169
specification 167–168
workload required 167
standards 220
system build and buy-off 
completion design 172
design elements 171
FMEA 171
kick-off meeting 170–171
maintenance review 171–172
system design and manufacture 
avoidance of problem resolution 182
change control 181
warranty 219
Automation strategy 188–191
Automotive components 11, 15, 51–52, 79–80, 148–149
Automotive industry 2, 5, 10, 11–15, 16, 17–18, 20, 79–80

B

Bandoleer feeders 46
Batch sizes 37, 38, 128, 136, 152, 209, 214
Benefits 33–38, 77–78, 94–95, 152–153, 186, 189, 192–193
Blow feeders 45
Bowl feeders 44–45, 44f
Budget–budget cost 153, 154, 159–161
Business plans 188, 189, 190–191
Buy-off criteria 141–142, 143–144, 170–172, 216

C

Capital costs 38, 152–153
Capital investment 3–4, 164, 186, 192
Cartesian machines 26–27, 26f
Casting 91–92
Changeover time 116, 128, 151
Clam shell gripper 115
Commissioning 140–141, 172–174, 215
Compliance 8–9, 24–26, 58, 88, 156, 216
Control net 68
Conveyors-continuous, indexing 41–42, 65, 96
Conveyor systems 
belt 42
chain 42
continuous 41–42
indexing 41–42
roller 42
selection 41
Cost-benefit analysis 186
Cost savings 156–159
absenteeism 158
calculations 157
floor space 158
labour health and safety 158
labour turnover 158
overhead costs 159
Customer expectations, URS 134
buy-off criteria 141–142, 143–144
commissioning 140–141
delivery 140
documentation 142–143
factory acceptance tests 140–141
free-issue 137
functional design specification 138–139
installation 140–141
issues 136–137
management 138
manufacture and assembly 139
performance parameters 143
predelivery tests 139–140
quality services 138
safety requirements 137
site acceptance test 141–142
standby 142
training 142
URS 143
warranty period 143
Customer Factory Acceptance Tests (CFAT) 213
Cycle time 106, 209, 213–215, 216–217
Cylindrical 28

D

DC servo 21
Deburring 15, 58, 85, 87–89, 95, 113, 124
Delta configuration robot 9–10
Device net 68
Die casting 91–92, 91f
Discrete automation 5
Discrete vehicles-AGV 42–43
Dispensing 
paint applications 81–83
sealant and adhesive applications 83–85
Dispensing-adhesives, sealants 49, 57
Documentation 142–143, 174, 217–218
Downtime 37, 51, 106, 127–128, 129, 130, 136, 143–144, 151, 171–172, 207, 209, 210, 214, 216–217
Dress package 79

E

Efficiency 106, 130
Effective organisation 192
Electrical and electronics industries, robots 16
Electric drives 9, 13, 20, 21, 59–60, 61
Electronic products 100–101
Employment 17–18
End users benefits, industrial robots 35–38
capital costs reduction 38
health and safety legislation 37–38
increase yield 37
labour turnover and hiring workers reduction 38
material waste reduction 37
minimise floor space 38
operating cost reduction 35
operation and maintenance 36
production output rate 36
product manufacturing flexibility 37
product quality and consistency 36
Equipment, automation systems 40–46
adhesives/sealants 57
arc welding 51–56
automated guided vehicles 42–43
conveyor systems 41–42
cutting and material removal techniques 
polishing and deburring 58
routing 57–58
sawing 57–58
water jet cutting 58
feeding system 43–46
objectives 40–41
painting 56–57
self-guided vehicles 42–43
spot welding 50–51
Error recovery 136, 142, 218
Ethernet 66, 67–68

F

Factory acceptance test (FAT) 139
customer expectations, URS 140–141
project planning 166
Factory automation 5
Failure mode effects analysis (FMEA) 171
Fault finding 142, 218
Feeding equipment system 43–46
bandoliers 46
blow feeders 45
bowl feeders 44–45, 44f
linear feeders 45
magazine feeders 46
Final assembly 14, 16, 64, 122
Final testing 141–142, 216
Financial analysis 153–156
Financial justification 
budgets 160–161
attitude 155–156
competitors 155
customer requests 155
flexibility 154–155
future proofed 155
internal training and ramp-up time 154
labour saving 153–154
technical risk 154
cost savings identification 156–159
development of 159–160
robot benefits 
capital cost 152–153
consistency 150
investment 155
manufacturing flexibility 151
operating costs 149–150
production output 151, 152
product quality 150
quality of work 150
reduce labour turnover 152
reducing material waste 151
rework 150
safety rules 152
space required 153
workplace health 152
workplace safety 152
yield increase 151
Fixtures 37, 42, 43, 62, 64–65, 67, 76–77, 86, 107, 109–110, 122, 123, 126, 128, 139–140, 206, 209, 213
Flexibility 37, 128, 151, 154–155
FlexPicker robot 9–10
Food industry, robots 16
Four-axis robot 24–25, 98–99, 109, 114
Free-issue 137, 211
Functional design specification (FDS) 138–139

G

Gantry 9, 26–27
General Motors 1–2, 4–5, 7–9, 8f, 10, 20, 67–68
Goalpost test 25–26, 29–30, 101
Golden part 143–144
Grinding 15, 87–89
Grippers and tool changers, automation 
balloons 61
Clamshell grippers 60–61, 60f
hydraulics 61
machine tool tending 111–112
palletising 115
pneumatic grippers 61
pneumatic vacuum cups 60
two-jaw gripper 59–60, 59f
vacuum grippers 60
Guarding 
ABB's Safemove 71–72
arc welding 69
doors 70
key exchange system 69–70
laser applications 69
lightguards 70–71
palletising systems 72
scanning area guards 71
training 72

H

Handling and machine tending 
casting 91–92
injection-moulding machines 92–93, 93f
inspection and testing 97–98
machine tools 94–97, 95f
measurement devices 97–98
packing and picking applications 99–100, 100f
palletising 98–99, 98f
stamping and forging 93–94
Hard and soft automation 5–6
Health and safety 37–38, 158
Human machine interface (HMI) 66–67, 124–125
Hydraulics 20, 21, 59–60, 61

I

Industrial robot definition (ISO 8373) 7, 20
Industrial robots 1–2
articulated/jointed arm 22–24, 23f
Cartesian category 26–27, 26f
challenges 2
cylindrical 28
definition 2
electric drives 20, 21
end users benefits 35–38
capital costs reduction 38
health and safety legislation 37–38
increase yield 37
labour turnover and hiring workers reduction 38
material waste reduction 37
minimise floor space 38
operating cost reduction 35
operation and maintenance 36
production output rate 36
product manufacturing flexibility 37
product quality and consistency 36
history 7–8
hydraulics 20, 21
ISO 8373 definition 7, 20
mechanical designs 20
parallel/delta robot configuration 27–28, 27f
pneumatics 21
potential benefits 33–34
reach and working envelope 29
repeatability 29
SCARA configuration 24–26
selection of 31–33
speed 29–30
system integrators benefits 34–35
weight-carrying capacity 29, 30f
working envelope 21–22, 22f
Infeed 114, 115, 120, 124
Inspection and testing applications 97–98
Installation 140–141, 172–174, 215
International Federation of Robotics (IFR) 10
IRB 6 robot 8–9, 9f

J

Justification, cost justification 160–161

K

Kick off meeting 138, 166, 167, 170-171, 212

L

Labour turnover 38, 152, 158
Laser cutting 86–87
Laser welding 80–81, 123
Layer sheets 116, 121
Lean manufacturing 188–189, 192
Lightguards 70–71
Lighting 47–48
Linear feeders 45

M

Machine tool load/unload 15
Machine tool tending 94–97, 95f
benefits 94–95
buffering 113
deburring 95, 113
effectiveness 114
gripping method 111–112
input and output conveyors 96
load capacity 112
maintenance/fixture changeovers 114
objectives 111–112
press brakes 96–97, 97f
reach 96
tool changeovers 96
tool changers 113
unloading/loading operation 111–112
vision system 96
weight-carrying capacity 96
Machine vision 46–47
Magazine feeders 46
Magnetic 7–8
Maintenance 36, 114, 125–126, 171–172, 177–178, 182
Manufacturing automation protocol (MAP) 67–68
Manufacturing strategy 189
Material removal 57–58, 124
Material waste 37, 151
Mean time between failure (MTBF) 34, 106
Mean time to repair (MTTR) 34
Mechanical cutting 85
Metal finishing 15

N

Network 67–68

O

Olivetti SIGMA robot 8–9
Operating costs 35, 149–150
Operating requirements 135–136, 208
Output stations 85, 113, 116

P

Packing and picking applications 99–100, 100f
handling and machine tending 99–100, 100f
primary 117–119
secondary 119–121
vision systems 48
Painting 7–8, 13–14, 15, 21, 24, 37, 41–42, 56–57, 81–83, 123–124, 185
Palletising systems 98–99, 98f
automated pallet dispenser 116
grippers 115
grippers and tool changers 115
guarding 72, 117
handling and machine tending 98–99, 98f
infeed 115
layer sheets 116
pallet stack 116
reach requirement 114–115
throughput 117
weight capacity requirement 115
Parallel/delta robot configuration 27–28, 27f
Part feeding equipment 43–46, 123
Payback–payback period 148, 153, 154–156, 158, 160–161
Payload 32, 101
Personnel protective equipment (PPE) 149–150
Plastic moulding 27, 86, 92–93
Pneumatics 21, 50–51, 58, 59–60, 61, 115, 219
Polishing 58, 89–90
Positioner 77, 108–109
Predelivery tests 139–140
Press shop 14
Primary packing 99–100, 117–119, 126–127
Process automation 5
Product consistency 36, 150
Product manufacturing flexibility 37
Product output rate 33, 36
Product quality 36, 150
Profibus 66, 67–68
Programmable logic controller (PLC) 66–68, 126
Programmable universal machine for assembly (PUMA) 8–9
Process package 82, 111
Product and process innovation 192
Production rate 95, 106, 109–110, 111, 127, 128, 134, 144, 150, 183–184, 186, 209
Programming 13, 14, 66, 67, 69–70, 72, 125, 127, 139–140, 150, 166, 189, 218
Project conception 
state-of-art or immature technology 179
timescale expectations are unrealistic 179–180
unrealistic business case 179
Project initiation 
failure of document requirements 180
failure of equitable relationship 180
poor planning, management and execution 181
roles and responsibilities 181
staff’s lack of involvement 180
unrealistic expectations 180
Project management 138, 212
Project manager 138, 164, 165, 166, 167, 170–171, 212, 213, 215, 218
Project planning 4, 164–167, 181, 212

Q

Quality of work (for employees) 33, 36, 149, 150

R

Reach 29, 96, 101, 114–115
Recruitment 34, 38, 149, 152
Repeatability 20, 21, 22–24, 29, 32, 42, 46, 49, 50, 51, 57, 78, 79, 83, 91, 96–97, 102, 105, 207
Return on Investment (ROI) 33, 38, 130
Rework 35, 78, 82–83, 150, 157
Robot polishing 89–90
Robotics, three laws 6
Robot performance 28–31
Robots 
automation 4–6 See also (Automation)
description 6
development of 
automotive components 15
automotive industry 11–15
electrical and electronics industries 16
food industry 16
future aspects 16
employment 17–18
financial justification 
capital cost benefits 152–153
consistency 150
investment 155
manufacturing flexibility 151
operating costs 149–150
production output 151, 152
product quality 150
quality of work 150
reduce labour turnover 152
reducing material waste 151
rework 150
safety rules 152
space required 153
workplace health 152
workplace safety 152
yield increase 151
industrial robots 1–2 See also (Industrial robots)
challenges 2
definition 2
history 7–8
ISO 8373 definition 7
laws of 6
scope 2–4
service robots 6
Robot structures 21–28
Routing 15, 57–58, 63, 85, 124, 126–127

S

Safemove 71–72
Safety 37–38, 69–72, 124–126, 137, 152, 158, 173, 186, 211
Safety rules 152
Save space 34, 38, 149, 153
Scope of supply 137–143, 211–218
Scrap 35, 40–41, 150, 157
Sealing 13, 14, 81, 121
Secondary packing 99, 117, 119–121
Selective compliance assembly robot arm (SCARA) 8–10, 24–26, 25f, 28–29, 32, 65, 100–101
Self-guided vehicles 42–43
Service robots 6, 7–8
Simulation 
discrete event simulation 127–128
kinematic simulation 127
Single-axis positioner 53, 53f, 108–109
Site acceptance test (SAT) 141
customer expectations, URS 141–142
project planning 166
Soft automation 5–6
Speed 5–6, 8–9, 20, 24–25, 27–30, 31, 32, 38, 41–42, 47, 51–52, 65, 71–72, 78, 79–80, 83, 84–85, 86, 89, 92–93, 98, 99, 100–101, 120, 126–127, 152
Spot welding 7–8, 11–12, 12f, 20, 21, 29, 50–52, 78–80, 123
automotive industry 79–80, 80f
benefits 78
dress package 79
packing and picking applications 79
process equipment 50–51
repeatability and flexibility 79
Stamping and forging 93–94
Standby 142
Start of production (SOP) 164–165, 166
System controls, automation 40, 66–68
HMI 66–67
MAP 67–68
networks 68
PLC 66
System integrator 2, 3, 34–35

T

Throughput 42, 65, 76, 77, 82, 92–93, 99, 113–114, 115, 117, 118–119, 120, 121, 136, 141, 150, 153, 154, 174–175
Tool changers 59–62, 113, 115
Tooling/fixturing, automation 62–64
Training 72, 142, 154, 166, 182, 218
Turn-key 137, 141–142, 181, 211
Turntable 53–55, 76, 77, 79–80, 107, 109, 125
Two-axis positioner 53–55, 54f, 109
Two jaw gripper 59–60
Two station 53–55, 54f, 76, 108–109, 110–111, 110f

U

Unimate 7–8, 7f, 22, 23f
Unimation 7–9, 7f, 22, 23f
User requirements specification (URS) 134
automation concept 135
buy-off criteria 141–142, 143–144
commissioning 140–141
concept of automation 207–208
controls and HMI 210
covering letter 144–145
current welding operation 206–207
cycle time and availability 209
delivery 140
documentation 142–143
enclosure 210–211
factory acceptance tests 140–141
fixtures 209
free-issue 137
functional design specification 138–139
golden part 143–144
installation 140–141
issues 136–137
management 138
manufacture and assembly 139
multiple personnel 143
performance parameters 143
predelivery tests 139–140
products 208
quality services 138
request for quotation letter 201
requirements 135–137
safety requirements 137
scope of supply 
CFAT 213
cycle time calculations 213–215, 216–217
delivery 215
design 212
documentation 217–218
free issue 211
installation and commissioning 215
installation requirements 215
manufacture and assembly 212–213
pre-delivery tests 213–215
project management 212
safety 211
services 211
site acceptance test 216–217
spares and service contract 218
testing and buy-off 216
training 218
site acceptance test 141–142
standby 142
tolerances and quality 208–209
training 142
URS 143
warranty period 143
welding equipment 209–210

V

Vacuum cups 51–52, 59, 60, 94, 99, 118
Vendor 134, 135, 136, 137, 138, 139–142, 143, 144–145, 206, 207, 208–209, 211, 212, 213–214, 215, 219
Vendor selection 134
Vibratory bowl feeders 44–45, 44f
Vision systems, automation 
back lighting 48
barcode reader 49
depth of field 47
field of view 47
fixture 49
focal length 47
lighting 47–48
machine vision 46–47
operations 47
packing applications 48
quality control 49
reliability 48

W

Warranty 143, 219
Water jet cutting 86
Weight-Load carrying capacity 20, 21, 31, 61
Weld guidance 48, 76
Welding 
arc welding system 77f
benefits 77–78
multiaxis positioners and vision tracking 77
unloading and reloading operations 76–77
laser welding 80–81
spot welding robots 
automotive industry 79–80, 80f
benefits 78
dress package 79
process equipment 50–51
repeatability and flexibility 79
Weld torch service centre 55f, 111
Working envelope 21–24, 22f, 29, 31, 32, 34, 100–101, 116
World Robotics, International Federation of Robotics 10, 10f, 11, 11f, 17f

Y

Yield 37, 151
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