Industrial Robots: From Basics to Practical Application

Part 1 Basic TheoryChapter 1 Introduction to Robots 11.1 Robot Concept 11.1.1 Definition 11.1.2 Appearance Types 11.1.3 Three Principles of Robots 51.2 Types of Robots 51.2.1 Classification by Application Field 51.2.2 Classification by Motion Form 51.2.3 Classification by Control Method 61.2.4 Classification by Mechanical Structure Form 61.2.5 Classification by Coordinate System 71.2.6 Classification by Drive Device 81.3 Composition and Working Principles of Robots 81.3.1 Composition of Robot Hardware System 81.3.2 Composition of Robot Software System 111.3.3 Working Principles of Robots 161.4 History and Development of Robots 161.4.1 History of Robots 161.4.2 Development of Robots 181.5 Key Technologies of Industrial Robots 181.5.1 High-precision Robot Reducers 181.5.2 High-performance AC and DC Servo Motors and Drivers 201.5.3 High-performance Robot Controllers 201.5.4 Robot Operating Systems 201.5.5 Cost Proportions of Each Component in the Entire Robot 211.6 Industrial Robot Industry Chain 211.7 Domestic and International Industrial Robot Manufacturers 21Chapter Summary 22Thinking and Practice Questions 23References 23Chapter 2 Rigid Body Pose Description and Homogeneous Transformation 242.1 Rigid Body Pose Description 242.1.1 Description of Position 242.1.2 Description of Attitude 242.1.3 Description of Pose 252.1.4 Gripper Coordinate System 252.2 Coordinate Transformation 262.2.1 Coordinate Translation 262.2.2 Coordinate Rotation 262.2.3 General Transformation (Translation + Rotation) 282.2.4 Several Special Cases of 3D Coordinate Transformation 292.3 General Formula for Rotation Transformation and Equivalent Rotation Axis and Angle 312.3.1 General Formula for Rotation Transformation 312.3.2 Equivalent Rotation Axis and Angle 332.4 Homogeneous Coordinates and Homogeneous Transformation 342.4.1 Introduction of Homogeneous Coordinates 342.4.2 Rewrite Composite Transformation into Homogeneous Transformation 342.4.3 Three Special Homogeneous Transformation Matrices for Rotation around Coordinate Axes 352.4.4 Homogeneous Rotation Matrices and Translation Matrices 352.4.5 Characteristics of Homogeneous Transformation Matrices 362.5 Establishing the Kinematics of Industrial Robots 362.6 Example Applications of Coordinate Transformation 372.6.1 Coordinate Transformation between Robots and Environment 372.6.2 Coordinate Transformation between Camera Coordinate System and Coordinates 37Chapter Summary 39Thinking and Practice Questions 39References 40Chapter 3 Robot Kinematics 413.1 Link Parameters and Link Coordinate Systems 413.1.1 Concepts of Robot Links and Joints 413.1.2 Link Parameters 413.1.3 Link Coordinate Systems 423.2 Establishing Robot Kinematics Equations Using D-H Method 423.2.1 Concept and Idea of D-H Method 423.2.2 Characteristics of Establishing Link Coordinate Systems Using D-H Method 423.2.3 Transformation between Adjacent Link Coordinate Systems 433.2.4 Further Explanation of Homogeneous Transformation Matrices between Adjacent Link Coordinate Systems 443.3 Forms and Establishment Steps of Robot Kinematics Equations 453.3.1 Forms of Robot Kinematics Equations 453.3.2 Steps for Establishing Robot Kinematics Equations 463.3.3 Points to Note When Establishing Robot Kinematics Equations Using D-H Method 463.4 Establishing Kinematics Equations for PUMA560 Robot 483.4.1 Establishing Coordinate Systems for Each Link of PUMA560 Robot 483.4.2 Filling in the Link Parameter Table 483.4.3 Writing the Homogeneous Transformation Matrix between Adjacent Links 493.4.4 Writing the Kinematics Equations 513.5 Kinematics Equations of Robots 523.6 Inverse Kinematics Problems of Robots 523.6.1 Concept of Inverse Kinematics 523.6.2 Process of Finding Inverse Solutions 533.6.3 Multiple Solutions in Kinematic Inverse Solutions 543.6.4 Points to Note When Finding Inverse Kinematics Solutions for Industrial Robots 543.7 Example of Establishing Robot Kinematics Equations 553.7.1 Establishing Kinematics Equations for RV-M1 Robot 553.7.2 Establishing Kinematics Equations for Bosh’s Four-degree-of-freedom SCARA Robot 58Chapter Summary 61Thinking and Practice Questions 61References 64Chapter 4 Robot Dynamics 654.1 Why Learn Robot Dynamics 654.2 Several Concepts Closely Related to Dynamics 654.3 Establishing Robot Dynamics Equations Using Lagrangian Method 674.3.1 Lagrangian Dynamics Equations 674.3.2 General Steps for Solving Problems Using Lagrangian Equations 684.3.3 Advantages of Solving Problems Using Lagrangian Equations 684.3.4 Single Degree of Freedom – Cart-Spring System 684.3.5 Two Degree of Freedom System – Cart-Spring Pendulum System 694.3.6 Concentrated Mass Double Link System 714.3.7 Two Degree of Freedom Robot Arm (Distributed Mass) 724.4 Establishing Dynamics Equations for Multi-degree-of-freedom Robots 754.4.1 Ideas for Establishing Dynamics Equations for Multi-degree-of-freedom Robots 754.4.2 Dynamics Equations for PUMA560 Robot 754.5 Dynamics Equations for Joint Space and Operational Space 764.5.1 Joint Space Dynamics Equations 764.5.2 Operational Space Dynamics Equations 764.5.3 Operational Torque Equations 764.5.4 Jacobian Matrix 764.5.5 Relationship between End-effector Operational Force and Joint Driving Torque 78Chapter Summary 80Thinking and Practice Questions 80References 81Chapter 5 Trajectory Planning 825.1 Overview of Trajectory Planning 825.2 Basic Principles of Trajectory Planning 835.2.1 Joint Space Trajectory Planning Principles 835.2.2 Rectangular Coordinate Space Trajectory Planning Principles 845.3 Joint Space Trajectory Planning 845.3.1 Cubic Polynomial Trajectory Planning 845.3.2 Quintic Polynomial Trajectory Planning 865.4 Trajectory Planning in Rectangular Coordinate Space 875.5 Continuous Trajectory Recording 90Chapter Summary 90Thinking and Practice Questions 90References 90Part 2 Industrial Robot SystemsChapter 6 Mechanical Systems of Industrial Robots 916.1 Composition of Industrial Robots 916.1.1 Concept and Overall Composition of Industrial Robots 916.1.2 Mechanical Structure 936.1.3 Various Drive Devices 956.1.4 Various Sensors 966.1.5 Various Controllers 976.2 Working Principles of Industrial Robots 986.2.1 Task Analysis 986.2.2 Trajectory Planning 996.2.3 Programming and Debugging 996.2.4 Robot Operation 996.3 Mechanical Structure of Industrial Robots 1006.3.1 Robot Configuration Forms 1006.3.2 Overall Structure and Motion 1016.3.3 Coordinate Structure Forms 1026.3.4 Base and Waist 1036.3.5 Upper Arm and Link Assembly 1056.3.6 Robot Wrist 1056.3.7 Gripper Structure 1066.3.8 Joint Structure Forms 1086.3.9 Common Mechanical Drive Devices in Robots 1096.4 Graphical Symbol Representation of Robot Structures 1116.4.1 Common Symbol Representations 1116.4.2 Examples of Robot Graphical Symbol Representations 1126.5 Main Technical Parameters of Industrial Robots 1126.6 Several Typical Mechanical Structures of Industrial Robots 1156.6.1 Mechanical Structure of RV-M1 Robot 1156.6.2 Mechanical Structure of Bosh’s Four-degree-of-freedom SCARA Robot 1176.6.3 Mechanical Structure of Huibo Modular Robot 120Chapter Summary 124Thinking and Practice Questions 124References 124Chapter 7 Control Systems of Industrial Robots 1257.1 Functions of Robot Control Systems 1257.2 Types of Robot Control Systems 1267.2.1 Classification by Different Controllers 1267.2.2 Classification by Different Drive Devices 1287.3 Structure of Robot Control Systems 1307.3.1 Hierarchical Distributed Control 1307.3.2 Independent Joint Control 1327.3.3 Joint Control 1327.4 Analysis Methods for Robot Control Systems 1347.5 Analysis of Single Joint Position Control Servo System Based on Transfer Function 1347.5.1 Mathematical Model of Robot Joint Control System (Transfer Function Method) 1347.5.2 Analysis of Single Joint Position Control System 1377.6 Examples of Robot Control Systems 1377.6.1 Control System of RV-M1 Robot 1377.6.2 Control System of Bosh’s Four-degree-of-freedom SCARA Robot 1407.6.3 Control System of Huibo Modular Robot 143Chapter Summary 146Thinking and Practice Questions 146References 147Chapter 8 Robot Visual Servo Systems 1488.1 Overview of Robot Visual Servo Systems 1488.1.1 Composition of Robot Visual Servo Systems 1488.1.2 Working Process of Robot Visual Servo Systems 1498.1.3 Types of Robot Visual Servo Systems 1528.1.4 Key Issues in Robot Visual Servo Systems 1548.2 Robot Visual Systems 1548.2.1 Image Acquisition and Processing Process of Visual Systems 1548.2.2 Composition of Visual Systems 1558.2.3 Working Principles of Two Types of Digital Cameras 1618.3 Robot Visual Image Processing 1678.3.1 Objects of Visual Image Processing 1678.3.2 Purposes of Visual Image Processing 1678.3.3 Basic Theories of Visual Image Processing 1678.3.4 Methods of Visual Image Processing 1688.3.5 Basic Methods of Visual Image Processing and MATLAB Programs 1698.4 Robot Visual Image Analysis and Recognition 1808.4.1 Concepts and Common Methods of Image Recognition 1808.4.2 Feature Recognition 1818.4.3 Biometric Recognition Technologies 1818.5 Key Issues in Robot Visual Servo Systems 1838.5.1 Calibration Issues 1838.5.2 Positioning Issues 1878.6 Common Software for Robot Visual Image Processing and Analysis 1878.6.1 Introduction to Common Software for Visual Image Processing and Analysis 1878.6.2 Main Application Scenarios of Robot Vision 1938.7 Examples of Robot Visual Servo Systems 1998.7.1 Composition of Bosh’s Four-degree-of-freedom SCARA Robot Visual Servo System 1998.7.2 Development and Design of Control Program for Bosh’s Four-degree-of-freedom SCARA Robot Visual Servo Control System 204Chapter Summary 205Thinking and Practice Questions 206References 206Chapter 9 Robot Programming 2079.1 Overview 2079.1.1 Significance of Robot Programming 2079.1.2 Functions to be Achieved by Robot Programming Systems 2079.1.3 Types of Robot Programming 2079.2 Teaching Programming 2079.2.1 Types of Teaching Programming 2079.2.2 Process of Teaching Programming 2099.2.3 Basic Functions of Teaching Devices or Software 2099.3 Robot Languages 2099.3.1 Types of Robot Languages 2099.3.2 Development Process of Robot Languages 2109.3.3 Structure and Basic Functions of Robot Language Systems 2159.4 Offline Programming of Robots 2159.4.1 What is Robot Offline Programming 2159.4.2 Comparison between Offline Programming and Teaching Programming 2169.4.3 Structure of Robot Offline Programming Systems 2169.4.4 Main Content of Robot Offline Programming 2169.5 Programming of RV-M1 Robot 2169.5.1 Hardware Composition of RV-M1 Robot Programming System 2169.5.2 Software Composition of RV-M1 Robot Programming System 2179.5.3 Operating Sequence of Online Teaching Programming 2179.5.4 Introduction to Various Button Switches on the Teaching Box 2179.5.5 Online Programming Software – COSIPROG 2199.5.6 Offline Programming and Simulation Software – COSIMIR 2219.5.7 Command System of Mitsubishi RV-M1 Robot 2239.5.8 Example Program 1 of Mitsubishi RV-M1 Robot 2249.5.9 Example Program 2 of Mitsubishi RV-M1 Robot 2259.6 Programming of Bosh’s Four-degree-of-freedom SCARA Robot 2279.6.1 Composition of Bosh’s Four-degree-of-freedom SCARA Robot Programming System 2279.6.2 RBT-4S01S – Functions of Robot Control System Software 2279.6.3 Debugging System for MAC-3002SSP4 Series Servo Motor Control Card 2279.6.4 Process of Teaching Reproduction for Robots 229Chapter Summary 229Thinking and Practice Questions 229References 230Part 3 Practical Applications of Industrial RobotsChapter 10 Practical Applications of Industrial Robot Design 23110.1 Overview of Industrial Robot Design 23110.1.1 What is Design 23110.1.2 Design Concepts of Industrial Robots 23110.1.3 Design Characteristics of Mechanical and Electronic Systems 23210.1.4 Design of Embedded IoT Control Systems 23310.1.5 Design Concepts of Industrial Robot Mechanical Systems 24310.1.6 Design Concepts of Industrial Robot Control Systems 24510.2 Mechanical System Design of Industrial Robots 24610.2.1 Mechanical Structure Characteristics of Industrial Robots 24610.2.2 Drive Devices 24610.2.3 Mechanical Transmission Devices 25510.2.4 Selection of Spatial Coordinate Structure Forms 25610.2.5 Selection of Installation Methods 25710.2.6 Hand Design 25710.2.7 Wrist Design 26010.2.8 Arm Design 26110.2.9 Body Design 26310.2.10 Base Structure of Industrial Robots 26510.2.11 Balance System Design 26710.2.12 Buffering and Positioning Mechanisms 26710.2.13 Material Selection 26810.3 Control System Design of Industrial Robots 26810.3.1 Motion Control Process of Industrial Robots 26810.3.2 Overall Architecture of Motion Control Systems for Industrial Robots 26910.3.3 Structural Design of Industrial Robot Control Systems 27010.3.4 Hardware Design of Industrial Robot Control Systems 27210.3.5 Software Design of Industrial Robot Control Systems 27710.3.6 Intelligent Robot Control Systems 27810.4 Design Examples of Industrial Robots 27810.4.1 Mechanical System of RV-M1 Robot 27810.4.2 Control System of RV-M1 Robot 27910.4.3 Mechanical Structure Design of Huibo Modular Robot 28210.4.4 Control System of Huibo Modular Robot 282Chapter Summary 284Thinking and Practice Questions 285References 285Chapter 11 Applications of Industrial Robots in Intelligent Manufacturing 28611.1 Intelligent Manufacturing Systems 28611.1.1 Definition of Manufacturing Technology 28611.1.2 Development of Industrial Revolution 28611.1.3 Intelligent Manufacturing 28711.2 Cyber-Physical Systems 29211.3 Applications of Robots in Intelligent Manufacturing 297Chapter Summary 301Thinking and Practice Questions 301References 301