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Although there has been always existing a strong desire to apply adjustable dynamic electrode force in resistance spot welding (RSW) over decades, technical limitation laid a barrier to its implementation and application. However, with the introduction of servo motor control technology into spot welding gun, this issue will not stay unsolvable any more. After a brief introduction of RSW process and...
Industrial robots offer a cheaper yet more flexible alternative to the CNC machines in the cleaning and pre-machining applications of automotive aluminum castings. But the low stiffness has limited the application of industrial robots to the machining tasks with very low precision requirement. This paper presents a practical method to compensate the robot deformation caused by the machining force...
Although robotics based flexible automation is considered as an ideal solution for foundry pre-machining operation, very few successful installations have been seen due to many major challenges involved in robotic machining processes using conventional articulated robot, such as limited material removal rate, low surface quality, and chatter/vibration. This paper explains the reasons for low surface...
A hybrid mechanism is a configuration that combines the motions of two characteristically different electric motors by means of a mechanism to produce programmable output. In this paper, by means of establishing mathematic model for the influence of output accuracy of a planar hybrid five-bar mechanism affected by manufacturing error of link length, the sensitive coefficient of manufacturing error...
A force-control-based robotic machining system is introduced in this paper. Firstly, the machining process is analyzed. Three key technologies: lead-through teaching, path learning and template-based automatic program generation are described and then a fast programming method is proposed. It is proved practically that it can shorten the programming time from days to minutes in robotic machining programming.
In this paper, critical issues and various methodologies to improve resistance spot welding performance with electrically driven welding clamps controlled by industrial robots are presented, where previous research on position and torque control of electric servo motor is expanded into servo gun based spot welding application and particular attention is paid to the accurate output of clamping force...
This paper presents the critical issues and methodologies to improve robotic machining performance with industrial robots. A complete solution using active force control is introduced to address various issues arouse during the robotic machining process. Programming complex contour parts without a CAD model is made easy using force control functions such as lead-through and path-learning. The problem...
One of the most challenging issues in robotic machining process is to know the vibration/chatter characteristics. To reduce the trial and error frustration, this paper presents the underline mechanism and theoretical analysis to provide physical understanding for the onset of chatter problem and principles to prevent that. First, the cutting force model and robot structure model are established for...
This paper presents engine piston installation using industrial robots. Because the current manual and hard automation engine piston installation systems are either labour intensive or inflexible and costly, the three-robot and two-robot piston installation systems are developed and investigated. The robotic piston installation process is simulated. A robotic piston stuffing gripper with ring detection...
An self-tuning PI control with anti-windup scheme for the force regulation in robotic machining process is proposed in this paper. The experimentally identified robot dynamic model and nonlinear process model are used in the control algorithm design and simulation. Both the PI controller gains and the exact linearization procedure for the nonlinear process model are continuously tuned based on the...
Cast aluminum wheels must be deburred and polished before chrome plating operation. Manual deburring and polishing is tedious and monotonous. Industrial robots are attracting more and more attention for the deburring applications. However, Each wheel path program was taking eight to ten weeks to create because the position and orientation of the deburring tool must be accurately identified based on...
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