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Robotlu boyamada bir simulasyon yöntemi

Başlık çevirisi mevcut değil.

  1. Tez No: 75207
  2. Yazar: EMİN TAHRALI
  3. Danışmanlar: YRD. DOÇ. DR. A. COŞKUN SÖNMEZ
  4. Tez Türü: Yüksek Lisans
  5. Konular: Bilgisayar Mühendisliği Bilimleri-Bilgisayar ve Kontrol, Computer Engineering and Computer Science and Control
  6. Anahtar Kelimeler: Belirtilmemiş.
  7. Yıl: 1998
  8. Dil: Türkçe
  9. Üniversite: İstanbul Teknik Üniversitesi
  10. Enstitü: Fen Bilimleri Enstitüsü
  11. Ana Bilim Dalı: Kontrol ve Bilgisayar Mühendisliği Ana Bilim Dalı
  12. Bilim Dalı: Belirtilmemiş.
  13. Sayfa Sayısı: 85

Özet

ÖZET Robotlar endüstriyel boyama uygulamalarında çokça kullanılmalarına rağmen, uygulama alanları, önceden programlanmış standart komponentlerin boyanmasıyla sınırlıdır. Bu tür ekipmanlar düşük sayıda ya da tek seferli boya geçişinin yapılması gereken ve değişik şekildeki parça sayısının çok fazla olduğu, programlama maliyetlerinin çok yüksek olduğu durumlarda verimli olarak kullanılamamaktadır. Bu tür problemlerle çeşitli endüstrilerde çokça karşılaşılmaktadır. Yapılan bu çalımada endüstriyel robotlarda boyama uygulamaları için bir simülasyon yöntemi uygulanmıştır. Bu simülasyon yöntemi yardımıyla belirli boyama yörüngeleri için boyanın kaplama kalınlıkları hesaplanabilecektir. Aynı zamanda bu simülasyon sayesinde her bir boyama yörüngesi için boya kalınlıklanndaki değişimler, süreksizlikler, gözlemlenebildiği gibi, boyama hızlarının profili ve bu hızlardaki süreksizlikler de gözlemlenebilecektir. Bu simülasyon yöntemini geliştirebilmek için literatürede varolan matematiksel modeller incelenmiş, bu modellerden faydalanılmış, ancak bu modellerde bulunan karmaşık matematik ifadeler yerine simülasyon modelinin sonucunda elde edilen daha basit yöntemlerle boya kalınlığı hesaplanmıştır. Bu modelde, boyanacak yüzey belirli noktalara ayrılmış, ve her noktada sprey içinde kaldığı sürece, boyanın dağılım fonksiyonunda verilen ifadesine göre kümülatif toplamı alınmıştır. Böylece teorik olarak integral ifadeleri bulmak yerine, pratikte yüzey üzerinde biriken boyanın miktarı toplanarak, oluşacak boya kalınlığının belirlenmesi yoluna gidilmiştir. Simülasyon Matlab ortamında 5.0 versiyonu kullanılarak gerçekleştirilmiştir. Bu simülasyon yöntemi Altınay firması tarafından geliştirilmiş olan cam tuğla boyama uygulamasına yönelik olarak hazırlanmıştır. Bu simülasyon aynı zamanda, cam tuğla boyama sistemi için bir off-line programlama tool'unu da içermektedir. Boyama sisteminde varolan bütün ekipmaların konumları, robotun ivmeleri ve hızları parametere olarak girilmekte, sonuç olarak istenen boyama konumlan ve boyama yörüngeleri elde edilebilmektedir. vııı

Özet (Çeviri)

SUMMARY A SIMULATION METHOD FOR ROBOTIZED PAINTING According to the statistics“World Industrial Robots 1997”published by The International Federation of Robotics IFR, the operational stock of robots at end 1996 is 562.085. 9.792 of them is in the painting application area with the percentage of %1.7. Robotic Painting Systems are used in several industrial branches all over the world. The branches known up to now are as follows: primarily automotive, then ship building, aircraft building, engine block production, woodwork and furniture, leather, plastic, domestic electrical appliance, ceramic and most recently glass industry. There are several reasons, for using robots in painting applications. We can classify them into three main groups : a) Job humanization : Work in a paint shop is physically strenuous and detrimental to health. Automatization of this job serves to shifting of workers from toxic and harmful environments to safe working conditions. b) Reduction of paint material : Reducing the overspray lessens the environmental impact of paint shop operation. In addition to this, cost reduction, reduced finishing and booth maintenance, reduced energy requirements are the other results of material savings. c) Improvement and stabilization of the coating quality. [2][7] Despite the benefits mentioned above, it's not always feasible to use a flexible- robotized system for every type of application. You have to choose of three spray painting methods :. Manual. A human operator with spray gun.. Hard automation. Spray guns affixed to stationary gun arms or systems such as reciprocators, spinning guns or two- or three-axis positioners.. Robot. Generally a six-axis programmable device capable of complex arm and wrist motion. We can state the necessary criteria to decide between them as follows : Object shape, object variety, cycle time, paint savings, coating material compatibility, load restrictions, painting speed, and capital and operating costs. A special application of painting, glass brick painting is a sub-process in the glass brick production. In this process, the four sides, except the back and front side, will be painted with a water based (aqurilic) painting material. The sides, which will be IXpainted are normally invisible and will be coated with plaster in the construction. There are three reasons for coating the glass brick with paint: 1. The primary and main reason is that to form a protective area between the glass and plaster to prevent the chemical reaction between glass and plaster. 2. To make a layer that the plaster can adhere, because the glass surface is smooth and even. 3. Decorative purposes, these surfaces are not directly visible. However the reflection of a painted inside view is more aesthetically than viewing the gray plaster. In the R&D studies, made for painting glass bricks with different dimensions under the restrictions mentioned above the following decisions had to be done : The painting trajectory must be calculated, the kinematic structure for following this trajectory continuously must be developed, the total cycle time according to speed must be calculated. As a result of this research, it was seen that a robotized solution to this painting problem is best suitable. Once decided to develop a robotized solution, some topics have to be studied carefully: Robot type selection, deciding on the number of robots to be used, conveyor, part fixture and indexing mechanisms, spray booth design, design of robot hand and paint gun mounting, determining the work envelope, studies for obstacle avoidance and collision avoidance, programming of painting trajectory: point to point programming, lead-through programming, off-line programming, paint gun cleaning, etc. The painting parameters which must be taken into consideration are as follows: Atomization air, fan air (shaping air, fan shape), paint flow-rate (fluid flow-rate), distance the of paint gun from the part to be painted, robot speed, viscosity of fluid. After all these studies and research, it has been decided on the best suited robot type, number of robots, control architecture, the mechanical structure of robot hand, it was determined from which components and subsystems it must be composed. The system which is developed in Altinay, Inc. constitutes of several modular subsystems. We classify this subsystems in each level as follow:. Mechanical Level :. Glass Brick Transferring System,. Rotating System,. Indexing System. Robotized Painting System. Software and Control Level. System Software: It provides the control for the whole system except the robots, and it manages the communication btw. the system and the robots.. Robot Software: Includes the program developed to control the movements of the SCARA robots and the communication procedure btw. the system software and the robots.Interface Level. System user interface. Robot hand held terminals Figure 1 System components and their interactions Robotized Painting System, provides that the glass bricks are painted with equal paint distribution and in the desired trajectory. While doing this the two sides which are not to be painted must be protected against paint. After the painting operation, the bricks must be put on the drying line. For meeting all these requirements a specialized robot hand was designed. This hand has two servo axis, and two pneumatic axis, equipped with electro, servo-motors, pistons and sensors. These scara robots have three axes, except the two axes in the hand. So these robots are a planar working system. Two of these axes are for positioning in the x-y plane and an axis is for orientation in that plane. As known in spatial systems, three axes (x, y, z) are for positioning in the space, and three (a, P, x) for orientation. In planar systems x,y are variables, z=constant, a variable, p,x= constant. In the robot's hand, two servo axis are for rotating the glass bricks with a determined speed, with aim of providing desired paint-coverage.The two pneumatic axis are for protection of the two sides of the brick against paint. With this specially designed hand-tool, the main special feature of this system that differs from the others is that materials to be painted are held in the robot's hand, and painting guns are fixed. In the systems examined yet, the painting-gun is placed in the robot's hand and, materials are indexed or stationary. This is because of the materials to be painted are small in dimensions (max. 240x240 mm.) and the opposite four sides will be painted. And another restriction on that system is that the painting gun must always be perpendicular to the painting surface for equal paint-distribution. If in this system the painting-gun were in the hand, the robot had to follow a wide and very complex trajectory, or extra servo axis and extra mechanical designs had to be added to the system for rotating the brick. And with such a solution the system is taken away from simplicity in violation with the main reason, and the system will get closer to hard automation. The difficulty on this system is that extra care must be taken for sealing. XIIn this system 4 bricks can be painted simultaneously. Each robot paints two bricks, and there are two robots in the system. The reason is reliability. Normally a robot working with maximum speed, can support all the system. However the glass brick production is uninterruptable and the production rate is too high. The robots must be stopped at different times with several reasons such as cleaning or repairing. So two robots are used in the system. While working normally these two robots can support the system with %40 of maximum speed. With the operations in low speed-rate, also the systems mechanical life-time is increased. Although robots are extensively used in industrial spray painting, the range of application is restricted to situations in which the equipment is used to paint a small number of preprogrammed standard components. Such equipment cannot be used economically to paint small or even single runs in situations where the number of components is very large because of the prohibitive cost of the programming involved. There are many situations in different industries like shipbuilding, automotive, construction, etc. The purpose of this study is to extend the range of application to spray painting of curved surfaces. To generate a product model for this process, we need to find suitable trajectory for the robot tool center (which is a spray gun) such that every part of the surface receives a layer of paint whose thickness and quality lies within specified tolerances. This tool will form the basis for a graphical painting simulator which can be used to investigate various strategies for painting a variety of surfaces. Knowledge gained from the investigations can be used to design algorithms for predicting optimal or suboptimal tool center trajectories for painting a given structure. This study is on examining the paint coverage and paint thickness, and programming this programming this system off-line. As a result of this study only the glass brick sizes will be entered as a parameter, and than simulation of working trajectory, and simulation of painting application through mathematical modeling of painting will be calculated. To do this we need to make an accurate mathematical model for the spraying process, which can be used to calculate the surface coverage for a given motion of the tool center. We then need to find algorithms which will enable us to find good task curves for a given surfaces so that the coating quality criteria are satisfied globally. An elliptical cone containing the an aerosol consisting of small paint particles suspended in air is ejected from the spray gun. The geometry of this cone is shown below : XIIFigure 2 Showing the geometry of the spray cone If we consider to paint a long strip on a flat plate using a spray whose axis u3 is perpendicular to the plate and whose height z above the plate kept constant. The other two axes ul and u2 are kept fixed in space and the spray gun moves parallel to u2 with constant speed V. We suppose that outer limits of the spray in the direction of ul subtend an angle 201 at the tool center. For commercially available sprays,this angle is typically 45 or 60 degrees. The angle subtended by outer limits in the direction of u2 tends to be much smaller, so that elliptical cross sections of the cone tend to be fairly eccentric. These paint coverage model is applied to glass bricks, for two special painting trajectory: These trajectories, and resultant paint coverage profiles extended out by the simulation is below: i 0 100 200 300 400 600 TOO Figure 3 The ideal paint trajectory and corresponding coverage profile XIIItm ISO z O 100 3D 300 100 5(D GtO TO Figure 4 The simple paint trajectory and corresponding coverage profile XIV

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