Many high value-machining processes such as milling and drilling have been performed by expensive and dedicated (single purpose) machine tools including CNC machine tools. Industrial robots are a good alternative to these conventional dedicated machine tools due to the robots’ many advantages such as lower cost, larger workspace, higher flexibility of motion, and versatility. Despite these advantages, several barriers prevent them from being widely adopted for high value machining purposes. Two of these barriers are low and nonlinear stiffness of the industrial robot arm and the manufacturing end-users not knowing the capabilities and advantages of robots in machining applications. This research sets out to help a typical machining operator who is not an expert in robotics to learn the capability of a given robotic machining system. This study should help the operator plan robotic machining processes by presenting process models and visual maps for a variety of machining processes and workpiece materials. The study shows in particular how the cutting force and the compliance of a robotic machining system affect machining processes. To meet this objective, we present a framework for planning development for any given robotic machining application domain. First, we select primary performance parameters (including joint torque limit and end-effector positional error) and control parameters (including machining parameters, end-effector position, and workpiece position) for robotic machining. Then, we present the system models and visual performance maps for the functional parameters of robotic machining processes. The focus is on cutting forces for the ten selected machining processes and end-effector positional error of a robotic machining system due to the compliance of a robotic system (i.e., robot manipulator and cutting tool) and joint error (due to sensor error and gear backlash). Finally, we present five applications to show how to use visual maps for preliminary planning scnearios of robotic machining processes. The applications present a step-by-step process for selecting from cutting parameters to workpiece position parameters by utilizing performance requirements and visual maps developed in this research. / text

There are several advantages to replacing CNC machinery with robotic machine tools and as such robotic machining is emerging into the manufacturing and metal cutting industry. There remain several disadvantages to using robots over CNC stations primarily due to flexibility in robotic manipulators, which severely reduces accuracy when operating under high machining forces. This flexibility is dependent on configuration and thus the configuration can be optimised through posture selection to minimise deflection. In previous work little has been done to account for operating frequency and the additional complications that can arise from frequency dependent responses of robotic machine tools. A Fanuc S-360 manipulator was used to experimentally investigate the benefits of including frequency compensation in posture selection. The robot dynamics first had to be identified and experimental modal analysis was selected due the inherent dependency on frequency characteristics. Specifically, a circle fit operation identified modal parameters and a least squares optimisation generated dynamic parameters for a spatial model. A rigid-link flexible-joint model was selected and a pseudo-joint was used to create an additional DOF to accommodate link flexibility. Posture optimisation was performed using a gradient-descent algorithm that used several starting points to identify a global minimum. The results showed that a subset of modal data that excluded the mode shape vectors could be used to create a model to predict the manipulator vibration response. It was also found that the receptance variation of the manipulator with configuration was insufficient to verify the optimisation throughout the entire selected workspace; however the model was shown to be useful in regions containing multiple peaks where the modelled dynamics were dominant over the highly volatile measured data. Simulations were performed on a redundant planar manipulator to overcome the lack of receptance variation found in the Fanuc manipulator. These simulations showed that there were two mechanisms driving the optimisation; overall amplitude reduction and frequency specific amplitude reduction. Using a stiffness posture measure for comparison, the results of the frequency specific reduction could be separated and were found to be particularly beneficial when operating close to resonant frequencies.

There are several advantages to replacing CNC machinery with robotic machine tools and as such robotic machining is emerging into the manufacturing and metal cutting industry. There remain several disadvantages to using robots over CNC stations primarily due to flexibility in robotic manipulators, which severely reduces accuracy when operating under high machining forces. This flexibility is dependent on configuration and thus the configuration can be optimised through posture selection to minimise deflection. In previous work little has been done to account for operating frequency and the additional complications that can arise from frequency dependent responses of robotic machine tools. A Fanuc S-360 manipulator was used to experimentally investigate the benefits of including frequency compensation in posture selection. The robot dynamics first had to be identified and experimental modal analysis was selected due the inherent dependency on frequency characteristics. Specifically, a circle fit operation identified modal parameters and a least squares optimisation generated dynamic parameters for a spatial model. A rigid-link flexible-joint model was selected and a pseudo-joint was used to create an additional DOF to accommodate link flexibility. Posture optimisation was performed using a gradient-descent algorithm that used several starting points to identify a global minimum. The results showed that a subset of modal data that excluded the mode shape vectors could be used to create a model to predict the manipulator vibration response. It was also found that the receptance variation of the manipulator with configuration was insufficient to verify the optimisation throughout the entire selected workspace; however the model was shown to be useful in regions containing multiple peaks where the modelled dynamics were dominant over the highly volatile measured data. Simulations were performed on a redundant planar manipulator to overcome the lack of receptance variation found in the Fanuc manipulator. These simulations showed that there were two mechanisms driving the optimisation; overall amplitude reduction and frequency specific amplitude reduction. Using a stiffness posture measure for comparison, the results of the frequency specific reduction could be separated and were found to be particularly beneficial when operating close to resonant frequencies.

Compared to conventional machine tools, industrial robots offer great advantages such as multitasking, larger workspace, and lower price. However, these advantages of robots are undermined by their high structural flexibility leading to excessive deflections, severe vibrations, and ultimately violating dimensional tolerances and poor surface finish. Modeling the dynamics of robots under machining (e.g. milling and drilling) forces is essential for reducing deflections and vibrations during the process. Although modeling the dynamics of traditional machining systems is a well-studied subject, the existing modeling approaches are not applicable to robotic manipulators because of the posture-dependent dynamics of industrial robots. Within this context, the presented thesis aims to predict the stability of vibrations during robotic machining operations through prediction of posture dependent dynamic behavior of robots. A rigid-body modeling approach is used to identify the dynamic parameters of the robotic manipulator based on least squares estimation method. Next, by adopting a rigid link flexible joint model and employing experimental modal analysis to identify the joint stiffness and damping parameters, posture dependent dynamic response prediction of the robot is achieved. Finally, the posture-dependent milling stability is presented as a function of the predicted tool center point transfer function, spindle speed, and axial depth of cut. A Staubli TX200 robot and a Kuka KR90 robot are used as experimental case studies. / Graduate

Diploma thesis presents a study focused at the current level of industrial robotsand ther applications in the machining process. It presents current technology used in the selected company to produce components for the automotive industry. Based on analysis of the finished products presents the possible ways of alternating the current technology to ensure the required quality of production. This thesis also includes a financial assessment of current technology.

Tesis por compendio / [ES] El mecanizado con brazos robots ha sido estudiado aproximadamente desde los años 90, durante este tiempo se han llevado a cabo importantes avances y descubrimientos en cuanto a su campo de aplicación. En general, los robots manipuladores tienen muchos beneficios y ventajas al ser usados en operaciones de mecanizado, tales como, flexibilidad, gran área de trabajo y facilidad de programación, entre otras, frente a las Máquinas Herramientas de Control numérico (MHCN) que necesitan de una gran inversión para trabajar piezas muy grandes o incrementar sus grados de libertad. Como desventajas, frente a las MHCN, los brazos robóticos poseen menor rigidez, lo que combinado con las altas fuerzas producidas en los procesos de mecanizado hace que aparezcan errores de precisión, desviaciones en las trayectorias, vibraciones y, por consiguiente, una mala calidad en las piezas fabricadas. Entre los brazos robots, los brazos colaborativos están en auge debido a su programación intuitiva y a sus medidas de seguridad, que les permiten trabajar en el mismo espacio que los operadores sin que estos corran riesgos. Como desventaja añadida de los robots colaborativos se encuentra la mayor flexibilidad que estos tienen en sus articulaciones, debido a que incluyen reductores del tipo Harmonic drive. El uso de un control de fuerza en procesos de mecanizado con brazos robots permite controlar y corregir en tiempo real las desviaciones generadas por la flexibilidad en las articulaciones del robot. Utilizar este método de control es beneficioso en cualquier brazo robot; sin embargo, el control interno que incluyen los robots colaborativos presenta ventajas que permiten que el control de fuerza pueda ser aplicado de una manera más eficiente. En el presente trabajo se desarrolla una propuesta real para la inclusión del control de esfuerzos en el brazo robot, así como también, se evalúa y cuantifica la capacidad de los robots industriales y colaborativos en tareas de mecanizado. La propuesta plantea cómo mejorar la utilización de un control de fuerza por bucle interior/exterior aplicado en un brazo colaborativo cuando se desconocen los pares reales de los motores del robot, así como otros parámetros internos que los fabricantes no dan a conocer. Este bucle de control interior/exterior ha sido utilizado en aplicaciones de pulido y lijado sobre diferentes materiales. Los resultados indican que el robot colaborativo es factible para realizar tales operaciones de mecanizado. Sus mejores resultados se obtienen cuando se utiliza un bucle de control interno por velocidad y un bucle de control externo de fuerza con algoritmos, Proporcional-Integral-Derivativo o Proporcional más Pre-Alimentación de la Fuerza. / [CA] El mecanitzat amb braços robots ha estat estudiat aproximadament des dels anys 90, durant aquest temps s'han dut a terme importants avanços i descobriments en el que fa al seu camp d'aplicació. En general, els robots manipuladors tenen molts beneficis i avantatges al ser usats en operacions de mecanitzat, com ara, flexibilitat, gran àrea de treball i facilitat de programació, entre d'altres, davant de Màquines Eines de Control Numèric (MECN) que necessiten d'una gran inversió per treballar peces molt grans o incrementar els seus graus de llibertat. Com a desavantatges, enfront de les MECN, els braços robòtics posseeixen menor rigidesa, el que combinat amb les altes forces produïdes en els processos de mecanitzat fa que apareguin errors de precisió, desviacions en les trajectòries, vibracions i, per tant, una mala qualitat en les peces fabricades. Entre els braços robots, els braços col·laboratius estan en auge a causa de la seva programació intuïtiva i a les seves mesures de seguretat, que els permeten treballar en el mateix espai que els operadors sense que aquests corrin riscos. Com desavantatge afegida als robots col·laboratius es troba la major flexibilitat que aquests tenen en les seves articulacions, a causa de que inclouen reductors del tipus Harmonic drive. L'ús d'un control de força en processos de mecanitzat amb braços robots permet controlar, i corregir, en temps real les desviacions generades per la flexibilitat en les articulacions del robot. Utilitzar aquest mètode de control és beneficiós en qualsevol braç robot, però, el control intern que inclouen els robots col·laboratius presenta avantatges que permeten que el control de força es puga aplicar d'una manera més eficient. En el present treball es desenvolupa una proposta real per a la inclusió del control d'esforços en el braç robot, així com s'avalua i quantifica la capacitat dels robots industrials i col·laboratius en tasques de mecanitzat. La proposta planteja com millorar la utilització d'un control de força per bucle interior/exterior aplicat en un braç col·laboratiu, quan es desconeixen els parells reals dels motors del robot, així com altres paràmetres interns que els fabricants no donen a conèixer. Aquest bucle de control interior/exterior ha estat utilitzat en aplicacions de polit sobre diferents materials. Els resultats indiquen que el robot col·laboratiu és factible de realitzar aquestes operacions de mecanitzat. Els seus millors resultats s'obtenen quan s'utilitza un bucle de control intern per velocitat i un bucle de control extern de força amb els algoritmes Proporcional-Integral-Derivatiu o Proporcional més Pre-alimentació de la Força. / [EN] Machining with robot arms has been studied approximately since the 90s; during this time, important advances and discoveries have been made in its field of application. In general, manipulative robots have many benefits and advantages when they are used in machining operations, such as flexibility, large work area, and ease of programming, among others, compared to Numerical Control Machine Tools (NCMT) that need a great investment to work very large pieces or increase their degrees of freedom. As for disadvantages, compared to NCMT, robotic arms have lower rigidity, which, combined with the high forces produced in machining processes, causes precision errors, path deviations, vibrations, and, consequently, poor quality in the manufactured parts. Among robot arms, collaborative arms are on the rise due to their intuitive programming and safety measures, which allow them to work in the same space without risk for the operators. An added disadvantage of collaborative robots is their flexibility in their joints because they include Harmonic drive type reducers. The use of force control in machining processes with robot arms makes possible to control and correct, in real-time, the deviations generated by the flexibility in the robot's joints. The use of this control method is beneficial for any robot arm. However, the internal control included in collaborative robots has advantages that allow the force control to be applied more efficiently. In this work, a real proposal is developed to include effort control in the robot arm. The capacity of industrial and collaborative robots in machining tasks is evaluated and quantified. The proposal recommends how to improve the use of an inner/outer force control loop applied in a collaborative arm, when the real torques of the robot's motors are unknown and other internal parameters that manufacturers do not disclose. This inner/outer control loop has been used in polishing and sanding applications on different materials. The results indicate that the collaborative robot is feasible to perform such machining operations. Best results are obtained using an internal velocity control loop and external force control loop with Proportional-Integral-Derivative or Proportional plus Feed Forward. / The authors are grateful for the financial support of the Spanish Ministry of Economy and European Union, grant DPI2016-81002-R (AEI/FEDER, UE). This work was funded by the CONICYT PFCHA/DOCTORADO BECAS CHILE/2017 – 72180157. / Pérez Ubeda, RA. (2022). Propuesta de inclusión de esfuerzos en el control de un brazo robot para asegurar el cumplimiento de la rugosidad superficial durante operaciones de lijado en diferentes materiales [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/182000 / TESIS / Compendio