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<p>Industrial robots have been used for a long time in the industry. Despite this thedevelopment of advanced force control system using industrial robots is relativelylimited. Using force controlled robot systems expands the possibility of what canbe done with industrial robots.Previously a force feedback system for a standard industrial robot from ABBhas been developed. The system is developed towards the aircraft industry, where amounted drill machine on the robot has to fulfill the requirements in robot drillingin aircraft structures. This thesis presents experimental results and improvementsof this industrial robot system. Mechanical modifications and tests of a new endeffector are analyzed.</p>

Robot manufacturers, like many other manufacturers, are experiencing increasing competition in a global market where one way to confront the challenge is by making the development process more efficient. One way to speed up the time to market for new products is to take advantage of design optimization based on simulation models. By optimizing performance with the help of dynamic simulation, an immense amount of both time and money may be saved. In this thesis, design optimization strategies for industrial robot design are studied. Often, the trade-offs between performance, cost and quality are essential for design decisions. These tradeoffs can be investigated with the help of simulation models. Generating the trade-offs can be both cumbersome and time-consuming, but the process may be partly automated with the help of optimization algorithms. How the optimization problem needs to be formulated to generate the trade-off is discussed in this thesis. Robot design problems usually consist of a mixture of deciding continuous parameters as well as selecting components from catalogs and databases. Hence, there is a need for optimization algorithms which can handle variables of both a discrete and a continuous nature. A new method has been developed to address this problem. The method has also been improved by adding adaptive characteristics for further efficient design optimization. The ideas in this thesis have been applied to both simulation models of conceptual degrees of elaboration as well as simulation models of complete robot systems. An optimization procedure which shows how optimization can be used in the early phases of a development process is developed. The objective of the optimization is to determine optimal gearboxes and arm lengths from an acceleration capability perspective. An optimization based design method for robot drive trains is also presented. For further efficient use of already installed robots the concept of application adapted performance optimization is introduced. This means that the robot control is optimized with respect to thermal and fatigue load for the specific program that the robot performs. The motion program itself, i.e. the path planning, can be optimized at the same time in order to get the most out of the robot.

This thesis deals with the design of a software library for PLC Siemens S7-1200 usable in programming of robotic cell. The theoretical part explains the principle of PLC programming and the configuration of an industrial robot. The practical part presents the design of the software library and then the individual blocks of the library are described. The library contains blocks for PLC and is also supplemented by blocks for HMI. Using the proposed library reduces the time required for programming. The software library allows the creation of a unified structure of control programs within the company. The result of the diploma thesis is a tested software library usable in the field.

The theoretical part deals with the basic division of industrial robots, their structure and working space. It analyzes propulsion using the industrial robots and sensors required to operate in the robot. The practical part describes the design of a mechanical arm for an industrial robot manipulator. The practical part also includes a description of the sensor and a description of the control unit.

Industrial robots are increasingly used within the manufacturing industry, especially in collaborative applications, where robots and operators are intended to work together in certain tasks. This collaboration needs to be safe, to ensure that an operator does not get injured in any way. One of several solutions to this is to use virtual safety zones, which limits the robots working range and area to operate within, and may be more flexible than physical fences. When the robot exceeds the allowed limit of the virtual safety zone, a control system that monitors the robot position, forces to robot to stop. Depending on the current speed and payload of the robot, the initialized stop has a braking distance until the robot has completely stopped. How far the separation distance between human and robot must be, is calculated using ISO-standard guidelines when doing risk assessments. To support affected personnel in their work, an investigation and experimentation of braking distances among several robots has been conducted. These testing experiments have been designed to simulate a collaborative operation which is an excessive risk in a robot cell. The tests have been performed with various speeds and payloads, for comparison between the robot models and for validation against already existing data. The difference with this study compared to existing ones is that several robot axis’ are used simultaneously in the testing movements, which is a benefit since a robot rarely operates with only one axis at a time.  Main results of the performed tests are that the robot doesn’t obtain speeds over 2000 mm/s when axis 1 is not involved, before the virtual safety zone is reached. Axis 1 can generate the highest speeds overall, and is therefore a significant factor of the braking distance. The results and conclusions from this thesis states that these kinds of tests give useful information to the industry when it comes to safety separation distance and risk assessments. When applying the information in a correct way, the benefits are that a shorter safety separation distance can be used without compromising on safety. This leads to great advantages in robot cell design, because space is limited on the factory floor.