This diploma thesis deals with the design of a virtual model of a robotic workplace. Robot and robotic workplaces are researched. Further, the design and safety phases of these workplaces are discussed. A conceptual model of the robotic workplace with robot IRB 4400/60 is designed, which is placed in the machine laboratory C1 of the Institute of Production Machines, Systems and Robotics at the Faculty of Mechanical Engineering of the Brno University of Technology. The virtual model is created in Process Simulate 13.0. It is designed to manipulate the dice, weld and operate the vertical machine tool.

This thesis solves design of the pneumobile bodywork designated for robotic manufacturing using curved folding method. The thesis evaluates possibilities of this technology and issue of specific behaviour of CCF geometries. With intention to simplify and speedup the proces of designing, the suggestion of software tool for CCF geometry simulation is proposed. Obtained pieces of knowledge are being used in creating the prototype of designed solution using curved folding.

This diploma thesis is dealt with the virtual commissioning of a palletizing line, which is palletized using an industrial robot. In the theoretical part I describe the applications, divisions and effectors of the industrial robots and the reasons and the benefits of palletizing. Furthermore, the issue of virtual commissioning is described, including sensors, that are served for the proper operation of the workplace and the virtual simulation. In the practical part I describe the future workplace, creating a simulation and the program in the RobotStudio software.

This work deals with the virtual and later real commissioning of the workplace for cold spraying of rotating parts, which is located in the laboratories of the Institute of Materials Science and Engineering, Faculty of Mechanical Engineering, Brno University of Technology. The workplace put into operation in this way serves the employees of the mentioned institute for experimental activities in the field of cold spraying. The theoretical part of the thesis describes all the essentials associated with virtual commissioning and the theory of cold spray. The practical part then deals with the creation of a robotic program, including the user interface, which is used to control the workplace. Part of this diploma thesis is also the realization of the connection between the external motor driver and the robot controller via the PROFINET communication bus.

This diploma thesis deals with the design of robot machining of three-dimensional objects. Used method is Part to tool, in which robot holds the part in its gripper and with stacionary clamped mill, machines the part. Overally three parts for machining are designed, everyone of them shows the different style of machining. Every machining operations are described in details. For their creation was used program Mastercam. Furthermore is described transfer of the data for industrial robot using program Robotmaster and recomanded algorithm for creation of similar tasks. The design of simplified workplace for demonstrative show of the milling of all the parts is also solved.

This thesis demonstrates a Research through Design process for creating user experience design to support users in making sustainable decisions. The research and design were carried out in the context of industrial robot operating software, using ABB's RobotStudio as the design basis. After specifying the scope of sustainability in this paper to energy consumption, the main research question is: How might UX design facilitate users to use industrial robots in a sustainable way to reduce energy consumption? The design not only considers the user's experience, but also considers the business profit needs. Therefore, this thesis also conducts research from the perspective of economic sustainability. Theories such as the Kano model, user pleasure, and loss aversion are used. The design result is a redesigned UI prototype based on the future vision of RobotStudio. Eco-feedback and optimization proposals are used to present energy efficiency in terms of business profit, so that users can intuitively see the results of their actions on the interface. Limitations and future research considerations are further explored.

A theoretical and experimental study of mechanical properties of electrical cables with multi order helical structure has been performed. Relations between applied deformations and local strains in the first order helical structure have been developed. The model is then generalized with a hierarchical approach where the strains at any order helical structure are expressed as functions of strains in the upper order helix under the assumption that all components are sticking to each other. The force balance between the strains and the friction forces is considered. When the cable is exposed to small bending curvature, the slippage of the component is prevented by the frictional force. At this stage, the components of the cable behave as solid beams. Slippage occurs between the components when the tensile force in the components overcomes the frictional force. This state occurs at sufficiently large bending curvatures and results in a variable bending stiffness varying with the magnitude of the applied bending curvature. The response of the cable to pure bending is measured and the data is evaluated using the theoretical model described above. Magnitudes of un- known properties of the cable are estimated by comparing the theoretical and experimental data. To utilize the model in terms of life time estimation, a number of parameters were suggested to relate the mechanical properties of the cable to wear and fatigue. A parametric study has been done to investigate how these parameters are affected by changing cable properties or the loading condition. / QC 20101203

Diese Dissertation befasst sich mit der sensorgeführten Regelung von Industrierobotern zur Konturverfolgung. Beispiele dafür sind das robotergestützte Nähen, Entgraten oder das Auftragen von Dichtmasse entlang von Schweißnähten. Beim Nähen und Entgraten müssen während der Verfolgung der Kontur bestimmte Kontaktkräfte an möglicherweise nachgiebigen Werkstücken eingehalten werden. Dabei ist es in modernen Fertigungsprozessen wichtig, die Bewegung des Roboters mit wenig Einrichtaufwand vorzugeben. Dazu werden Sensorsysteme eingesetzt, die Bildinformationen und Kraftmessungen verarbeiten, um den Roboter mit gewünschter Kontaktkraft entlang sichtbarer Konturen eines Werkstückes zu führen. Der Fokus dieser Arbeit ist die Fusion der Sensordaten, um die Vorteile der einzelnen Sensoren in einer Aufgabe zu vereinen. Es werden Messwerte eines Kraft-Momenten Sensors, einer Kamera, eines Beschleunigungssensors und der kartesischen Position und Orientierung des Roboters verwendet. Zuerst wird die Berechnung der kartesischen Roboterposition untersucht. Es wird ein Beobachter vorgestellt, um unter Verwendung eines Beschleunigungssensors die Präzision des Positionssignales zu erhöhen. Anschließend wird das Kamerasystem untersucht und ein Verfahren vorgestellt, um Geschwindigkeit, Position und Orientierung des robotergeführten Werkzeuges entlang der Kontur vorzugeben. Danach wird auf die Ermittlung von Kontaktkräften eingegangen, wobei die Kompensation von Trägheitskräften mittels Beschleunigungssensoren untersucht wird. Der letzte Abschnitt befasst sich mit der Verbindung von bildgestützter Konturverfolgung und Kraftregelung an nachgiebigen Werkstücken. Durch die Nachgiebigkeit des Werkstückmaterials verformt sich die Kontur bei Kontakt. Durch bildgestützte Konturverfolgung wird eine Anpassung an diese Verformung vorgenommen -- somit besteht über die Verformbarkeit des Werkstückes eine Kopplung zwischen den beiden Regelkreisen. Diese Kopplung wird gelöst, indem auf Basis eines dynamischen Modells der Umgebung eine Kompensation der Werkstückverformung berechnet wird. Die Modellparameter zur Kompensation werden durch online Identifikation ermittelt. / This thesis focuses on the sensor-guided control of industrial robots for contour-following. Examples include the robot-guided sewing, grinding or the application of sealant along weld seams. Grinding and sewing require a certain contact force while following a countour of a workpiece, whereas the worpieces might be compliant. Modern production processes require a fast and simple way to set up the motion of the robot for the required task. Therefore sensor systems are used, which process visual and tactile information to guide the tool at a desired contact force along visible contours of a workpiece. The focus of this work is the fusion of sensor data, used to benefit from the advantages of each of the individual sensors in one control scheme. I combine the measurements of a force-torque sensor, a camera, an acceleration sensor and of the Cartesian position of the robot. First, I introduce details on the calculation of the Cartesian robot position. I present an observer-based structure that uses an acceleration sensor to improve the precision of the robot position signal. Then, I analyze the camera system and present a control structure that adapts the position, orientation and velocity of the robot-guided tool along the contour. Thereafter, I show details of force measurement, whereas I compensate for inertial forces using an acceleration sensor. The last chapter addresses the combination of visual contour-following and force control on compliant workpieces. Under a certain contact force, the workpiece deforms due to its compliance. The position and orientation then is adapted to this deformed contour by visual control -- hence, there is a coupling between force and visual control. This coupling is solved by compensating for workpiece deformation using a dynamic model of the environment. The environmental parameters for compensation are identified online.

Les robots industriels représentent un moyen de production sophistiqués pour l'industrie manufacturière d'aujourd'hui. Ces manipulateurs sont plus agiles, plus flexibles et moins coûteux que les machines-outils spécialisées. L'exploitation de ces avantages fait l'objet d'une demande croissante de l'industrie. La dynamique de ces manipulateurs est soumise à des nombreuses sources d'imprécision. En effet les défauts de la chaîne de transmission, ou encore les éléments de liaisons peuvent être le siège de déformations et de vibrations dégradant sensiblement leur précision. Ces phénomènes physiques sont d'autant plus difficiles à compenser que seul un sous ensemble des états du système est mesuré par les codeurs moteurs. La structure de commande industrielle actuelle d'un robot n'agit donc pas directement sur ces phénomènes. Il est nécessaire alors de progresser sur le front de l'amélioration de la précision par l'adaptation de la commande à ces nouvelles exigences. Un état de l'art met en évidence un manque de travaux qui traitent de l'élaboration d'anticipations adaptées aux axes d'un robot et intégrant les phénomènes de déformation. En outre, la planification de trajectoire n'est classiquement pas remise en cause et peu évoquée. Elle représente pourtant un moyen d'action éprouvé afin d'améliorer les performances dynamiques en suivi de profil. L'approche proposée dans ce mémoire se veut une alternative à ces méthodes. Elle est basée sur une exploitation d'un modèle dynamique représentatif et détaillé. Il intègre les principaux phénomènes physiques mis en évidence tels que les effets de la gravité, les systèmes mécaniques de compensation, les forces de frottement et la flexibilité articulaire. Cette modélisation associée à des méthodes d'identification expérimentale est exploitée afin de déduire une structure de commande. Elle permet la réduction des déformations élastiques et des vibrations par une action sur la précommande et sur la loi de mouvement adaptée. Ainsi, nous introduisons une méthode d'estimation non asymptotique appliquée en robotique, afin d'estimer rapidement les paramètres vibratoires de ce dernier et contribue à une réactualisation des modèles exploités. Des résultats expérimentaux montrent que cette méthodologie mène à une amélioration des performances de positionnement par rapport à la commande industrielle. / Anthropomorphic robots are widely used in many fields of industry to carry out repetitive tasks such as pick and place, welding, assembling, and so on. Due to their flexibility and ability to perform complex tasks in a large workspace, industrial robots are finding their way to realize continuous operations. Then, high level pose accuracy is required to achieve a good path tracking. Unfortunately these systems were designed to have a good repeatability but not a good accuracy. The dynamics of these manipulators is subject to many sources of inaccuracy. Indeed, friction, kinematic errors and joint flexibilities may be the seat of deformation and vibration which degrade the position performance. These physical phenomena are even more difficult to manage even only a subset of states of the system is measured by motor encoders. Hence, the structure of current industrial control does not act directly on these phenomena. Nevertheless, there is a growing interest from industry for an improved path tracking accuracy with standard robots controllers. A state of the art highlights a lack of works considering the development of expectations adapted to the axes of an industrial robot and incorporating deformation phenomena. The approach proposed in this PhD. Thesis is meant to be an alternative to such techniques by proposing a methodology based on exploitation of detailed physical modeling and associated to experimental identification methods. This model incorporates the main highlighted physical phenomena. It is then exploited to obtain adapted control structures and tuning methods allowing enhancing the system's performance. It is integrated in our trajectory planner in order to realize a compensation scheme of joint errors. Thus, we introduce a new non-asymptotic estimation method applied in robotics, to on-line estimate the vibration parameters and to update operated models. Experimental results show that the proposed methodology leads to an improved motion control of the point-tool.

The aim of this thesis is to automate the depowdering step in binder-jet additive manufacturing using KUKA kr6 robot. The major tasks involved in this thesis work are commissioning of the KUKA kr6 robot, plan the actions required for automation process of binder jet considering the scaling factor of green bodies. For this purpose KUKA robot with a standard KUKA compact controller (KRC4) and KUKA system software 8.3 (KSS) has been used. In Peter Corke Matlab toolbox (Matlab toolbox), KUKA kr6 robot model has been simulated to understand forward kinematics problem which shows the study the motion of end effector of robot in space for picking process. These transformations between the Joint coordinate systems and Cartesian coordinate systems give the forward and inverse kinematics. Firstly, a KUKA kr6 robot has been programmed in a KUKA Robot Language (KRL) using an algebraic approach with geometric operator to automate the picking process of green bodies. These are fragile bodies thereby many number of tests have been conducted to improve the program. Also additional effort has been placed to test the customized gripper used for the layered pick and place of the components, customized vacuum cleaner for the vacuum cleaning in between the layers and to consider the scaling factor during the sintering step of the binder jet. Finally, KUKA kr6 robot model has been simulated in Matlab toolbox. The picking point in the space has been simulated to study the forward kinematics and to understand how the robot reaches a position and orientation in space. Cartesian trajectory has been simulated. Also, the Jacobian matrix, its rank and determinant are studied to understand the singularities in KUKA kr6 robot, basing on which the thesis work can be continued and enhanced further.