What are the applications and important components of industrial robots?
What role does it play in modern industry?
What other application directions will there be in the future?
In this issue of Science and Technology Weekly, reporters interviewed relevant industrial robot companies and science popularization bases, introducing the scientific principles and cutting-edge applications of industrial robots to everyone.
Mr. Lin, the head of the Industrial Robot Technology Application Innovation Science Popularization Base, and Mr. Luo, an engineer, told reporters that industrial robots are now widely used in industries such as automobiles, furniture, building materials, and electrical appliances, engaged in handling, laser, welding, polishing, spraying, stamping, collaboration, and other work. In the science popularization base, you can see industrial robot application workstations that showcase typical application scenarios of industrial robots, including visual application modules, trajectory application modules, palletizing application modules, assembly application modules, etc.
Visual application module
Positioning hands and target recognition in complex scenes
Similar to how humans primarily rely on their eyes to perceive the external environment, vision will also provide perception and decision support for robots, thereby helping industrial robots complete various tasks.
The vision system first collects visual data of the robot's working environment, and then performs calibration of the vision system, especially the 3D coordinate calibration of the vision system on the robot's manipulator and base, to assist the robot in completing tasks. With the continuous iteration and upgrading of AI algorithms nowadays, vision can help robots achieve functions such as anomaly detection, target recognition, color recognition, geometric feature recognition, etc.
Nowadays, vision can assist industrial robots in accomplishing multiple tasks. Used for detecting defects such as scratches, cracks, and dents on the surface of workpieces, as well as measuring the dimensions and deformation of components; For example, it is used for workpiece recognition and sorting, helping robots recognize different types of targets, and simultaneously recognize multiple targets in complex scenes for task allocation and path planning; Determine the three-dimensional spatial coordinates and pose of the target object through the visual system, and guide the robot to perform high-precision assembly operations.
Trajectory application module
Accurately planning paths to control motion patterns
To truly help with work, industrial robots not only need a pair of "sharp eyes", but also "limbs" that can operate accurately.
The industrial robot trajectory application module is an important component for implementing robot motion path planning and control, and it plays a key role in industrial automation production. By relying on industrial robot trajectory programming and key components such as precision reducers and servo motors within the robot body, the robot can determine the motion path of the robotic arm from the starting point to the endpoint, including various forms such as straight lines, curves, and arcs. In addition, it can also perform speed and acceleration control, plan the speed and acceleration changes of the robot on the path, and ensure the smoothness and stability of the motion.
Mr. Luo introduced that the industrial robot trajectory application module has many important application scenarios, and a typical application is robot glue coating in automotive factories. By relying on the robotic arm and trajectory programming of industrial robots, the robots can standardize the glue application for car window glass, achieving the uniformity of glue width and height trajectory, thereby greatly improving the yield rate of car window glass installation. In robot operations such as welding and spraying, trajectory applications also play a crucial role. "Not only in the automotive industry, but also in many home appliance fields, such as the TV we watch in our daily lives, robots need to be used to glue and install the edges of the screen
Stacking application module
Capture, stack, and stack easily, freeing up manpower
Accurate material handling is a major "job" of industrial robots, also known as palletizing. Stacking refers to the process of neatly stacking items onto pallets, pallets, and other carriers in industry. Nowadays, industrial robot palletizing has been widely used in logistics, chemical, food and beverage industries.
Usually, palletizing robots have high precision, high load capacity, and flexibility, and can adapt to materials of different shapes and weights. These robots achieve automated operations through computer programming and sensor technology, accurately grasping materials and placing them in designated positions. This type of robot also needs to be equipped with powerful end effectors, such as grippers, vacuum suction cups, etc., for grasping and placing materials. By replacing the end effectors or adjusting the program, the palletizing robot can adapt to materials of different shapes and weights.
Usually, after the material reaches the robot's grasping position through the conveying system, the robot can obtain the material's position information through vision or other sensors. Subsequently, the robot uses end effectors to grab materials and place them on pallets. Some pallets can also automatically lift and lower during the palletizing process to meet the palletizing needs of different heights. After palletizing is completed, the pallets will be transported to the next process.
In real-life factory scenarios, palletizing industrial robots can collaborate with AGVs (Automated Guided Vehicles) to complete material handling, thereby promoting the unmanned operation of factories. The application scenarios of robot palletizing can include logistics warehousing, improving warehouse management efficiency; Stacking in hazardous environments to protect workers' health; It can also be used in the food and beverage industry for palletizing packaging boxes, bottled items, etc. Taking skincare product palletizing as an example, palletizing robots can assist in the loading and unloading of products on the production line. After the finished products are packaged on the production line, multiple materials need to be sorted and taken off from the conveyor belt, and then wait for the next batch of materials to arrive and execute again. When the palletizing reaches the specified quantity, this work can be completed, "Mr. Luo explained.
Assembly application module
High precision assembly of parts from airplanes to mobile phones
Nowadays, humanoid robots have begun to enter the market and "screw up". In fact, assembly has always been one of the traditional "main businesses" of industrial robots.
Industrial robot assembly is mainly used to achieve high-precision and high-efficiency automated assembly of components in various manufacturing industries. It plays an important role in improving production efficiency, reducing labor costs, and enhancing product quality, and is an indispensable part of modern manufacturing.
Assembly modules often include assembly tables, positioning mechanisms, clamping mechanisms, material blocking mechanisms, etc. With the cooperation of robotic arms, these components can ensure that materials are accurately positioned and fixed during the assembly process. In some complex assembly tasks, multiple industrial robots need to work together to complete the assembly of large components. Industrial robot assembly is usually used in conjunction with PLC (Programmable Logic Controller) to achieve automation control.
The assembly module of industrial robots can be large or small, and can be used for the production of large products such as automotive manufacturing and aerospace; Small ones can be used for the production and manufacturing of electronic products such as mobile phones. The robotic arm of the robot can be configured with different ends according to requirements, thereby achieving different assembly functions.
Mr. Luo introduced, "The assembly process often requires multiple industrial robots to work together in multiple modules. For example, when installing a mobile phone screen, in the early stage, the industrial robot needs to hold materials for cleaning and inspection. After confirming that they meet the requirements through visual inspection, the mobile phone can be assembled
Mr. Luo told reporters that robots are no longer exclusive to standardized factories with high technological value such as mobile phones and cars. He and his colleagues once helped a foreign trade mop factory improve production efficiency. "When installing mops in the factory, it used to require manual removal of Velcro from the material tape and then manual adhesion to the end of the mop. Previously, it was done manually, but now we have helped manufacturers achieve automation in this step
Develop integrated joint module
Realize localization of core functional components
The relevant person in charge introduced to the reporter that in March this year, the company has successfully developed an "integrated joint module" containing a series of core functional components such as "world-class precision and lifespan harmonic reducer" and "high-precision encoder" through independent technological innovation, breaking the monopoly of foreign technology and achieving the comprehensive localization of robot core functional components, paving the way for the large-scale application of robots in multiple fields.
Company Introduction: The integrated joint module integrates various components such as motors (driving devices), reducers (transmission devices), encoders (sensing devices), servo drives, and control software (control devices), integrating three core functions: power output, precision transmission, and intelligent control.
Its technical architecture is divided into three layers, namely the power layer: through independently developed harmonic reducers and high-precision servo systems, torque amplification and dynamic response are achieved; Sensing layer: integrating six axis force sensors and dual absolute encoders, providing real-time feedback on torque, position, and attitude data; Control layer: based on the motion control technology of Infranor Group, multi axis collaboration and edge computing are realized. The collaborative effort of the three-layer architecture can build a "perception decision execution" closed loop to assist robots in accurately completing complex actions.
The integrated joint module of robots can be regarded as the "core hub" of robots, playing a key role in the hardware cost and motion performance of robots. It is cleverly installed at the joints of the robot, which can convert the rotational motion of the motor into the motion of the driving linkage mechanism, providing continuous and stable power for the agile operation of the robot.
Industrial robots are a top choice for migrant workers
Alternative hazardous work: grinding faucets under dust
In addition to minimizing labor costs to the greatest extent possible, industrial robots can also help humans escape from dangerous working environments.
Mr. Luo told reporters that nowadays, the polishing of metal parts such as faucets has basically relied on industrial robots. "In the past, the polishing of faucets would produce a lot of dust, which would cause great harm to the human body. Now, using robots instead of manual labor for fast and standardized polishing has an accuracy deviation of less than one thousandth. The yield rate is even higher than that of experienced masters
Shouldering repetitive labor: repeatedly verifying ATM stability
Mr. Luo believes that another important significance of industrial robots is to help humans break free from tedious and repetitive labor.
An interesting example is that we have collaborated with ATM machine manufacturers to use robots to improve the fatigue test results of ATM machines. "Luo Zijian told reporters that in order to verify the stability of ATM machines, in the past, manual labor was required to continuously insert cards, input buttons, and perform a series of verification operations such as saving and withdrawing money before leaving the factory. These operations must be repeated a certain number of times, and the ATM machine must not have any errors before it can pass quality inspection and leave the factory. To this end, Luo Zijian and his colleagues designed a program for an industrial robot that simulates human actions such as inserting, withdrawing, depositing, and unplugging cards through a robotic arm, ultimately allowing the worker robot to complete the work of a human quality inspector.
Scientists at the forefront of understanding
Humanoid robots and industrial robots
perfect match
Dr. Wu from the Robotics Technology Team at the Institute of Intelligent Manufacturing told reporters that in today's industrial application scenarios, there are still some tasks that industrial robots cannot do and can only be completed manually. For example, in scenarios where flexible objects or objects are prone to deformation, such as the final assembly of household appliances, industrial robots are less commonly used because they require high levels of dexterity, visual perception accuracy, and algorithm model adaptability, and cannot be modeled through a single mode.
For these scenarios, industrial robots will need to better integrate perception, planning, control, and execution through new technologies and large models in the future. In this way, when the robot operates on soft objects that are prone to deformation, it can generate corresponding actions based on the observed deformation of the object, solving actions that traditional robot technology cannot use.
In some factories, humanoid robots have already entered the factory to work alongside industrial robots - how can these two types of robots become harmonious "colleagues"? Wu Hongmin said, "The original intention of manufacturing humanoid robots is to enable them to do more complex tasks like humans. If humanoid robots are only used to do a single fixed task, we may as well use a single arm or dual arm industrial robot, which is more cost-effective and efficient
Dr. Wu stated that most industrial robots are fixed in a certain part of the factory and only responsible for one of their own processes, while humanoid robots enter the factory to work in order to complement industrial robots. In the future, industrial robots will continue to perform processes that require high precision and repeatability; Humanoid robots will mainly deal with production lines that require flexible production due to significant scene changes.
Robot joints
Breaking foreign monopolies
To achieve various module applications of industrial robots, the key is to continuously improve the level of key components of the robot. The most critical core components in industrial robots are servo motors, precision reducers, etc. In each joint of the robot, there are servo motors and precision reducers to help the robot achieve smooth and steady operation of each action.
Servo motor:
One of the core functions is to achieve high-precision position control. Through feedback devices such as encoders or rotary transformers, the motor can monitor its position in real time and provide data feedback to the control system. The control system adjusts the motion of the motor based on the deviation between the target position and the actual position, thereby achieving precise position control.
Precision reducer:
Capable of achieving complex motion control of robots, supporting robots to complete tasks such as multi axis linkage and trajectory tracking. By precisely controlling the motion of each joint, robots can achieve complex actions such as welding, spraying, assembly, etc.
The person in charge introduced to the reporter that the company's core components such as harmonic reducers, encoders, and six axis force sensors have achieved 100% independent research and development. Compared with imported solutions, the cost has dropped by 50%, making China's robot joint modules independently controllable in core technology and possessing the core strength to compete with international giants. At the same time, the integrated joint module uses high-performance frameless torque motors with 3.5 times overload capacity, smooth operation, small current fluctuations, and more precise and safe force control. Equipped with high-precision dual absolute encoders, the output accuracy is high, and the repeated positioning accuracy is as high as 0.003 °, meeting the stringent requirements of high-end manufacturing for robot performance. The module adopts a large hollow design, which not only meets the requirements of central wiring, but also makes the joint structure more compact and the volume smaller, effectively reducing the weight of the robot joint module, ensuring the robot's load-bearing ratio, and enabling it to adapt to more diverse work scenarios and task requirements. The module also uses high-precision, long-life, high rigidity, and low-noise harmonic reducers, and is equipped with high-precision sensors to monitor the module's heating situation in real time, ensuring long-term stable operation.