1,720,967 research outputs found
Energy-optimal layout design of robotic work cells: Potential assessment on an industrial case study
No full textThis paper presents a new method for optimizing the layout position of several Industrial Robots (IRs) placed within manufacturing work-cells, in order to execute a set of specified tasks with the minimum energy consumption. At first, a mechatronic model of an anthropomorphous IR is developed, by leveraging on the Modelica/Dymola built-in capabilities. The IR sub-system components (namely mechanical structure, actuators, power electronic and control logics) are modeled with the level of detail strictly necessary for an accurate prediction of the system power consumption, while assuring efficient computational efforts. Secondly, once each IR task is assigned, the optimal work-cell layout is computed by using proper optimization techniques, which numerically retrieve the IR base position corresponding to the minimum energy consumption. As an output to this second development stage, a set of color/contour maps is provided, that depicts both energy demand and time required for the task completion as function of the robot position in the cell to support the designer in the development of an energy-efficient layout. At last, two robotic manufacturing work-cells are set-up within the Delmia Robotics environment, in order to provide a benchmark case study for the evaluation of any energy saving potential. Numerical results confirm possible savings up to 20% with respect to state-of-the-art work-cell design practice
Towards Energy-Optimal Layout Design of Robotic Work Cells
No full textThis paper presents a new method for optimizing the layout position of an Industrial Robot (IR) in order to execute a specified task with the minimum energy consumption. First, using the Modelica language, an IR mechatronic model is developed, focusing on computational efficiency: addressing the power flow from the electrical network, the sub-system components are modeled with the level of detail strictly necessary for an accurate prediction of the power consumption, while assuring efficient computational efforts. Once a robot task is assigned, the optimal layout IR position is calculated using optimization techniques that retrieve the robot base position corresponding to the minimum energy consumption. Additionally, the designer can optimize the overall robotic work cell with the aid of a set of colour/contour maps that depict the energy demand along with the time required for the task
completion. Development, simulation and optimization phases are performed in Dymola environment
Energy-optimal motions for Servo-Systems: A comparison of spline interpolants and performance indexes using a CAD-based approach
No full textPosition-controlled Servo-Systems (SeSs) may be envisaged as a key technology to keep the manufacturing industry at the leading edge. Unfortunately, based on the current state-of-the-art, these mechatronic devices are well performing but intrinsically energy intensive, thus compromising the overall system sustainability. Therefore, traditional design and optimization paradigms, previously focused on productivity and quality improvement, should be critically reviewed so as to introduce energy efficiency as an optimality criterion alongside with the global production rate. In particular, focusing on mono-actuator systems with one degree-of-freedom, among the several design factors that can influence the SeS overall performance, the end-effector motion law can be easily modified without either hardware substitution or further investments. In this context, the purpose of the present paper is twofold. On one side, an effective method for the quick set-up of an energy-predictive CAD-based virtual prototype is discussed. In parallel, an energy comparison of some commonly employed Point-To-Point motions and optimization cost functions is provided. For what concerns the trajectory interpolation scheme, a standard optimization problem based on the aforementioned virtual model is solved by means of either algebraic or trigonometric splines. For what concerns the optimality criterion, either the system energy consumption or the root-means square value of the actuator torque are taken into account. In general, torque-based approaches, which may be preferred since they do not require a full knowledge of the SeS electrical parameters, can be effectively employed only when friction effects are negligible as compared to purely inertial loads. In parallel, cubic algebraic splines outperform other types of trajectories, although losing continuity of the resulting jerk profile
Towards Energy-Optimal Layout Design of Robotic Work Cells
No full textThis paper presents a new method for optimizing the layout position of an Industrial Robot (IR) in order to execute a specified task with the minimum energy consumption. First, using the Modelica language, an IR mechatronic model is developed, focusing on computational efficiency: addressing the power flow from the electrical network, the sub-system components are modeled with the level of detail strictly necessary for an accurate prediction of the power consumption, while assuring efficient computational efforts. Once a robot task is assigned, the optimal layout IR position is calculated using optimization techniques that retrieve the robot base position corresponding to the minimum energy consumption. Additionally, the designer can optimize the overall robotic work cell with the aid of a set of colour/contour maps that depict the energy demand along with the time required for the task completion. Development, simulation and optimization phases are performed in Dymola environment
A signal based approach for condition monitoring and predictive maintenance of a capsule filler machine
No full textThe need to increase manufacturing systems productivity and reduce their downtimes has led researchers to
investigate and develop Predictive Maintenance practices. One of the major challenges to cope with Predictive
Maintenance is related with the health assessment and analytics (i.e.: diagnostic and prognostic methods): the
identification of the incoming faults is difficult and hard to deploy in complex automated machinery operating in
real life conditions. At state of the art, established approaches are based on locating specific sensors as near as
possible to the potential failure. However, such approach is expensive and often hard to realize due to machine
topologies. The present work deals with a fault detection signal based approach, which analyses the vibrations of
a complete pharmaceutical capsule filler machine and detects the signature of a fault on a critical stage to build a
pattern threshold for Predictive Maintenance. The main novelty and strength of the proposed engineering method
is that the detection can be achieved despite the sensor position and in presence of many sources, as it is in real life
industrial environments. An industrial case study, on a pharmaceutical capsule filler is presente
Optimization of the energy consumption of industrial robots for automatic code generation
No full textAt present, energy consumption strongly affects the financial payback period of industrial robots, as well as the related manufacturing process sustainability. Henceforth, during both design and manufacturing management stages, it becomes crucial to assess and optimize the overall energy efficiency of a robotic cell by means of digital manufacturing tools. In practice, robotic plant designers and managers should be able to provide accurate decisions also aimed at the energy optimization of the robotic processes. The strong scientific and industrial relevance of the topic has led to the development of many solutions but, unfortunately, state of the art industrial manipulators are equipped with closed controllers, which heavily limit the feasibility and performance of most of the proposed approaches. In light of the aforementioned considerations, the present paper presents a novel simulation tool, seamlessly interfaced with current robot offline programming tools used in industrial practices, which allows to automatically compute energy-optimal motion parameters, thus reducing the robot energy consumption, while also keeping the same productivity and manufacturing quality. The main advantage of this method, as compared to other optimization routines that are not conceived for direct integration with commercial industrial manipulators, is that the computed parameters are the same ones settable in the robot control codes, so that the results can automatically generate ready-to-use energy-optimal robot code. Experimental tests, performed on a KUKA Quantec KR210 R2700 prime industrial robot, have confirmed the effectiveness of the method and engineering tool
A comparative study on computer-integrated set-ups to design human-centred manufacturing systems
Full text linkManufacturing ergonomics refers to the application of ergonomic principles and human factors analysis to the design of manufacturing tasks with the final aim to optimize the workers’ wellbeing and guarantee the expected process performance. Traditional design approaches are based on the observation of individual workers performing their jobs, the detection of unnatural postures (e.g., bending, twisting, overextending, rotating), and the definition of late corrective actions according to ergonomic guidelines. Recently, computer-integrated simulations based on virtual prototypes and digital human models (DHMs) can be used to assess manufacturing ergonomics on virtual manikins operating in digital workplaces. Such simulations allow validating different design alternatives and optimizing the workstation design before the creation, and pave the way to a new approach to manufacturing system design. The present paper aims at comparing different computer-integrated set-ups to support the design of human-centred manufacturing workstations. It defines a protocol analysis to support workstation design by analysing both physical and cognitive aspects, and applies the protocol within different digital set-ups. In particular, the study investigates a 2D desktop set-up using standardized DHMs and a 3D immersive mixed reality set-up based on motion capture of real workers’ acting into a mixed environment, comparing them with the traditional approach. An industrial case study focusing on design optimization of a manufacturing workstation in the energy industry is used to test the effectiveness of the two digital set-ups for the definition of re-design actions
A Simulation Tool for Computing Energy Optimal Motion Parameters of Industrial Robots
Full text linkThis paper presents a novel robot simulation tool, fully interfaced with a common Robot Offline Programming software (i.e. Delmia Robotics), which allows to automatically compute energy-optimal motion parameters, for a given end-effector path, by tuning the joint speed/acceleration during point-to-point motions whenever allowed by the manufacturing constraints. The main advantage of this method, as compared to other optimization routines that are not conceived for a seamless integration with commercial industrial manipulators, is that the computed parameters are the same required by the robot controls, so that the results can generate ready-to-use energy-optimal robot code
Progettazione di traiettorie energeticamente efficienti in servomeccanismi per macchine automatiche
No full textI Servomeccanismi (SM), anche detti camme elettroniche, sono sempre più utilizzati in sostituzione alle tradizionali camme meccaniche, al fine di incrementare la flessibilita' e la ri-configurabilita' delle moderne macchine automatiche. Nel tentativo di ottimizzare le prestazioni globali di un SM è necessario considerare vari fattori, tra cui le dinamiche di meccanismo a membri rigidi, motore elettrico e sistema di controllo, nonchè dalle leggi di moto richieste. In particolare, le traiettorie punto-punto (PP) vengono progettate sulla base di esigenze di processo e, allo stesso tempo, cercando di minimizzare opportuni indici di costo quali, ad esempio, la richiesta di coppia o potenza. Questa memoria presenta un metodo innovativo per generare traiettorie energeticamente efficienti, utilizzando spline cubiche o del quinto grado. Le funzioni costo sono calcolate utilizzando un prototipo virtuale del sistema che comprende la modellazione di tutti i principali sottosistemi di un SM. I risultati ottenuti sono affiancati a misure di validazione sperimentale ottenute su un prototipo fisico
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