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njit-etd1991-017 - New Jersey Institute of Technology

1. Select the STEPSIZE Button and change the Simulation Step Size to be 0 2 seconds and Steps per graphic update to 1 This means that the system will calculate and display the simulation at 0 2 second intervals and update and display the graphics every step Select the ACTIVATE Button and choose the All Devices option to activate all the Devices that have GSL programs loaded into them Select the RUN Button using the RMB to skip the Popup This will use the Previous Values for the Device locations and their Joint positions The World Display Buttons on the bottom of the screen may be selected and used any time during a simulation run To inspect the simulation while it 1s running select the CYCLE Button and then pick the Device Choose the Cycle Time On option to display Popup that indicates the current Cycle Time for the Device Similarly to see a display of the Joint values select the JNT VALS Button Chapter 4 Off Line Programming OLP 4 1 Introduction Presently most robots are programmed on the shop floor by the traditional methods of teach by show or walk through These methods require the operator to lead the robot through the motions using a teach pendant The motions are recorded in the computer memory to be played back later on The other method of direct programming involves manual programming using a keyboard in situ These techniques are not very effective in an assembly line as
2. Se ee da 81 5 3 Simulation R n Step seo eua A A Og 82 5 4 Simulation R nt Step 4 9 ex RR A 83 5 5 Simulation Rune Step 4s i 3 4 ata A do Cook 86 5 6 Simulation Run 5 87 Chapter 1 Introduction 1 1 Simulation Simulation is the technique of constructing and running a computer model of a real system in order to make a dynamic analysis without disrupting its environment prior to its implementation Simulation provides requisite information to determine the feasibility of a system by studying it under totally dynamic conditions It is used to construct and display mathematical models with the same constraints as those of the actual robots so as to manipulate and visualize the three dimensional models accurately lt is also a real time analysis and control tool as it allows the designer to visualize motions at every stage of the cycle in real time It also helps an engineer select the best robot for the job based on interference checks and reachability of various points in the workcell Various studies like cycle time analysis and collision detection help in optimization Simulation is one of the best ways to design an integrated complex robotic workcell It reduces the overall design time and increases the probability of success of the workcell implementation 1 2 Off Line Programming Off Line Programming OLP is the technique of deve
3. DOUT 2 ON I O WAIT UNTIL DIN 1 WHILE TRUE DO start tag_is ch str g i tag_isno tag is str hg ct dev_is chip str g 1 dev_isno dev is str dg j 58 CHAPTER 3 SIMULATION MOVE NEAR tag_isno BY m MOVE TO tag_isno GRAB dev_isno AT LINK 6 MOVE AWAY m update_chips dev_isno MOVE NEAR cp3 BY m MOVE TO cp3 MOVE AWAY m MOVE TO 3 MOVE AWAY m DOUT 1 ON WAIT UNTIL DIN 1 ON DOUT 1 OFF pl pt tag is str g 1 MOVE NEAR pl pt BY m MOVE TO pl pt RELEASE dev isno MOVE AWAY m MOVE TO sp2 IF j 9 THEN GOTO out ENDIF 3 j 1 1 1 10 ENDWHILE out 59 CHAPTER 3 SIMULATION DOUT 1 ON MOVE TO sp2 MOVE TO sp3 MOVE NEAR 761 BY margin UTOOL 0 0 0 0 0 0 MOVE TO 261 RELEASE gripper DOUT 3 ON MOVE AWAY margin MOVE HOME DOUT 1 OFF WRITE 04 CLS WRITE 4 DEMO COMPLETED CR CLI SET TIME STEP TO 0 05 Restores the Simulation Step Size after demo is completed END VAR which_one INTEGER why STRING 60 CHAPTER 3 SIMULATION why SUBSTR dev_isno 6 1 which_one VAL why SWITCH which_one CASE O CLI PLACE chip31 TAG ch30 Places Device chip31 at Tag point ch30 in zero simulation time CLI PLACE chip32 AT TAG ch31 CLI PLACE chip33 AT TAG ch32 CLI ROTATE chip34 ABOUT X_AXIS BY 40 CLI PLACE chip34 AT TA
4. like noiseless temperate atmosphere and ergonomic systems 4 4 OLP Systems There are three types of OLP systems 1 Specific application programs generated from the CAD system as a result of de signing the workpiece 2 Programs that are developed by answering a series of questions 3 Translators that are used to convert an already existing program into a format suitable for further processing OLP systems use either a textual or a graphical method to generate the robot pro gram The textual approach involves the use of a high level programming language which provides powerful data manipulation and arithmetic capabilities On the other hand the graphical approach uses interactive CAD techniques as well as the part geometry from a CAD database to simulate the workcell operation and subsequently uses the simulation data to program the robot Immediate visual feedback at all stages of the simulation makes for a realistic visualization of the workcell and aids in synchronization of the robot with other equipment Reachability collision detection cycle time estimations and optimization of the layout are the other important benefits of the graphical approach CHAPTER 4 OFF LINE PROGRAMMING OLP 68 The graphical method is used in this work to implement OLP The manipulator selection and the chip placement is done interactively and the relevant data such as the Place points are stored in the file xxx out 4 4 1 CAD system Wh
5. oro eh Ree i ee EUR RES 66 OLP A kuywan o m Mae quate 66 11 4 4 OLP Systems e 4 4 8 9 9 4 AAT CAD Systems 5 SUQ EUR RAS 4 5 OLP software 4 6 Postprocessor 4 gt a y 4 4 4 t a 8 4 G o 8 4 9 4 Eo E Program 4 dur es 4 6 2 AWK 4 7 OLP Benefits 5 Simulation Run e b 4 4 2 44 9 w o s o 9 4 o o o ShnulaoHn Setup AAA A 8 2 52 Running the simulation 25 5 X3 eo e w o ex 5 3 Output File 6 Conclusions 5 4 9 0 0 U 09 9 7 9 ws 4a 09 96 2 C 7 Recommendations Appendix Appendix Glossary Sources Consulted 90 91 93 97 100 List of Figures fi 22 CONTROL PANEL gt 3 35 309 28 136 we ied ye 8 AL OLPSchemall e RATO EN UR e Bie ie Se 70 Sb ATG FA WS 200 22 SUS IS eg 80 5 2 Simulation Rune Step 1 ux
6. roboti CR ENDIF UNTIL stop Repeats until the routine stop returns true ouch CLI SET VIEW TO nor IN 1 DOUT 10 ON DOUT 1 ON WRITE Q1 CLS WRITE 3 CLS CHAPTER 3 SIMULATION 42 not_used WRITE 04 It took Cycle_time sec to complete the run CR WRITE 02 RUN TIME Cycle_time CR WRITE 04 Your output is in deneb igrip 4d att outfile out CR READ_KBD Do you want to download to the FWS now lt y gt dl IF dl y THEN cmd att hit att outfile out CLI SYSTEM cmd ENDIF Makes a system call to invoke the C program IF dl n THEN WRITE 04 To download your O P go to usr deneb igrip 4d att CR WRITE 04 enter hit outfile out CR ENDIF DELAY 7000 Delays execution for 7000 milliseconds CLI FULL SCREEN Invokes the full screen mode of IGRIP MOVE HOME CLOSE 1 CLOSE 01 CLOSE 03 CLOSE 2 Closes all open files and windows CHAPTER 3 SIMULATION 43 END MAIN e a ms we eu s ap ap CUP ao QUE s s Gus W v uem v s mum A PROCEDURE move_to pint STRING ma A di SWITCH pint CASE pick_pt CLI SET VIEW TO clchide IN 1 MOVE NEAR pick_pt BY margin MOVE TO
7. Button which doubles the Stepsize Once the demo is over the user is queried for a speed of the manipulators The speed for the 78 CHAPTER 5 SIMULATION RUN 79 manipulators on the FWS is limited to 25 inches per second but the apt speed is in the vicinity of 5 inches per second The next query is for an offset which is the distance away from the chip for all subsequent motions of the arms This is given to avoid hitting any projections or obstacles in the manipulator s path The apt offset is around 0 5 inches 5 2 Running the simulation After logging into the SGI workstation e Move to the IGRIP directory by entering cd usr deneb igrip 4d e Invoke the fullscreen mode of IGRIP by entering igrip f e Select the MOTION Context and the SIMULATE Page e Select the RETRIEVE WORKCELL Button select harry from the Popup pick att_fws and then pick att_fws 200 e Select MOTION Context Select Load with MMB and pick robot1 from the Popup The Current Program will be att_1 2 gsl Choose Re load Current Program Repeat for robot2 and load att_2_1 gsl Select ACTIVATE and choose All Devices option from the Popup Select RUN with RMB to get the simulation running Type y in response to Would you like to see a demo lt n gt if you desire to see a demonstration of the working of the FWS If not just hit lt RET gt Enter a filename for the file in
8. Select the RETRIEVE WORKCELL Button and retrieve your Workcell from your directory e Select the I O Page e Select the DUAL CONNECTION Button to allow signals to be sent both directions Pick the first Device and select I O 01 as the line you want to connect to it Now pick the second Device to connect line 01 to Select I O 01 as the corresponding line e Select DISPLAY CONNECTION Button and pick the Device whose signals you want to display The Popup will show the Device s input 01 coming from the other Device and it s output 01 going to the other 3 3 7 PROGRAM The PROGRAM Page in the MOTION Context is primarily used for Program Scripting This is the process of automatically scripting program statements with correct syntax to a GSL program using menu Buttons The program statements are executed when they are scripted so that you can interactively see the effect of each statement To use the PROGRAM Page for program writing e Select NEW PROGRAM pick the Device to be programmed and enter the program name Program Edit Window should appear with a basic program template in it e Select the SYSTEM VARS Button set the variables desired by choosing the UNITS Speed Motype options Select the MOVE Button and choose the Move To option Pick the Tag Point to be moved to and the Device should move to it If you cant see the Tag Point to CHAPTER 3 SIMULATION 29 pick it select the Move To option using th
9. WRITE 04 CLS CHAPTER 3 SIMULATION 37 READ_KBD Enter desired output filename outfile OPEN FILE usr deneb igrip 4d att outfile out FOR APPEND AS 1 Opens a file in the usr deneb igrip 4d att directory with the user specified filename with a out extension as file 1 in append mode CLI RESTORE ALL POSITIONS Restores the original positions of all Devices after the demo ends READ_KBD Enter desired speed of robot arms lt 20in sec gt fast Speed fast Sets the speed to the user defined value from the variable fast WRITE 02 SPEED fast CR READ_KBD Enter an offset lt 1 in gt margin WRITE 2 OFFSET margin CR CLI SET VIEW TO clrobs IN 1 WRITE 1 ROBOT roboti CR WRITE 1 SPEED fast CR WRITE 1 OFFSET margin CR WRITE 01 The robot arm on your left is used to handle CR WRITE 1 the grey colored chips on the left feeders CR WRITE 1 The robot arm on your right is used to handle the CR WRITE 1 yellow chips on the right feeder CR WRITE 3 Select one of the robot arms CR WHILE NOT MOUSE_PICK DEVICE WORKCELL rob_arm x y z DU SIM UPDATE ENDWHILE Waits until a Device is picked by mouse IF rob arm roboti THEN CHAPTER 3 SIMULATION 38 DOUT 1 OFF ENDIF If the picked Device is robotl then the 0 P signal 1 is set off IF rob_arm ro
10. style robot Simple Kinematics was not suitable for the purpose Then the Generic kinematics method was used and finally the Device Kinematics method was used There are 2 methods of configuring the manipulators of the FWS 200 one by using an inverse kinematics routine from the IGRIP library and two by using Generic Kinematics To model a new Device the kinematics of any of the existing Devices can be used if the following conditions are satisfied 1 The base coordinate systems for each part on each Device must match exactly The positive negative directions of rotation must be identical 2 The number of dofs for both Devices must be same 3 The type of dof must be the same in both Devices i e ROTATIONAL vs TRANSLATIONAL CHAPTER 3 SIMULATION 23 Selecting Device Kinematics from the displayed Popup allows the user to select any Device existing in the DEVICE directory The Device being built will assume the kinematics math routine defined for the Device name selected from the file list Popup Note that if any of the parameters mentioned above link lengths link offsets link types mounting plate offset or DOF definition do not match those of the selected Device the new Device will not be able to reach its points Select JOINT LENGTHS This is where the D H parameters The Denavit Hartenberg notation is used to represent the robot kinematics parameters The gist of this is to represent the robot kinematically using link
11. to be subsequently used in carrying out the motions of the manipulators The CHAPTER 2 AT amp T FWS 200 11 program is invoked by typing run cdemo at the mml prompt on the FWS after the power up sequence ap as am as ae mo qm am m e a ddr sdefine comi Defines the device called comi i e the serial port stype comi Uses the device handler called comi for the device previously defined with the sdefine command sset port 1 sset baud 9600 sset parity even sset size 7 i sset stopb 1 sset enable 1 Sets the database fields name base port avail baud parity size stopb to their respective values loadg datapts Loads the geometry variables from the file named datapts v call com Calls the procedure called com CHAPTER 2 AT amp T FWS 200 int a O string s string i string j int errflag true int rob 1 string tol vac point safpt 5 1 point pp point cpoint point plpoint offset over offset 0 0 0 5 O sopen Opens a connection to the device called coml while j lt gt END sgets comi Obtains a string s from the SID device called comi i strtok Is the first invocation of strtok that 15 to be used The string s is passed along with the delimiter j strtok wend sclose comi Closes the connection to the device called coml fopen 1 3 testy da
12. TO pl_pt RELEASE dev_isno Releases the previously grabbed Device MOVE AWAY m 1 1 1 10 IF i 1 AND j gt 3 THEN 1 1 1 47 CHAPTER 3 SIMULATION j 0 1 10 1 ENDIF IF Gi 2 AND j gt 2 THEN GOTO out ENDIF ENDWHILE out DOUT 1 ON MOVE TO spi WAIT UNTIL DIN 3 ON MOVE HOME DOUT 1 OFF END PROCEDURE update_chips dev_isno STRING VAR which_chip STRING which which_one INTEGER wh why STRING CHAPTER 3 SIMULATION o dd BEGIN wh SUBSTR dev_isno 5 1 why SUBSTR dev_isno 6 1 which VAL wh which_one VAL why Assigns the integral value of a string variable SWITCH which CASE 1 GOTO helli CASE 2 GOTO hell2 ENDSWITCH hell1 SWITCH which_one CASE 0 CLI PLACE chipii TAG ch10 CLI PLACE 12 AT TAG chit CLI PLACE chipi3 AT TAG chi2 CLI PLACE chipi4 AT TAG chi3 CLI ROTATE chipi5 ABOUT X AXIS BY 40 CLI PLACE 15 AT TAG ch14 CASE 1 CLI PLACE chipi2 AT TAG chi0 CLI PLACE chipi3 AT TAG chii CLI PLACE chipi4 AT TAG ch12 CLI PLACE chip15 AT TAG chi3 CASE 2 49 CHAPTER 3 SIMULATION CLI PLACE chip13 AT TAG chi0 CLI PLACE chipi4 AT TAG ch11 CLI PLACE 15 AT TAG ch12 CASE 3 CLI PLACE chipi4 TAG chi0 CLI PLACE 15 AT TAG chii CASE 4 CLI PLACE chipi5 AT TAG ch10 RETURN ENDSWITCH 112
13. William Simulation v47 p63 7 Aug 86 100
14. and END is the main body of the program The overall structure of a GSL program is PROGRAM progname Declaration_section CHAPTER 3 SIMULATION 30 Subprogram_section BEGIN progname MAIN Statement_block END progname MAIN Subprogram_section where progname is the user defined name of the program Declaration Section Comprises 1 or more of the different data sections Global Structure Variable Cli var Constant and Forward section All variables declared in GSL are automatically initial ized The initial value is zero for numeric FALSE for boolean and blank for string e GLOBAL Variables declared in this section are global 1 values set for these variables in one program are accessible by any other program in the workcell All programs referencing a global variable must declare it in their Global section with the same data type e VAR All variables referenced within a GSL program must be declared in this section INTEGER Variables of integer type can store integral values only REAL Variables of this type can store fractional values BOOLEAN Boolean variables can store a TRUE or FALSE value only STRING String variables can store 0 or more characters POSITION and PATH Variables of these types refer to Tag Points and Paths within a Workcell These are read only string variables with pre assigned values CHAPTER 3 SIMULATION 31 e CLL VAR Variables to be share
15. and z coordinate of a point respectively dz dy dz Distance in the x y and z direction respectively d Total Cartesian distance V Object volume A Object area dia Polygon diameter ang Angle between entities R P Y Roll Pitch and Yaw angle about Z Y and X axis respectively e SYSTEM The SYSTEM Context provides system utilities to modify the system environment and world attributes as well as to interact with the UNIX file system CHAPTER 3 SIMULATION 20 CLI The CLI Command Line Interpreter Button is used to enter CLI commands interactively This enables the expert user to type in a command from any Context without switching to the relevant Context 3 3 1 CAD Before beginning the design of Parts the units should be set up if other than the default mm is desired as below Select the ANALYSIS context Select the UNITS Button and enter the new units in the Popup or use the LMB to select from the choices The new units will be used for all subsequent operations To actually design the Parts select the CAD context and click on the CREATE Button to go to the CREATE page The CAD context is used to model the ge ometry used to design Parts which consist of one or more Objects which in turn comprise one or more Subobjects composed of Lines and Polygons Objects are created using the CAD primitives Block Cylinder Cone Wedge Pipe and Sphere These Objects are modified using the CA
16. geometric motion paths This is the path generator To program the path the programmer working at a CRT and a keypad specifies robot joint action and tool point location sequences OLP software prompts the programmer asking him questions to lead him through the process Programming procedures vary in the amount of interaction between the computer and the programmer Command oriented The display shows READY The programmer is then on his own to enter motion commands Prompting The display asks the programmer to respond to questions that flash on the screen until the computer has elicited enough information to perform an operation Prompt programming sometimes requires lengthy answers Compared to command oriented prompt programming is tedious but it requires less operator programming expertise Menu driven Also a question and answer procedure the screen displays lists of possible moves for the programmer He responds by typing a Y or N for yes or no or by se lecting by mouse pick This is the easiest method of programming less tedious than the prompting method but slower than the command oriented The programming procedure used here is a mix between the Prompting and the CHAPTER 4 OFF LINE PROGRAMMING OLP 72 Menu driven types The user is prompted to input speed and offset At the same time there is a default provided so that just a RETURN will do The other information is elicited from the user s selection by mouse pick The
17. good graphics capabilities as well as a solid mod eling module so that the user can validate the model for accuracy and completeness It should also allow the import of standard file formats such as IGES Initial Graphics Exchange Specification The system should be user friendly to enable easy interactive modeling and simulation Ability to simulate different operations like painting welding etc is desired to increase the system s versatility Features like collision detection and cycle time analysis are a must to assist in optimization The user should have access to a database of the most commonly used robots The system should be able to simulate the kinematic and dynamic behavior of the robots The simulation system should possess the capability of interfacing with the shop floor equipment so as to download the simulation sequences directly to the robot controller Simulation should be continued even after workcell implementation on the shop floor for optimization The underlying philosophy is to provide a dynamic interactive environment on a high performance engineering workstation and to be able to shorten the design evaluation cycle as well as optimize the operations 3 3 IGRIP IGRIPTM is a user friendly computer graphics based simulation system for workcell lay out simulation and off line programming OLP Parts modeled within the Part Modeler CAD Context are put together to define Devices with multiple degrees of freedom A
18. i j ct 1 K m INTEGER tag_is tag_isno STRING dev_is dev_isno STRING pl_pt STRING ch cp STRING cp1 2 POSITION flag BOOLEAN Variable declarations ees x s GER s s s s O UD Ge ee eu SAP am P m CHAPTER 3 SIMULATION BEGIN 0 ct cp cp2 flag TRUE Variable initializations CLI SET VIEW TO demovw IN 1 CLI SET TIME STEP TO 0 1 Sets the Simulation Step Size to 0 1 seconds WHILE TRUE DO start WRITE 04 CLS WRITE 04 DEMO IN PROGRESS CR MOVE TO spi tag ch str g i tag isno tag is str g ct dev is chip str g i dev isno dev is str g Appends numerals to the string variable MOVE NEAR tag BY m MOVE TO tag isno GRAB isno AT LINK 6 46 CHAPTER 3 SIMULATION Grabs Device dev_isno by joint 6 MOVE AWAY m update_chips dev_isno pl_pt tag is str g 1 MOVE NEAR cp BY m MOVE TO cp MOVE AWAY m IF flag THEN WAIT UNTIL DIN 2 ON DOUT 1 ON flag FALSE GOTO skip ENDIF DOUT 1 ON WAIT UNTIL DIN 1 ON Skip DOUT 1 OFF MOVE NEAR pl_pt BY m MOVE
19. lengths and offsets based on the coordinate system of each link fixed at arbitrary locations i e lengths between base coordinate systems as well as offsets from the principal plane are assigned Select BASE PRT and pick the Part of the Device which is to serve as the base Use UFRAME under the MOTION Context to verify by picking the Display option from the Popup that the UFRAME is the base Coorsys of the Base Part Select the MNT PLT Button Here the user graphically selects the part which represents the Device mounting plate and defines the offset values Use UTOOL Button under MOTION Context to set the Tool Point Pick Display from the Popup and verify the Tool Point Select HOME POSITION Button and set the home position to be the current Joint value by choosing the Use Current Position option in the Popup Select the SPEEDS Button located under the LIMITS Title and complete the Popup Select the ACCELS Button and set the maximum accelerations CHAPTER 3 SIMULATION 24 Select the TRAVEL Button and set the travel limits This completes the definition of the new Device If any modifications are necessary use REDEFINE DEVICE Button and make the requisite changes in the Popup Finally select SAVE DEVICE Button and complete the Popup with the name of your directory and the filename The Generic Kinematics method can be used to model a new robot with any number of degrees of freed
20. of the handshake protocol between the different hardwares involved At first the following program was used BEGIN FS ROBOT if 2 roboti printf s n 1 x gt usr deneb igrip 4d att out else printf s n 2 x gt usr deneb igrip 4d att out SPEED print 2 x gt usr deneb igrip 4d att out OFFSET print 2 x gt usr deneb igrip 4d att out SAFE POINT printf s n 2 x gt usr deneb igrip 4d att out PICK POINT printf s n 2 x gt usr deneb igrip 4d att out CHAPTER 4 OFF LINE PROGRAMMING OLP 76 PLACE POINT printf s n 2 x gt usr deneb igrip 4d att out CHECK POINT printf s n 2 x gt usr deneb igrip 4d att out END 4 printf s endx gt usr deneb igrip 4d att out This program appended a x to each line of the input file Here the field separator was specified as using the BEGIN statement The regular expressions SPEED PLACE POINT etc were used to base the corresponding action on If the pattern was one of the POINTs then the action was to append a x to it and write it to the file called out in the usr deneb igrip 4d att directory If the pattern was SPEED or OFFSET the second field viz the user specified values was printed with a trailing x to the file out If ROBOT was the pattern the relevant number with a trailing x was written to the file out Lastly endx
21. pick_pt GRAB chip AT LINK 6 MOVE AWAY margin update_chips chip Calls the update_chips procedure CASE place_pt CLI SET VIEW TO clside IN 1 MOVE NEAR place_pt BY margin MOVE TO place_pt RELEASE chip MOVE AWAY margin CLI SET VIEW TO nor IN 1 MOVE TO spi GOTO next ENDSWITCH CLI SET VIEW TO nor IN 1 CHAPTER 3 SIMULATION MOVE NEAR chk_pt BY margin MOVE TO chk_pt MOVE AWAY margin next END e di ROUTINE query BOOLEAN VAR ans BOOLEAN ques STRING ans FALSE READ_KBD Do you want to activate the other arm lt n gt ques IF ques y THEN ans TRUE ENDIF RETURN ans END ub me ee ar ee ge s cut v s ce v UD GO v ee ee s n ee ee UP ae Q w UND s x ane ee ri CHAPTER 3 SIMULATION status BODLEAN qu STRING BEGIN status FALSE READ KEYBOARD Continuing q TO QUIT qu IF qu q THEN status TRUE ENDIF RETURN status END O M v v v UR Gem URP UND s PROCEDURE demo VAR
22. production For the shop floor engineer the step from teach pendant to OLP at a computer ter minal can be a big one Menu driven user friendly OLP packages smooth the transition The robot programmer is asked questions regarding parameters like speed location and the like leading him through the steps to create robot motion programs The questions are backed up by computer subroutines that save the programmer the trouble of telling the computer how to execute the statements By this the user creates an error free pro gram ready for direct downloading to the robot controller The library interacts with cell layout and kinematic and geometric functions speed and location data of program ming alerting the programmer to errors of component choice With the cell laid out WORKFLOW THROUGH AN OLP CAD SIMULATION STATION OLP SCHEMATIC Figure 4 1 CHAPTER 4 OFF LINE PROGRAMMING OLP 71 the programmer defines the task and writes motion commands for the robot He then executes the program and makes changes to avoid collisions or to decrease process time When satisfied with the program he loads it into the postprocessor which translates the program into the robot control language and downloads it into the robot controller The CAD system used here is the IGRIP simulation system Refer previous chapter 4 5 OLP software OLP software runs at two levels Level one compiles a list o motion commands that will take the robot through its
23. set up The work in this thesis can be broadly classified into two sections In the first the simulation setup was designed This involved modeling of the AT amp T FWS 200 setting up the kinematics of the manipulators and programming of the FWS simulation setup using GSL The second part involved the setting up of a physical communication link between the Silicon Graphics Workstation on which the IGRIP software resides and the FWS on the factory floor via a RS 232 cable running between their serial ports programming to enable communication between the simulation system IGRIP and the AT amp T FWS using C The following chapters discuss how the AT amp T FWS 200 has been modeled simu lated and programmed off line from the simulation software IGRIP Chapter 2 AT amp T FWS 200 2 1 General Overview The AT amp T FWS 200 Flexible Work Station is a pick and place robot with a built in operator interface and programmed in a multitasking control language M L Modular Manufacturing Language The FWS 200 is an overhead gantry style four axis robot primarily used for precise positioning of light to moderate weight work pieces It supports multiple manipulators within a common workspace It can be easily customized and can function as a stand alone unit or as an integrated part of an assembly line The FWS is modular in design and equipped with an user programmable touch screen interface A 80386 based PC is used for robot system contr
24. which the O P to be downloaded will be stored ROBOT 7 The manipulator on your right is used for CHIP chip10 x x the yellow chips on the right feeder SAFE POINT sp1 The points on the PCB denote the positions PICK POINT ch10 a of the chips CHECK POINT PLACE POINT 110 PP oe Select a light greu colored place point Select the first chip one of the feeders Select a corresponding color place point ilf Ius OFFSET 0 5 2 ROBOT 1 CHIP chip20 SAFE POINT sp1 PICK POINT 20 CHECK POINT cpl The manipulator on your right is used for the yellow chips on the right feeder The points on the PCB denote the positions of the chips Select one of the robot arms Select the first chip in one of the feeders manipulator on your left is used for grey colored chips on the left feeders manipulator on your right is used for yellow chips on the right feeder 0 5 CHAPTER 5 SIMULATION RUN 84 Enter the desired speed of the robot arms in inches per second max 18 30in sec Enter an offset for the arms The maximum offset is 1 in You ll notice that your selections are listed in the window at the upper left corner The window called ATT FWS at the upper right corner offers some ex planation about the FWS The USER INTERFACE window leads you through the simulation Select one of the manipulators with the L
25. will be used to approach the Tag Point Speed_Mode PERCENT Indicates that speed will be interpreted as a percentage of maximum tcp speed Initialization of variables margin 1 demon n dl yt hype TRUE OPEN WINDOW ATT FWS 00 5 1 0 4 as 1 OPEN WINDOW ATT FLEXIBLE WORKSTATION 0 0 3 0 5 2 as 4 OPEN WINDOW YOUR SELECTION 0 1 0 1 0 6 as 2 OPEN WINDOW USER INTERFACE 00 5 0 0 3 as 3 Opens a window called USER INTERFACE at 5 0 with 3 lines as window 3 pens windows with the specified name at the specified location with CHAPTER 3 SIMULATION 36 the specified number of lines in the windows CLI SET VIEW TO tv IN 0 CLI SET VIEW TO rfv IN 1 CLI SET VIEW TO rgv in 1 CLI SET VIEW TO rrv IN 1 CLI SET VIEW TO rv IN 1 CLI SET VIEW TO lrv IN 1 CLI SET VIEW TO lv IN 1 CLI SET VIEW TO 1 IN 1 CLI SET VIEW TO fv IN 0 Changes view to the specified user defined view in the specified time WRITE 04 WELCOME TO FWS SIMULATION CR Displays WELCOME TO FWS SIMULATION in window 4 READ KBD Would you like to see a demo lt n gt demon Displays prompt and reads data into a variable from the keyboard IF demon y THEN DOUT 5 ON DOUT 4 ON demo ENDIF If the variable demon contains y O P signals 4 5 are set on and the demo procedure is invoked DOUT 4 ON DOUT 1 OFF Sets the 0 P signal 1 off
26. 31 CLI PLACE chip38 AT TAG ch32 CLI ROTATE chip39 ABOUT X AXIS BY 40 CLI PLACE chip39 AT TAG ch33 CASE 6 CLI PLACE chip37 AT TAG ch30 CLI PLACE chip38 AT TAG ch31 CLI PLACE chip39 AT TAG ch32 CASE 7 CLI PLACE chip38 TAG ch30 CLI PLACE chip39 AT TAG ch31 CASE 8 CLI PLACE chip39 AT TAG ch30 RETURN ENDSWITCH END w EP an s Amp GR Gum s O QD dea ms cms am v s s 3 39 MOTION e Select the MOTION Context and the SIMULATE Page e Select the RETRIEVE WORKCELL Button and pick the desired Workcell from the Popup e Select Load using the MMB this displays a list of all the Devices in the Workcell Pick the Device to be loaded choose the Load Selected Program option from the CHAPTER 3 SIMULATION 64 Popup and pick the program to be loaded into it If the message window doesn t read Program xxx gsl successfully loaded there are errors in the Program choose the Yes option from the Edit Program window The gedit window will appear to allow you to debug the Program If vi editor is preferred change the editor option to vi by picking the Environ Button under the WORLD Page in the SYSTEM Context
27. Computer POWER light will illuminate and the computer will boot up Turn on Servo 1 and Servo 2 by pressing the START pushbuttons The Servo lights will illuminate CHAPTER 2 AT amp T FWS 200 10 5 Press the AIR ON pushbutton The AIR light will illuminate The air valve will open supplying air pressure to the system Note If the air pressure is insufficient lt 85 psi the INTERLOCK fault light will illuminate 6 Check INTERLOCK light if it is lit close any open drawers safety shields or correct the air pressure 2 3 MML Procedures There are three methods of executing a procedure in M L e The run command runs the procedure with all the currently defined variables avail able to it run procname arglist where procname is the name of the procedure to run and arglist is a list of argu ments separated by commas e The call command also runs the given procedure but in a different data space This means that any variables that the procedure creates will be gone when the procedure returns call procname arglist e The debug command is identical to the call command except that execution is suspended before each line of the procedure in order for you to inspect variables set breakpoints etc debug procnamel arglist The procedure com is used to configure the serial port of the PC running M L The procedure demorun2 is used to read the data sent over the RS 232 cable from the SGI
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29. D operators such as Cut Mirror Loft Clone Extrude amp Revolve From MODIFY page use Merge Smash Scale Cut Color Object and Extract Obj to further modify the Objects From Auxiliary page create Coorsys to assist in attaching subobjects to make up an Object 3 3 2 DEVICE To build a new Device use the following procedure Select the DEVICE Context then the NEW DEVICE Button You will be placed in the Syslib PARTS directory Select the appropriate directory in the Popup to CHAPTER 3 SIMULATION 21 move to your directory Select the Part to be used as the base of the new Device Enter a name for the Device and accept the defaults for the Device parameters in the Popup Select the 5 Button then pick the Part that was Just retrieved to force the Coorsyses to always stay visible Select the ATTACH PART Button and then pick the base of the Part to indicate the Part that the new Part will be attached onto Choose the other Parts and then the key Coorsyses placed in the CAD Context to facilitate easy positioning of the Parts Select the KIN Page and select the JOINT TYPES Button This is where the Translational vs Rotational dof are assigned at each joint Change the first three to be Translational and accept the default Rotational for the other three joints Select the SET DOF Button and pick the Part which is supposed to move along X and or Y axis The Link Transformation Popup is used to desc
30. Device has both geometric and non geometric information stored with it Non geometric information like kinematics dynamics velocities etc can be entered through inter active menus A Workcell is composed of Devices positioned relative to each other WORKCELL Context Devices may be selected from a library of robots conveyors CHAPTER 3 SIMULATION 18 end effectors or modeled by the user in the DEVICE context IGRIP has the capability to generate robot programs interactively MOTION Context Several Devices may be simulated simultaneously with Input Output signaling set up between them The IGRIP menu system is divided mainly into Contexts which are arranged across the top of the IGRIP screen each of which has a group of subdivisions called Pages The Contexts are CAD The CAD Context allows the user to create and modify 3 D surface or wireframe geometry used to represent Parts DEVICE The DEVICE Context allows the user to build and modify Devices by putting together the Parts built in the CAD context LAYOUT The LAYOUT Context allows the user to lay out a workcell This includes positioning Devices creating Paths for motion definition connecting 1 signals and creating Collision Queues MOTION The MOTION Context allows the user to define and execute motion for Devices Motion can be commanded interactively or through Program control when running a simulation Simulation Programs can also be downloaded to sp
31. G ch33 Chip is rotated before placing to accomodate the junction in the feeder CLI PLACE chip35 AT TAG ch34 CLI PLACE chip36 AT TAG ch35 CLI PLACE chip37 AT TAG ch36 CLI PLACE chip38 TAG ch37 CLI PLACE chip39 AT TAG ch38 CASE 1 CLI PLACE chip32 AT TAG ch30 CLI PLACE chip33 AT TAG ch31 CLI PLACE chip34 AT TAG ch32 CLI ROTATE chip35 ABOUT X AXIS BY 40 CLI PLACE chip35 AT TAG ch33 CLI PLACE chip36 AT TAG ch34 CLI PLACE chip37 AT TAG ch35 CLI PLACE chip38 AT TAG ch36 CHAPTER 3 SIMULATION CLI PLACE chip39 AT TAG CASE 2 CLI PLACE chip33 AT TAG CLI PLACE chip34 AT TAG CLI PLACE chip35 AT TAG CLI ROTATE chip36 ABOUT CLI PLACE chip36 AT TAG CLI PLACE chip37 AT TAG CLI PLACE chip38 AT TAG CLI PLACE chip39 AT TAG CASE 3 CLI PLACE chip34 TAG CLI PLACE chip35 AT TAG CLI PLACE chip36 TAG CLI ROTATE chip37 ABOUT CLI PLACE chip37 AT TAG CLI PLACE chip38 AT TAG CLI PLACE chip39 AT TAG CASE 4 CLI PLACE chip35 AT TAG CLI PLACE chip36 AT TAG CLI PLACE chip37 AT TAG CLI ROTATE chip38 ABOUT CLI PLACE chip38 AT TAG CLI PLACE chip39 AT TAG CASE 5 ch37 ch30 ch31 ch32 X AXIS BY 40 ch33 ch34 ch35 ch36 ch30 ch31 ch32 X_AXIS BY 40 ch33 ch34 ch35 ch30 ch31 ch32 X_AXIS BY 40 ch33 ch34 CHAPTER 3 SIMULATION 63 CLI PLACE chip36 TAG ch30 CLI PLACE chip37 AT TAG ch
32. ICK POINT pick_pt CR CHAPTER 3 SIMULATION 40 WRITE 1 CHECK_POINT chk_pt CR WRITE 02 CHECK POINT chk_pt CR move_to pick_pt Invokes the procedure move_to with pick_pt as the argument CLI SET VIEW TO clpcb IN 0 WRITE 3 Select a corresponding color place point CR WHILE NOT MOUSE_PICK TAG robot1 place_pt x y z DO SIM_UPDATE ENDWHILE Waits until Tag point is picked wrt roboti and assigned to the variable place_pt IF pick pt chi0 THEN IF NOT VAL SUBSTR place pt 3 1 1 THEN Checks if the third character of the variable place pt is a 1 WRITE 03 This chip does not belong here CR WRITE 03 Select a dark grey colored place point CR WHILE NOT MOUSE PICK TAG roboti place pt x y z DO SIM UPDATE ENDWHILE ENDIF ENDIF IF pick pt ch20 THEN IF NOT VAL SUBSTR place pt 3 1 2 THEN WRITE 03 This chip does not belong here CR WRITE 03 Select light grey colored place point CR WHILE NOT MOUSE PICK TAG roboti place pt x y z DO CHAPTER 3 SIMULATION 41 SIM_UPDATE ENDWHILE ENDIF ENDIF WRITE 1 PLACE_POINT place_pt CR WRITE 02 PLACE POINT place_pt CR CLI SET VIEW TO nor IN 1 move to place pt IF queryO THEN Checks if the routine query returns true DOUT 1 ON WAIT UNTIL DIN 1 ON DOUT 1 OFF IF DIN 10 ON THEN GOTO ouch ENDIF WRITE 1 ROBOT
33. MB Pick a chip from the feeders at the rear If you pick a yellow colored chip when the manipulator chosen by you is robot1 you will be asked to pick again as these chips are handled by the right manipulator Pick either of the first chips on the left two feeders The manipulator you selected will move out of its home position and pick up the selected chip and move to the check point to check the chip Pick a place point on the pcb If you pick a position where the selected chip doesn t belong you ll be asked to pick a corresponding color place point The arm will then move there and place the chip After the chip is in position the arm will move to a safe point You ll be asked if you want to activate the other manipulator Type y if you desire to use the other arm and if not just hit lt RET gt The manipulator on the right will move out of it s home position and pick up the gripper from the tool stand Repeat the above procedure and pick a yellow chip and a yellow colored position It ll go the through the same sequence of motions If you want to stop here just hit lt RET gt to continue with the same arm and then type q to quit or else it ll continue with the same arm If you type q CHAPTER 5 SIMULATION RUN 85 the cycle time will be displayed This is the time required to complete the simulation run The window will tell you where your output is it ll be in the usr deneb igrip 4d att di
34. N 1 ON IF DIN 10 ON THEN GOTO not used ENDIF OPEN FILE usr deneb igrip 4d att outfile out FOR APPEND AS 1 MOVE NEAR gi BY margin MOVE TO gl GRAB gripper AT LINK 6 MOVE AWAY margin UTOOL 0 125 1 655 0 125 0 90 O CHAPTER 3 SIMULATION 53 Sets the new Utool to accomodate the gripper MOVE TO sp3 WRITE 1 ROBOT robot2 CR again REPEAT IF gino TRUE THEN WRITE 02 ROBOT robot2 CR ENDIF CLI SET VIEW TO clchips IN 0 Jump WRITE 3 Select the first chip in the right feeder CR WHILE NOT MOUSE_PICK DEVICE roboti chip x y z DO SIM_UPDATE ENDWHILE chip_tag VAL SUBSTR chip 5 1 SWITCH chip_tag CASE 1 CONTINUE_CASE CASE 2 WRITE 3 These chips are to be handled CR WRITE 03 by the other robot arm CR gino FALSE GOTO again CASE 3 pick_pt ch30 chk_pt cp3 CHAPTER 3 SIMULATION 54 ENDSWITCH CLI SET VIEW TO nor IN 0 MOVE TO sp2 WRITE 2 CHIP chip CR WRITE 1 SAFE_POINT sp2 CR WRITE 02 SAFE POINT sp2 CR WRITE 1 PICK_POINT pick pt CR WRITE 02 PICK POINT pick pt CR WRITE 1 CHECK_POINT chk pt CR WRITE 2 CHECK POINT chk pt CR move to pick pt CLI SET VIEW TO clpcb IN 0 WRITE 03 Select a corresponding color place point CR WHILE NOT MOUSE PICK TAG robot1 place_
35. S operation A GSL Graphics Simulation Language program has been used to simulate the chip placements during PCB assembly The program leads the user through the motions of chip placement and after the simulation run downloads the motion sequence to the FWS The animation sequences of the FWS have been downloaded to the FWS on the Factory Floor using C program which is utilized to communicate the data to an program on the FWS An awk program is used to take care of the handshake protocol between the Silicon Graphics workstation running IGRIP and the 80386 PC running M L use of simulation has been observed to help the user in visualizing the sequence of chip placement OLP offers naive user the option of running the FWS without learning M2L and an experienced user significant savings in programming time and testbed for optimization ACKNOWLEDGEMENTS I would like to acknowledge Prof N Levy s role in this venture of mine and thank him for his suggestions during the course of this thesis I wish also to acknowledge the Graduate Advisor Prof H Herman and the Chairman Dr B Koplik for their support I would like to take this opportunity to express my gratitude to Prof D Lubliner for his invaluable guidance and moral support available to me all through Without his backing and encouragement at all times which is highly appreciated this thesis would never have been I would also like to thank Prof Leu for his he
36. SWITCH which_one CASE O CLI PLACE chip21 AT TAG ch20 CLI PLACE chip22 TAG ch21 CLI ROTATE chip23 ABOUT X AXIS BY 40 CLI PLACE chip23 AT TAG ch22 CASE 1 CLI PLACE chip22 AT TAG ch20 CLI PLACE chip23 AT TAG ch21 CASE 2 CLI PLACE chip23 AT TAG ch20 RETURN ENDSWITCH END 50 CHAPTER 3 SIMULATION PROGRAM ATT2 FORWARD stop ROUTINE BOOLEAN FORWARD query ROUTINE BOOLEAN FORWARD move_to PROCEDURE FORWARD demo PROCEDURE GLOBAL margin fast REAL pick_pt place_pt safe_pt chk_pt STRING x y 2 REAL outfile STRING rob_arm chip STRING chip_tag INTEGER VAR gino BOOLEAN me me M s aw s uum m aum UNITS ENGLISH Stepsize 0 2 Approach_Axis Y_AXIS Speed_Mode PERCENT UTOOL 0 0 0 0 0 0 Sets the Utool CHAPTER 3 SIMULATION 52 margin 1 gino TRUE OPEN WINDOW ATT FLEXIBLE WORKSTATION 0 0 3 0 5 2 AS 4 OPEN WINDOW USER INTERFACE 00 5 0 0 3 AS 3 OPEN WINDOW YOUR SELECTION 0 1 0 1 0 6 AS 2 OPEN WINDOW ATT FWS 00 5 1 0 4 AS 1 WAIT UNTIL DIN 4 ON DOUT 1 OFF IF DIN 5 ON THEN demo ELSE GOTO ok ENDIF 20k WRITE 04 CLS WAIT UNTIL DI
37. Y margin update chips chip CASE place pt CLI SET VIEW TO clside IN 1 MOVE NEAR place pt BY margin MOVE TO place pt RELEASE chip MOVE AWAY margin MOVE TO sp2 GOTO next ENDSWITCH CLI SET VIEW TO nor IN 1 CHAPTER 3 SIMULATION MOVE NEAR chk_pt BY margin MOVE TO chk_pt MOVE AWAY margin next END rd ROUTINE query BOOLEAN As above in PROGRAM ATT ROUTINE stop BOOLEAN above in PROGRAM ATT1 s re eee GEM id C c me qm cup que db UP Me V qu v VAR i j ct 1 m INTEGER tag_is tag_isno STRING dev_is dev_isno STRING pl pt STRING ch chip STRING 3 sp2 sp3 STRING gl POSITION UNITS ENGLISH _ 1 Y_Axis CHAPTER 3 SIMULATION Speed 5 Sets the speed to 5 inches per second UTOOL 0 0 0 0 0 0 1 3 150 1 10 m 1 ct 0 CLI SET TIME STEP TO 0 1 MOVE NEAR 261 BY m MOVE TO g1 GRAB gripper AT LINK 6 MOVE AWAY m UTOOL 0 125 1 655 0 125 0 90 0 MOVE TO sp3 MOVE TO sp2
38. an expert user can use it as a testbed for optimization and to test out new M L programs without using the FWS and in comfort 89 Chapter 7 Recommendations Now that downloading has been implemented the obvious next step is to reverse the process Uploading is the process of carrying out an actual run on the FWS and then sending over the data to the simulation system to enable real time simulation update and any required modifications Real time control of the FWS can be implemented using two way communication Every motion of the FWS model on the terminal should be replicated by the FWS on the factory floor In this case every step of the simulation run should be instantly downloaded to the FWS instead of downloading the entire sequence of motions at one time At the other end the FWS should send a signal on completion of motion replication to the simulation system On the other hand a motion of the FWS on the floor could be replicated on the terminal The simulation setup could be used for chip placement optimization Different printed circuit boards could be modeled and the optimum chip placement sequence could be determined on the basis of cycle time analysis A code generator for M L could be written in the C language After testing simulating the program which is automatically generated could be either downloaded to the FWS and or saved for future work on the FWS 90 Appendix MML Commands e attach Used to tell th
39. anslational and a rotational component 3 3 8 GSL Programs The following GSL programs are loaded into the two manipulators of the FWS ATT 1 in the first manipulator with the vacuum as att_1_2 gsl and ATT2 in the second manipulator with the gripper as att_2_1 gsl These programs are used to run the simulation of the FWS and invoke the C program by way of a system call if the user chooses to download during the run The cycle time is also displayed at the end of the run CHAPTER 3 SIMULATION PROGRAM ATT1 Routine and Procedure declarations FORWARD stop ROUTINE BOOLEAN FORWARD query ROUTINE BOOLEAN FORWARD demo PROCEDURE FORWARD move_to PROCEDURE Global variables declaration GLOBAL demon STRING margin fast REAL pick_pt place_pt safe_pt chk_pt STRING X Y z REAL outfile STRING rob_arm chip STRING chip_tag INTEGER CLI variable declaration CLI_VAR cmd STRING Other variables declaration VAR 41 STRING BOOLEAN 34 CHAPTER 3 SIMULATION 35 ee an am us ap aep s ma Ges n s Cmm s cus Uem AR unm ums s ss UNITS ENGLISH Sets the units to inches Stepsize 0 2 Sets the value of the current Simulation Step Size to 0 2 seconds Approach_Axis Y_AXIS Indicates that the Y axis of the Device tool
40. back to the statement after the ENDSWITCH when a statement block is executed If CONTINUE CASE appears in the statement block execution continues with the following statement block without testing the corresponding case expression value This is useful when the same action is to performed in more than one case If CONTINUE TEST is present all following case expressions are tested until the test expression equals the case expression or a DEFAULT or ENDSWITCH state ment is encountered This is useful when more than one case can be satisfied simultaneously in the switch block e WAIT UNTIL Causes the Current Device s Program to pause until the specified input signal has the desired value e WHILE DO As long as the boolean expression evaluates to TRUE the statement block is executed The boolean expression is evaluated before each execution of the statement block e MOVE AWAY Will move the TCP of the Current Device in the negative approach axis direction by the distance specified e MOVE HOME Will move the Current Device to its current home position 94 NEAR Will move the Current Device near the Tag Point specified The move will stop the specified distance away from the Position offset along the neg ative approach axis direction MOVE TO Will move the TCP of the Current Device to the specified Tag Point MOVE JOINT Will move the Current Device s specified Joint by the specified amount SIMUL moves will oc
41. bot2 THEN DOUT 1 ON WAIT UNTIL DIN 1 ON IF DIN 10 ON THEN GOTO not_used ENDIF DOUT 1 OFF ENDIF If the picked Device is robot2 then the 0 P signal 1 is set on Waits for I P signal 1 to be on If I P signal 10 is also on program control jumps to the label not_used and 0 P signal 1 is set off CLI SET VIEW TO clpcb IN 1 WRITE 1 The points on the PCB denote the positions CR WRITE 1 of the chips CR again REPEAT IF hype THEN WRITE 02 ROBOT roboti CR ENDIF CLI SET VIEW TO clchips IN 0 WRITE 03 Select the first chip one of the feeders CR WHILE NOT MOUSE PICK DEVICE roboti chip x y z DO CHAPTER 3 SIMULATION 39 SIM_UPDATE ENDWHILE chip_tag VAL SUBSTR chip 5 1 Variable chip_tag is assigned the fifth character of the variable chip SWITCH chip_tag CASE 1 pick_pt chi0 chk_pt 2 CASE 2 pick pt ch20 chk_pt 1 CASE 3 WRITE 3 These chips are to be handled CR WRITE 03 by the robot arm on your right CR hype FALSE GOTO again If the third chip is picked the flag hype is set to false and program control jumps back to the label again to repeat ENDSWITCH CLI SET VIEW TO nor IN 1 MOVE TO spi WRITE 02 CHIP chip CR WRITE 1 SAFE_POINT sp1 CR WRITE 02 SAFE POINT spi CR WRITE 1 PICK_POINT pick pt CR WRITE 2 P
42. cates which axis of the Device tool will approach the Tag Point for MOVE NEAR and MOVE AWAY commands e CYCLE TIME indicates the Current Device s elapsed cycle time in seconds e SPEED indicates the desired speed for MOVE commands A valid value is a number representing cartesian speed in current units sec if SSPEED MODE is ACTUAL or a number between 0 and 1 representing the percentage of maximum CHAPTER 3 SIMULATION 33 speed if SSPEED MODE is PERCENT Cartesian speeds dont apply when moving in Joint interpolated mode or when moving Joints In this case SPEED will be interpreted as a percentage of maximum tcp speed and that percentage will be applied to the maximum speed for each Joint to determine the maximum Joint speeds for the move SPEED_MODE indicates the mode for interpreting SPEED Valid values are ACTUAL and PERCENT STEPSIZE contains the value of the current Simulation Step Size in seconds UFRAME is a six component variable x y z yaw pitch roll that repre sents a transformation which may be imposed on a Device in the Device reference frame The effect of UFRAME is to simulate shifting the base of the Device by the UFRAME offset values It is a write only variable e UNITS defines the units to be used by the system for the program e UTOOL is a six component real variable x y z yaw pitch roll which repre sents the tool point offset It is a write only variable It may consist of both a tr
43. cur simultaneously with subsequent MOVE JOINT statements NOSIMUL moves will begin immediately IMMEDIATE moves take no simulation time to complete and should be followed by a SIM_UPDATE statement GRAB Allows the user to attach a Device to the Current Device The Device specified will be grabbed by the Current Device at the specified link RELEASE Allows the user to detach a Device from the Device to which it is attached DELAY Allows the user to make a Device pause for the specified time interval indicated in milliseconds SIM_UPDATE Uses up the remaining time in the current simulation update for the Current Device A harmful effect is the subsequent increase in cycle time CLOSE Allows the user to close the specified file pipe or socket CLOSE WINDOW Allows the user to close the specified window OPEN FILE Allows the user to open a file for three types of operations INPUT OUTPUT or APPEND INPUT specifies that the file is to be opened for reading only OUTPUT specifies that the file is to be opened for writing H the file already exists its contents are lost APPEND specifies that the file is to be opened for 95 writing and its contents are to be retained Writing is always done at the end of the file file as well as a window can have the same unit number simultaneously OPEN WINDOW Will open the user defined window identified by 1 and 1 1 1 is the lower left corner and 1 1 is the upper right This w
44. d by the GSL program and CLI Command Line Interpreter are declared in this section e FORWARD This section is used to declare the identifiers which are fully defined after they are referenced in the program This makes it possible for Routines and Procedures to appear after the main program Subprogram Section Subprograms in GSL may be either Routines or Procedures H a subprogram returns a value it is a Routine otherwise it is a Procedure The data type of the value returned by a Routine defaults to Real Variables which store the values passed to a subprogram are known as parameters The parameter list is the list of these variables along with their data types If a parameter s name is preceded by VAR then it may be used to pass back a value from the subprogram Subprograms provide a method of performing repetitive tasks in a modular way Subprograms cant include other subprogram definitions within themselves They can be called by the program in which they are declared or by any subprogram defined in the same program A subprogram can call itself in a recursive fashion When the subprogram execution is completed the control passes back to the point where the subprogram call was made Subprograms work on a set of values in two ways The first method is to use Global and Main variables variables declared outside any subprogram in the subprogram and assign them the proper values before each invocation The second method is to use Pa
45. e Generic from the Popup Select MNT PLT and choose the plate at the tip of the tool Select BASE PRT and choose the plate attached to the top of the manipulator Select GENERIC KIN and choose Cartesian class Select JOINTS PRESENT and choose 6 Present Select OFFSETS and type in 0 5 for 1 amp 2 16 11 for 3 and 0 for the rest Select WRIST ROTN and type in 90 for Offset Z Rotn 3 3 4 WORKCELL Layout layout Workcell follow the steps below Select the LAYOUT Context and the WORKCELL Page Select the RETRIEVE DEVICE Button Choose your directory from the Popup and pick the relevant Device Select the AXES Button this will toggle the Device s display mode so that it s Coorsyses are always displayed Select the RETRIEVE DEVICE Button again to pick the other Devices to be laid out in the Workcell Select TRN DEV or ROT DEV to arrange the Devices in the Workcell The SNP Button is a quick way to do 90 degree rotations about the primary axis The LMB rotates about X MMB about Y and the RMB about the Z axis If any Devices are CHAPTER 3 SIMULATION 26 to be attached to another Device select SNAP DEV Button Choose the Frame option from the Snap Device On and pick the Coorsyses on the Device Select the ATTACH Button using the MMB Middle Mouse Button This will give a list of all the Devices that are currently in the Workcell C
46. e M2L interpreter which manipulator is to receive later machine control commands This is required as the other machine commands do not provide for the specification of a machine e home If a manipulator is moved into the home locks such that the HOME light on the control panel is on and the home command is executed each axis of the manipulator will be moved to a predetermined position and the position for each axis will be set to the hposition value e move Used to move the currently attached machine to the given absolute position The position maybe expressed as a point value or a list of numeric values separated by commas e imove An incremental move command which moves the manipulator relative to 158 current position e break Used to insure that a move has been completed before some other action is taken e signal Used to turn a discrete I O device ON or OFF e speed Sets the speed of the attached machine e here Returns the current position of the attached machine This position is returned as an M L point value in world frame coordinates e load Loads a M L procedure or variable list from disk Appends a m extension to the procedure name and loads the file from disk to an M L text segment 91 loadg Loads a M L geometry variable list from disk This differs from the load command by being able to load points frames and offsets through one command loadg will append a v ex
47. e MMB Middle Mouse Button and the system will let you select the Tag Point from the list of all available Tag Points You can also add Routines or Procedures If While For conditions to your program by picking the function Buttons You can enter text like sim_update using the GSL Button and the Enter Text option I O statements may be added by means of the I O Button To see the program run move the mouse up in the file until the highlighted line is the UNITS METRIC line Select the EXECUTE Button and watch the system step through the program If the program runs satisfactorily select the WRITE Button located on the left side of the Program Edit Window Save the program into your directory GSL Program Outline The Graphic Simulation Language GSL is a procedural language used to program in dividual Devices in a simulation to govern their actions and behavior It incorporates high level computer languages conventions with specific enhancements for Device motion and simulation environment inquiries GSL is not case sensitive and has a free format which means that multiple statements can be entered in one line and also one statement can wrap down to one or more lines A GSL program comprises a program declaration statement followed by declaration section subprograms section and the main body of the program A GSL program always starts with the program declaration The statement block within BEGIN
48. e a component to make sure that it is precise The programmer can rotate the view to look at different angles and check for clearances then back away to look at CHAPTER 4 OFF LINE PROGRAMMING OLP 69 the overall picture again can also introduce hypothetical situations to see what will happen for example if the controller should malfunction and the robot should increase its travel speed Would the robot cause any damage to any fixtures or to itself Simu lation removes any doubts It also allows users to view the process without endangering machinery or personnel The CAD database stores information on the limits of robot performance Should a programmer ask the robot to do things it cant do such as move too rapidly or too far the workstation displays an error message on the screen A clock on the screen records elapsed cycle time during simulation so that the programmer can see whether the process meets production goals With a routine proved out on the computer the program is translated by the post processor The program can be sent downloaded through electronic cable to the robot controller Now the user can activate the cell assured of collision free action and of cycle times that meet the production goal Should the user wish to modify the program add components to the cell or move existing components around he can do so by recalling the cell representation editing and rearranging on the terminal while the robot remains in
49. e entities comprising PARTS and their relationships to each other created in the CREATE DEVICE module WORKCELL WORKCELLS comprised of DEVICES positioned in arbi trary locationsorientations and TAG POINTS TAG POINT TAG POINTS are entities which represent a 3 dimensional point in space along with an orientation x y z yaw pitch roll PATH PATHS are entities which are comprised of a set of TAG POINTS COORSYS COORSYS are entities similar to TAG POINTS in that they repre sent a 3D point in space except that they can be manipulated only in the CREATE PART module They are used to attach one PART to another when creating a De vice and to set the TOOL POINT for a Device in the CREATE DEVICE module SUBOBJECTS SUBOBJECTS are arbitrary collections of polygons lines sur faces contours and coordinate systems SURFACES SURFACES are mathematical surfaces in space represented by a mesh of polygon facets but may be manipulated in ways different from polygons IGRIP s surfaces are Non Uniform Rational B Splines NURBS in support of the corresponding IGES entity VERTEX VERTEX is an X Y Z coordinate that is stored in the IGRIP database It is the fundamental primitive entity from which all other entities are composed 97 LINE LINE is straight segment connecting two Vertices and mathematically has no volume POLYGON POLYGON is a bounded plane defined by an ordered set of Vertices lying
50. ecific controller or generic formats DIMENSION The DIMENSION Context allows the user to create and manipu late various kinds of dimension entities to document workcell layouts and geometric data Dimensions are fully three dimensional planar entities and can be translated and rotated in space with respect to a coordinate system that is local to the dimen sion Dimensions are also dynamically associative or data driven which implies that the dimensions are attached to geometry and are continuously updated to reflect the current state of that geometry CHAPTER 3 SIMULATION 19 e USER The USER Context allows customization of the user interface to define custom Menu Pages with functions taken from other Pages or functions to invoke CLI Command Line Interpreter macro files e ANALYSIS The ANALYSIS Context allows the user to perform various forms of analysis Functions on the MEASURE Page allow identification of various items in the world as well as the determination of the distances and angles between them The units for reporting as well as the frame of reference may be set by the user Entity properties such as area and volume may be queried using functions on the PROPERTIES Page All analysis functions utilize Analysis Registers that can be used in conjunction with IGCALC Some of the Registers and the data values they represent are c Value of the current Popup field p Last value entered 2 X y
51. ematics deals with the various robot mechanism factors such as Joint parameters Link parameters and Degrees of freedom e point point is a set of 4 floating numbers corresponding to the X Y Z and 0 values of a point in 3 dimension physical space The 0 value is a rotation about the Z axis e offset An offset is a set of 4 floating numbers corresponding to the difference in X Y Z and 0 values of two points 99 Sources Consulted 10 11 12 13 14 AT amp T FWS 200 User s Manual AT amp T Aho A V Kernighan B W Weinberger P J The AWK Programming Lan guage Addison Wesley 1988 Cunningham Carole Manufacturing Engineering v101 p77 9 Oct 88 Derby Stephen Robotics Age v6 p11 13 Feb 84 Gondert Stephen Design News v40 p60 2 March 26 84 IGRIP Simulation System User Manual Deneb Robotics Inc Version 2 0 Mar 90 Iversen Wesley R Electronics v62 p39 Feb 89 Kacala James Machine Design v57 p89 92 November 7 85 Kamisetty Krishnaprasad V Simulation amp Off Line Programming of Robotic Workcells 1989 Kernighan Brian W Richie Dennis M The C Programming Language PHI 1986 Kuvin Brad F Welding Design amp Fabrication v58 p34 9 Nov 85 Lehtinen Merja H K American Machinist amp Automated Manufacturing v132 p62 5 May 88 Morris Henry M Control Engineering v32 p143 5 Sep 85 Schroer Bernard J Teoh
52. en plpoint ch310 CHAPTER 2 AT amp T FWS 200 15 call place plpoint over tol errflag Calls the procedure place move safpt endsw wend fclose 3 Closes the file with file identifier 3 2 4 Power down sequence To power down the unit 1 Press the AIR OFF pushbutton 2 Press the Servo 1 and Servo 2 OFF pushbuttons Turn the Main Power Key Switch to the OFF position Chapter 3 Simulation 3 1 Imtroduction Interactive computer graphics for simulation and Off Line Programming is a powerful tool for implementing robotic applications Simulation systems provide significant time savings in the layout and modeling of robotic workcells Furthermore as manufacturing equipment becomes more complex and costly these systems provide added assurance in cell layout optimization It has been estimated that 60 80 of the task of implement ing a robotic workcell is devoted to cell layout equipment design robot selection and hardware mockup of the workcell Remaining efforts are in the programming and actual implementation on the factory floor The general characteristics of a simulation system as well as the salient features of the IGRIP the simulation system used in this work are discussed 3 2 Characteristics of a simulation system The main objectives of a simulation system e Improved Accuracy e Improved Communication 16 CHAPTER 3 SIMULATION 17 e Reduced Development Time simulation system should have
53. haracters as the third argument specifies VAL Gives the value of the string argument EXIT Causes unconditional termination of the program You cant continue with GSL execution once the EXIT command has been executed GOTO Will transfer control to the statement following the label statement identi fied by the label specified in the GOTO statement A GOTO statement cant jump into a subprogram from outside or jump outside the subprogram from within IF THEN ELSE If the boolean expression evaluates to TRUE then the statement block under THEN gets executed otherwise the statement block under ELSE gets executed Execution is then continued with the statement after ENDIF LABEL Labels a location within a GSL program Control of the execution can be shifted to this location using a GOTO statement REPEAT UNTIL As long as the boolean expression evaluates to FALSE the statement block gets executed The statement block is executed at least once 93 e RETURN Used to stop the execution of a subprogram The RETURN statement cant have an expression if it appears within a Procedure and must have the expres sion if appearing within a Routine Furthermore a Routine must have at least one RETURN statement e SWITCH Allows multiple branchings depending on the conditions statement block gets executed if the corresponding case expression is equal to the test ex pression Normally the SWITCH statement is terminated control flows
54. he manipulator on your right is used for the yellow chips on the right feeder The points on the PCB denote the positions of the chips Select a cor the f 1 esponding color rst chip in the Select a corresponding color place point right feeder place point CHAPTER 5 SIMULATION RUN ROBOT roboti SAFE POINT spi PICK POINT chi0 CHECK POINT cp2 PLACE POINT chi50 ROBOT robot2 SAFE POINT sp2 PICK POINT ch30 CHECK POINT cp3 PLACE POINT ch310 ROBOT roboti SAFE POINT spi PICK POINT ch20 CHECK POINT PLACE POINT ch230 88 Chapter 6 Conclusions The successful implementation of Off Line Programming of the AT amp T FWS 200 the factory floor allows studies on the FWS to be conducted away from the machine with the FWS being used only for the final testing The ultimate objective is to be able to control the entire factory floor from the control room awk was used successfully to overcome the problem of data loss during transmission The UNIX utility sleep was used to protect data from being over written in the buffer The Generic Kinematics method of assigning kinematics to a Device proved to be as good as the Device Kinematics method The CLI PLACE command was very useful in animating the motion of the chips in the feeder subsequent to removal of the first chip The program developed allows a layman to run the FWS without prior knowledge of either M L or the FWS At the same time
55. hoose a Device and pick a part on the Device to attach it to The part should highlight and any Coorsyses if present will appear Pick the right Coorsys and the Device will snap onto the part using the orientation of the Coorsys At this point the locations and orientations of each Device should be saved Move to the SYSTEM Context WORLD Page and pick the SAVE POSITIONS Button Choose the All Devices option from the Save Restore Positions Popup This establishes Restore Positions for the location and the Joint values of each Device This can be used as the starting point when running simulations If this is not done when the simulation is RUN using Previous Values all the Devices jump to the World Origin Use the World Display functions to rove to a view of the Workcell that shows most of the Devices and save the Werkcell using SAVE WORKCELL Button 3 3 5 Tag Points Tag Points are primarily used to indicate destination positions for robot motion The user places Tag Points at the desired location and orientation and then instructs the robot to move to the Tag Point position Tag Points may be set up as follows Select the LAYOUT Context and then the RETRIEVE WORKCELL Button Choose the Workcell from the Popup CHAPTER 3 SIMULATION 27 e Select the TAGS Page and then the NEW PATH Button pick the Device to attach the Path to Select the SETUP Button and complete the Popup This allows you to con
56. ile developing programs offline makes the process easier and keeps the robot working during editing the final program still must be proved out on the shop floor To see what the robot will do before running the program in the robot cell CAD Simulation software is used CAD Simulation software stores sizes and capacities of workcell components robots end of arm tooling positioners and other components in a robot cell design database The programmer creates these databases from 3 D models of the equipment Some soft ware come equipped with a library of the products of major manufacturers These carry equipment specifications such as work envelope size range of operating speeds size and weight From a complete stored description of his robot or of several candidate robots the user chooses robot positioner and other components places them in a cell representa tion on the screen and views their capabilities for anticipated jobs He can check out numerous combinations and arrangements of equipment In effect he designs the cell before positioning or even before purchasing the equipment With components chosen and displayed on the screen in their cell positions the path is defined The programmer then simulates action on the screen using component repre sentations wire frame models or solid detailed color images He can interrupt simulation at any point in the program to change a command Or can zoom in on a location and isolat
57. ill open a window with the specified name at the specified location with the specified number of lines in the window e WRITE A unit number preceded by an for window and for file is used to identify where the WRITE statement should write to If unit number isn t specified the write is done on the Device s output window A CR indicates a new line and must be present in order for display to occur immediately upon statement execution This is due to the buffering of the print lists A CLS is used to clear the window e READ KBD Can read data for a list of variables from the keyboard Before reading the data the specified prompt is displayed This terminates only when Return Enter key is pressed or by entering D Ctrl D e CLI This procedure executes a CLI statement FULL SCREEN Will put the system in full screen mode SET VIEW Changes the viewing orientation to the specified user defined view in the specified time if the IN clause is used SYSTEM Sends the specified string as a command to the Unix system PLACE Will position the base coordinate system of the specified Device at the specified location This takes zero Workcell time to complete SET TIME STEP Will set the simulation step size to the specified value which must be greater than 0 96 Glossary OBJECT OBJECTS are entities created the CREATE PART module PART PARTS are entities made up of OBJECTS DEVICE DEVICES ar
58. in a plane EDGES EDGES are the boundaries of Polygons and may be free or shared by two Polygons PLANE PLANE is a non geometric entity and is used in a transient manner It is characterized by a direction 3 numbers A B C and an offset from the origin D BASE COORSYS Each Object has one Coorsys called its Base Coorsys All geometric entities composing the Object are defined relative to this coordinate system and Object manipulations occur with respect to it FRAME FRAME is either a Tag Point or Coorsys JOINTS LINKS DOFS JOINT refers to the axis of motion between rigid LINKS which are Parts Each Joint is a Degree Of Freedom or DOF CONTEXT CONTEXT is the main division of functions in the IGRIP Menu System The Contexts are arranged across the top of the IGRIP screen Each Context has a group of PAGES beneath it PAGE PAGEs are the secondary division of functions in IGRIP Each Page provides access to a group of BUTTONS BUTTON BUTTONS the basic functions that perform tasks for the user 98 e IGCALC IGCALC is an arithmetic expression evaluator that can be accessed by picking the DENEB logo It includes pre defined System Variables user defined variables and trigonometric functions Analysis Registers are pre defined IGCALC registers which are automatically assigned the most recent values for a parameter that result from analysis querys and calculations e Robot Kinematics Robot Kin
59. loping a computer program without involving the robot itself in the programming process to run a robot from a remote site Robots have conventionally been programmed by teach by show methods which involve using a teach pendant and are sometimes slow and tedious These involve stopping the assembly line for the duration of the teaching process to incorporate any changes On Line Programming involves coding and debugging on the machine which is trying and time consuming also it hinders production Off Line Programming is essential in CIM Computer Integrated Manufacturing It is very helpful in factory floor operation as it doesn t interfere with production It can prove very helpful if the assembly operation isn t fixed especially in a FMS Flexible Manufacturing System environment where reprogramming for different specifications can be very time consuming and tedious OLP assumes a great significance on account of its several advantages It does away with the teach pendant altogether It uses simulation and animation data to develop the robot program which can be modified very easily if required Once the workcell undergoes some test runs the probability of success of the program on the actual workcell increases The workcell need be taken out of production only when the program is ready for testing The program can be tested immediately by downloading it to the workcell via a hard wired connection the network if a card is present or
60. lpful suggestions Contents 1 Introduction 1 EL OIL 2 1 1 2 Off Line Programming es lt lt css Hee EE 2 DS SORIA x ns ee 2 h4 IE te a esas gre SE oe a Senate 3 135 ObjeeliV6 2 2g wx A Gi ate o 3 2 amp FWS 200 5 2 1 Generar OVERVIEW oo laa A e e AAA 5 211 Hardware Description 2 2 5 2 9 4 6 2 52 o MM Dal EI da e EVE Se od 9 22 PowerUp S quence 245455855 e ORES e es 9 23 MMLProcedures 4 Low da AR 10 24 Power down sequence oom vU o9 9 RE a 40 15 3 Simulation 16 dl ia ea So qe ral w 16 3 2 Characteristics of a simulation 16 GRIP b as ws 17 Book 20 02 dia 20 3 3 3 Setting up DEVICE 22 24 WORRCELL Layout oeh 4 Bw ge y 25 8 5 0 a AA 26 33 0 Input Output Signals E 2 8 Se a 27 doa PROGRAM Z Um AAA 28 295 GS ae ee I A a 33 30 MOTION aca as E wae ee G his 63 4 Off Line Programming OLP 65 LE ao Su aris Sw S SE eo NN 65 BD CONGR
61. mming the traversing path of the robot between different positions is described by the programmer with collision avoidance in mind The order of execution must be defined in such systems An interactive graphical input of geometric data is desired in addition to textual input Implicit programming assumes known environments which have to be previously described In a model the spatial conditions like the work envelope and the collision range of the robot and the object s coordinates must be completely specified Then there is the hybrid programming method wherein OLP is used for the order of execution or for the logic instructions and on line lead through style methods to collect geometric data such as the cartesian coordinates of the various points in the workcell 4 3 Principles of OLP The main 4 principles underlying the concept of OLP are e Minimum programming time e Real time simulation e Exact tool positioning CHAPTER 4 OFF LINE PROGRAMMING OLP 67 e Better working conditions for the operator Programs can be written in advance on the computer system so that only adaptation must be done on line leading to minimum programming time in the manufacturing facility Real time simulation can be carried out on the OLP system leading to time optimization Adherence to specific geometric conditions ensures accurate tool orientation in the actual workcell Programming at a remote site provides the operator with favorable conditions
62. nt programming or programming on the robot controller which has a limited display e He can edit existing programs created by OLP or by online programming while the robot continues to work on line Chapter 5 Simulation Run 5 1 Simulation Setup The simulation setup is laid out as below The three kinds of chips are located at the rear in chip feeders 2 square chips are in 2 feeders located on the left side at the rear while the yellow colored chips are in a feeder on the right side The manipulator on the left uses vacuum to handle the 2 square chips while the manipulator on the right uses a gripper for the yellow colored chips The manipulator on the right moves out of its home position to the tool changer and attaches the gripper before beginning its operations The manipulators are used to pick up the chips at the mouth of the feeders test them at the check point and then place them on the pcb at their proper locations In between the manipulators wait at safe points until the other manipulator has completed its operation After all the chips are in position the manipulators move back to their respective home positions If one desires a demonstration run is provided which gives one a better idea of how the FWS operates thus making the choices to answers to queries more apparent If one desires to get on with the simulation the demo can be hurried along by increasing the simulation Stepsize This is done by selecting the gt gt
63. ol The Modular Manufacturing Language M L is a modular BASIC like language which allows multi tasking control of the robot and other equipment such as machine vision systems The FWS has two manipulators one with a vacuum tool and a camera the other with a tool changer accomodating a gripper and a vacuum tool lt also includes an up looking camera connected to an SVP 512 vision system The FWS s main application is placement of a variety of components into a printed circuit board Both through hole and surface mount components are placed with the CHAPTER 2 AT amp T FWS 200 6 surface mount parts ranging from 25 to 50 mil pitch The through hole parts are picked from a feeder and mechanically nested before placement If the part does not immediately insert a spiral search pattern called vibratory insertion is used until the part drops in The 50 mil pitch surface mount devices are also mechanically nested The 25 mil pitch surface mount devices are visually nested before placement The manipulators can quickly accelerate to a velocity of 60 inches per second yielding a typical part acquisition placement cycle of 2 seconds per part per manipulator The maximum velocity of the X and Y axis is 75 inches per second but in practice it averages around 30 inches per second 2 1 1 Hardware Description The control cabinet houses e Control display system power buttons touch display pressure and vacuum gauges and emergency s
64. om dofs It is very slow to execute as compared to the closed form solutions on account of it uses an iterative approach which only searches for solutions which lie within the specified link limits It can provide a solution where other methods fail but at the same time it doesn t always come up with a solution even when one exists To setup the FWS manipulator using Generic Kinematics Select the DEVICE context then select the Attributes Button to go to the Attributes menu Page Select LINK TYPES and choose Translational for the first three joints and Rotational for the other three joints Select DOF This allows one to define the type of transformation being applied at each joint Choose the top part of the manipulator click on Set Home in the Popup then click on Trans X and type in 1 in response to the Popup and finally click on Return This signifies that the first dof is translational along the X axis Repeat the above sequence except this time choose Trans Y and type in 2 Next choose the middle part of the manipulator and repeat in the same order by choosing Trans 7 and typing 3 Then choose the bottom part of the manipulator and choose Rotate Z and type in 4 in the CHAPTER 3 SIMULATION 25 same order Finally choose the bottom plate at the tip of the tool and choose Rotate Y as 5 and Rotate X as 6 in the same sequence Select KINEMATICS and choos
65. pt x y z DO UPDATE ENDWHILE IF NOT VAL SUBSTR place_pt 3 1 3 THEN WRITE 03 This chip does not belong here CR WRITE 03 Select a yellow colored place point CR WHILE NOT MOUSE PICK TAG roboti place pt x y z DO SIM UPDATE ENDWHILE ENDIF WRITE 1 PLACE_POINT place_pt CR WRITE 02 PLACE POINT place pt CR CLI SET VIEW TO nor IN 1 CHAPTER 3 SIMULATION move_to place_pt IF query THEN DOUT 1 ON WAIT UNTIL DIN 1 ON DOUT 1 OFF IF DIN 10 ON THEN GOTO finito ENDIF WRITE 1 ROBOT robot2 CR GOTO again ENDIF UNTIL stop DOUT 10 ON DOUT 1 ON finito CLI SET VIEW TO nor IN 1 MOVE TO sp3 MOVE NEAR gi BY margin UTOOL 0 0 0 0 0 0 MOVE TO gi RELEASE gripper MOVE AWAY margin Sets the Utool back to the original after returning the gripper MOVE HOME not used SIM_UPDATE 55 CHAPTER 3 SIMULATION us na up Q ae QUA s s SUP Gne UU D aue AUD MUR Web x ee im m PROCEDURE move_to pint STRING BEGIN SWITCH pint CASE pick_pt CLI SET VIEW TO clchide IN 1 MOVE NEAR pick pt BY margin MOVE TO pick pt GRAB chip AT LINK 6 MOVE AWA
66. r appear literally on the command line as program or by using the f program file option the set of patterns may be in a program file With each pattern in the program there can be an associated action that will be performed when a line of a filename matches the pattern Each line in each input filename is matched against the pattern portion of every pattern action statement the associated action is performed for each matched pattern An input line is made up of fields separated by white space The field separator CHAPTER 4 OFF LINE PROGRAMMING OLP 75 may be changed using FS or Fc by starting the program with BEGIN FS c or the option Fc which means use the character c as the field separator Fields are denoted 1 2 and so forth 0 refers to the entire line A pattern action statement has the form pattern action A missing action means copy the line to the output a missing pattern always matches The special patterns BEGIN and END may be used to capture control they must be the first and last pattern respectively An action is a sequence of statements Statements are terminated by semicolons NEWLINE characters or right braces A statement may use if else while for printf etc The print statement prints its arguments on the standard output unless gt filename is present awk f program file Fc program variable value filename The awk program is utilized to avoid transmission loss and take care
67. r directives include lt math h gt CHAPTER 4 OFF LINE PROGRAMMING OLP 73 include lt string h gt to include relevant include lt ctype h gt include lt sys types h gt header files main argc argv int argc Arguments on the command line char argv char str 100 cmd FILE op ip Declarations int 1 op fopen dev ttyd4 r Open the serial port 4 of the SGI cmd awk F f usr deneb igrip 4d att wick Tell awk to read commands from a file and use as the delimiter strcat cmd argv 1 Concatenate the filename system cmd Make a system call to invoke awk ip fopen usr deneb igrip 4d att out r Open the file produced by awk for reading 1 1 Initialize the variable vhile i gt 0 CHAPTER 4 OFF LINE PROGRAMMING OLP 74 fscanf s str Read a string from the file fprintf op sn str Write a string out to the serial port system sleep 3 Delay using the UNIX sleep command if strcmp str z END endx 0 exit 1 Check for end of file and break out of loop fclose ip fclose op Close the file and the serial port 4 6 2 AWK awk is a pattern scanning and processing language It scans each of its input filenames for lines that match any of a set of patterns specified in a program The set of patterns may eithe
68. rameters Parameters are the local variables of a subprogram to which values are passed when a call to the subprogram is made The values to be passed to the parameters are called arguments Arguments are passed to the subprogram in two ways by reference CHAPTER 3 SIMULATION 32 or by value When arguments are passed by value the value of the argument expression is com puted when the call to the subprogram is made This value is assigned to the corre sponding parameter which is a new variable created for the life of the execution of the subprogram The value of the parameter is lost as soon as the subprogram execution 18 over When arguments are passed by reference the corresponding parameter uses the same memory location as the argument and starts with the value of the argument at the invocation of the call The final value of the parameter at the end of subprogram execution is accessible through the argument used This method is mainly used to return more than one value from a subprogram and to modify the values of variables in a subprogram Statement Block This forms the main body of the program and subprograms The statements here specify the task to be accomplished by the program System Variables are built into GSL and are used to control the motion and simulation related behavior of a Device during the program execution these variables start out with a default value and most are of type Real e APPROACH AXIS indi
69. rectory with out extension If the FWS on the factory floor is ready answer y to the prompt Do you want to download to the FWS now lt y gt The simulation details will be downloaded to the FWS Then the manipulators will move back to their home positions the right one after placing the gripper back in the tool stand If not then when the FWS is ready pick the SYSTEM Context and the FILE Page Pick the UNIX SHELL Button red border will appear click the LMB at a convenient spot and a window will appear Now you are in the usr deneb igrip 4d directory Type cd att If you want to see your selections from the run type cat filename out where filename is the name of the file you entered To download the file to the FWS type hit file out 5 3 Output File The user s selections during the simulation run are recorded in the file with a user chosen name to be input to the C program The output file from the GSL program is produced as below SPEED 100 OFFSET 0 5 ROBOT robot2 SAFE POINT sp2 PICK POINT ch30 CHECK POINT cp3 PLACE POINT ch3100 CHIP chip3D SAFE POINT sp2 PICK POINT ch30 CHECK POINT cp3 PLACE POINT ch380 RUN TIME 26 348 It took 26 348 sec to complete the run Your output is in deneb igrip 4d att hasf out ROBOT robot2 CHIP chip30 SRFE POINT sp2 PICK POINT ch3D CHECK POINT cp3 PLACE PDINT ch380 de T
70. ribe how the Joint should move The most common choices are to Translate along an axis or to Rotate about an axis First specify Set Home next specify Trans X enter a 1 for the Translate X Expr finally select Return The Set Home option indicates that the system should use the current location and orientation as the zero position when calcu lating the location The Trans X option defines motion along the Part s X axis This motion is tied to Degree of Freedom number 1 In other words Joint 1 is a Translational Joint that moves positive in the Part s positive X direction The CHAPTER 3 SIMULATION 22 Return choice completes the DOF definition It is possible to have more than one DOF number for the same Part as also to have one DOF number control motion for many Parts in many different directions as well as mixing types of motion Select the other Parts and repeat the above except choose Trans Y Trans 2 Rotate Z Rotate Y and Rotate X with DOF numbers 2 3 4 5 and 6 respec tively Now select the KINEMATICS Button and choose the Inverse Kinematics option from the Popup 3 3 3 Setting up DEVICE Kinematics To begin with the manipulators were assigned Simple Kinematics It was observed that the Device split up into its constituent Parts while moving to a Tag Point The Utool did align with the Tag Point but as the FWS is an overhead gantry
71. second level of OLP software is the language processor This program called postprocessor translates the list of commands into language that the robot controller can use to run the cell The postprocessor in this case consists of C awk and mml programs which download the relevant data to the FWS 4 6 Postprocessor physical communication link was made between the serial port of the SGI workstation and the serial port of the FWS via cable As there was too much transmission loss low loss cable was substituted Furthermore the data was sent over too fast the old data was being overwritten by the new before being used and acted upon by the M L gt which program This problem was circumvented by the use of the UNIX utility sleep suspends execution of the program for the specified number of seconds The C program opens the serial port of the SGI makes a system call to an awk program by supplying the field delimiter for the awk program and the filename which in turn was supplied to it by the GSL program It then reads the file out created by the awk program and writes the information to the serial port at intervals 1 e it writes one line of information waits for an interval and then writes out the next line of information 4 6 1 C Program The C program which makes a system call to the awk program and subsequently sends the data over the serial port is as below include lt stdio h gt Preprocesso
72. some transfer media like floppy disks 1 3 IGRIP IGRIP Interactive Graphics Robot Instruction Program from Deneb Robotics Inc is a simulation animation package used for workcell layout simulation and OLP IGRIP consists of a CAD section a Device modeler and Layout section Parts are modeled in the CAD section using primitives like cone block sphere pipe cylinder etc Devices with multiple degrees of freedom comprising Parts are defined in the Device section These Devices are laid out with I O signals set up between them in the Lay out section Simulation is carried out by running GSL Graphic Simulation Language programs in the Motion section 14 AT amp T FWS The AT amp T FWS 200 is a 4 axis gantry style pick and place robot with two types of manipulators one with a vacuum tool the other with a tool changer accommodating vacuum tool and a gripper It is programmed a multitasking modular BASIC like control language M L Modular Manufacturing Language and controlled by a 80386 based PC 1 5 Objective The objective of this work is to enable communication between the simulation system IGRIP and the FWS on the factory floor This involves overcoming the handshake protocol between the different hardware devices involved Serial communication requires protection against data loss during transmission As the FWS is not a member of the library of robots in IGRIP the kinematics of the manipulators need to be
73. strain or free the Degrees of Freedom Select the SURFACE Button and then using the LMB Left Mouse Button pick the surface to snap the Tag Point onto You may also select the VERTEX EDGE FRAME Buttons as appropriate If the orientation of the most recently created Tag Point is desired for subsequent Tag Point placements pick the surface with the RMB Right Mouse Button This will place a new Tag Point at that position with the same orientation as the pre vious H your Tag Point names end in integer numbers the new Tag Point will be added to the current Path and given the next available ending number If only part of the Tag Point is visible part of it is hidden inside of the polygon You may want to go to the SYSTEM Context and select the Z BUFFER Button it should dehighlight which means the real time Z Buffer is turned off and all of the Tag Point axes become visible This completes the Path layout To check on the reachability of these Tag Points select the T JOG Button Pick the Device Robot to be T Jogged when the Tags are moved Now the Device will move to any Tag Point picked align itself to the Tag Point using its Utool and follow it The Tag Points can be selected one by one to check position and orientation If needed any changes may be made using TRN TAG and ROT TAG Buttons 3 3 6 Input Output Signals To layout the I O connections CHAPTER 3 SIMULATION 28 e Select the LAYOUT Context and the WORKCELL Page
74. submitted to the faculty of the Graduate School of the New Jersey Institute of Technology in partial fulfillment of the requirements for the degree of Master of Science in Mechanical Engineering 1991 Title of Thesis Name of candidate Thesis and Abstract approved by Faculty Committee APPROVAL SHEET OFF LINE PROGRAMMING USING IGRIP Narahari K Bhandary Prof N Levy Date Associate Professor Department of Mechanical Engineering Een Prof D L bliner Date Adjunct Assistant Professor Department of Manufacturing Engineering Z sae Prof M Leu Date Professor Department of Mechanical Engineering VITA NAME Narahari K Bhandary DEGREE AND DATE TO BE CONFERRED M S M E October 1991 MAJOR Mechanical Engineering SECONDARY EDUCATION Central School K VM Mangalore India 1982 POST SECONDARY EDUCATION COLLEGE DATES DEGREE DATE OF DEGREE New Jersey Institute of Technology Newark 9 89 5 91 MSME Oct 1991 Sri Jayachamarajendra College of Engineering Mysore 9 84 11 88 BSME Nov 1988 ABSTRACT Title of Thesis OFF LINE PROGRAMMING USING IGRIP By Narahari K Bhandary MSME 1991 Thesis directed by Dr N Levy Department of Mechanical Engineering AT amp T s FWS 200 Flexible Work Station has been modeled and simulated to im plement Off Line Programming OLP IGRIP Interactive Graphics Robot Instruction Program from Deneb Robotics Inc has been used to simulate the FW
75. t Opens the file whose name is testy dat using mode i input CHAPTER 2 AT amp T FWS 200 13 And file identifier 3 while j lt gt END fline_input 3 s Places all the characters of a line from the file pointed to by 3 into the mml string s i strtok s j strtok k strtok xMn switch j case SPEED speed val k val k val k 500 Sets the speeds in in sec for X Y Z and deg sec for theta case OFFSET offset over offset 0 0 val k O case ROBOT if k 1 then attach 1 Will cause manipulator 1 to be attached to the mml interpreter and Also cause it to be completely initialized if k 1 then tol vac if k 2 then a 1 call home Calls the procedure called home if a 1 then call gettool 2 grip Calls the procedure called gettool to pick up the gripper from CHAPTER 2 AT amp T FWS 200 14 the tool changer if k 2 then imove 4 0 0 0 Moves the manipulator 4 inches away from the tool changer 0 if 1 then rob 1 SAFE_POINT if k spi then move sp break Used to insure that the move has been completed if k sp2 then safpt sp2 case PICK_POINT if k ch10 then pp ch 0 call pick pp over tol errflag Calls the procedure pick case CHECK_POINT if k cpi then cpoint cpl move cpointtover move cpoint move cpoint over case PLACE POINT if k ch310 th
76. tension to fname strtok Returns the next token in the argument string fopen Opens a file fline_input Reads all characters up to a newline from the file associated with the file descriptor and are stored into a variable fclose Closes the file associated with the specific file numbers sdefine Notifies M L which device is to be configured stype Notifies M L of what kind of device is being defined sset Sets each field in the database sopen Establishes a connection to a device The name of the device in the SIO database is used to determine what type of device is to be opened and how to initialize 11 sgets Is a function which obtains a string from a device and returns it to the M L procedure sclose Disconnects from a device The name of the device the SIO database 18 used to determine which device 1s to be closed 92 Appendix B GSL Commands and Functions STR Takes two arguments with format string as the first argument The format string may be any string expression which includes special formatting symbols which determine how the second argument is to be formed in the resulting string These symbols are preceded by a stand for real number in exponential form real number without exponent and shortest representation respectively SUBSTR Produces a subset of the string argument The output string will be gin with the character indexed by the second argument and will contain as many c
77. the robot will be tied up for the duration of the programming operation which by itself is a tedious and time consuming task Add to this the de bugging time the time required to correct any mistakes in the program and you have production line equipment idle for a considerable period of time Robots simply taught their motions through lead through steps as well as those running complicated high level languages can see a significant improvement in downtimes with the application of OLP Programming away from the robots can be done in as little as one fifth the time it would take to step through a procedure manually meanwhile the line can be running Overhead costs for some robots run 200 per hour combine that with downtime on the production line which can run into thousands of dollars per minute and the reason for using OLP becomes clear Also by downloading a program into a robot the user does 65 CHAPTER 4 OFF LINE PROGRAMMING OLP 66 not have to technically know the individual language that the robot runs on even though the eventual goal is to allow for user ignorance or invisible languages This is where Off Line Programming or OLP comes in 4 2 OLP Off Line Programming is the technique of developing a robot program without using the actual robot itself for the programming process A particular task is programmed using an implicit or explicit problem oriented programming language In explicit motion oriented progra
78. top button e 80386 based PC controls the FWS e Manipulators provide X Y Z amp 0 motion of the system e Pneumatic amp ventilation systems e Power supplies e Axes control electronics Industrial I O modules amp STD bus Control Control Vision System Cabinet Panel If Present Drive AT amp T Electronics PC6386 Manipulator 1 Manipulator 2 Frame FLEXIBLE WORK STATION Figure 2 1 H x ue a CONTROL PANEL Figure 2 2 CHAPTER 2 AT amp T FWS 200 9 2 1 2 MML is an interpretive language The interpreter reads and executes one line of a program at a time immediately and without requiring an intermediate compilation phase M Lis Familiar BASIC like syntax Multitasking can handle many tasks simultaneously while supporting communi cation and synchronization between various tasks Flexible can be customized to control any machine or process and is not restricted to just robot control Portable easily portable as it s written in Full Featured equipped with a full screen editor debugger and support for other editors like vi 2 2 Power Up Sequence To turn the FWS on Turn on the power by pressing the Emergency Reset ON pushbutton The fans will turn on and the Emergency Reset POWER light will illuminate Turn the Main Power Key Switch to the ON position Turn on the computer by pressing the Computer ON pushbutton The
79. was written to the file out via the END statement This method proved only partially successful as some of the characters were lost dur ing transmission Hence it was decided to buffet the data from both sides viz at the be ginning and the end of the words The following program inserts a line BEGIN startx at the beginning of the file out to indicate the start of data and prints out all the other lines in the file surrounded by some special characters viz z at the beginning of the word and x at the end of the word to protect the data against loss It also appends a line FEND endx at the end of the file out to signal end of data BEGIN printf sin z BEGIN startx gt usr deneb igrip 4d att out print 2 0 gt usr deneb igrip 4d att out END printf s Z END endx gt usr deneb igrip 4d att out 4 7 OLP Benefits OLP allows engineers to create a workable program on a computer and then send it to the robot controller The all too common scenario program test reprogram test can CHAPTER 4 OFF LINE PROGRAMMING OLP 77 take a robot out of production for days or weeks OLP avoids such interruptions OLP gives the fabricator these benefits e He can program robot motion at a computer terminal in an office in comfort and quiet away from the robot e He can view program statements which makes editing of long programs easy com pared to teach penda

njit-etd1991-017 - New Jersey Institute of Technology

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