CAD/CAM
ADVANCED MANUFACTURING SYSTEMS
[Link]
16BME1023
ABB IRB 1600 ROBOT
An articulated robot is a robot with rotary joints (e.g. a legged robot or an industrial robot).
Articulated robots can range from simple two-jointed structures to systems with 10 or more
interacting joints. They are powered by a variety of means, including electric motors. Some types of
robots, such as robotic arms, can be articulated or non-articulated. Articulated robots are generally
driven by electric motors where proper controlling signal with proper time synchronism are
needed to have control over the movement of the robot. Electric motors employed for the motion
control must be operated sequentially and with certain time duration. This paper discusses the
motion control of an articulated robot which can be used for precise positioning having
applications in various industries. Necessary conditions for the precise positioning of an
articulated robotic arm are determined, and ways to control the hand based on these
conditions are proposed.
SPECIFICATIONS:
ELECTRICAL CONNECTIONS:
SUPPLY VOLTAGE: 200-600V AT 50/60 Hertz.
POWER CONSUMPTION: 150 – CUBE at maximum speed 0.51 kW.
DIMENSIONS: Base - 484 x 648 mm.
Height – 1392 mm.
Weight – 250 kg.
ENVIRONMENT: Ambient Temperature for mechanical unit:
During Operation : 5⁰C - 45⁰C.
During transportation/storage : -25⁰C - 55⁰C.
Short periods (max 24h) – upto 70⁰C.
HUMIDITY: Maximum 95% relative humidity.
NOISE LEVEL: Maximum 73 decibel.
SAFETY: Double circuits with supervision
FUNCTIONS: 3 position enable device.
EMISSION: EMC/EMI shielded.
REACH – 1.5 m and HANDLING CAPACITY – 4 kg.
NUMBER OF AXES – 6
MOUNTING – Floor, Tilted & inverted. IRC 5 controller variants, single cabinet, dual cabinet,
panel mounted.
PERFORMANCE – Position repeatability – 0.02mm & Path repeatability – 0.48mm.
ROBOT VERSION – IRB 1600 – 411.5
ROBOT MOVEMENT IN ALL DOF
MAIN APPLICATIONS:
▪ Assembly
▪ Arc Welding
▪ Material Handling
▪ Machine Tending
▪ Material Removal
▪ Cleaning/Spraying
▪ Dispensing
▪ Packing
MTAB CNC MACHINES
XLMILL
This CNC Milling machine with an optional 6 station
Automatic Tool Changer is the ideal solution for
educational institutions for training purpose.
The machine can be offered with emulated control
system with either Fanuc or Siemens contro.
XLMILL can be integrated and interfaced with
robots, automatic storage & retrieval system
(ASRS), linear conveyor, into FMS and CIM systems.
Other necessary options include loading and
unloading device, auto door and hydro-pneumatic
vice.
XLMILL
WORKING/OPERATION:
The time required to produce a given quantity of parts includes the initial setup time and
the cycle time for each part. The setup time is composed of the time to setup the milling
machine, plan the tool movements (whether performed manually or by machine), and install
the fixture device into the milling machine. The cycle time can be divided into the following four
times:
1. Load/Unload time - The time required to load the workpiece into the milling machine and
secure it to the fixture, as well as the time to unload the finished part. The load time can
depend on the size, weight, and complexity of the workpiece, as well as the type of fixture.
2. Cut time - The time required for the cutter to make all the necessary cuts in the workpiece
for each operation. The cut time for any given operation is calculated by dividing the
total cut lengthfor that operation by the feed rate, which is the speed of the cutter relative
to the workpiece.
3. Idle time - Also referred to as non-productive time, this is the time required for any tasks
that occur during the process cycle that do not engage the workpiece and therefore remove
material. This idle time includes the tool approaching and retracting from the workpiece,
tool movements between features, adjusting machine settings, and changing tools.
4. Tool replacement time - The time required to replace a tool that has exceeded its lifetime
and therefore become to worn to cut effectively. This time is typically not performed in
every cycle, but rather only after the lifetime of the tool has been reached. In determining
the cycle time, the tool replacement time is adjusted for the production of a single part by
multiplying by the frequency of a tool replacement, which is the cut time divided by the tool
lifetime.
Following the milling process cycle, there is no post processing that is required. However,
secondary processes may be used to improve the surface finish of the part if it is required. The
scrap material, in the form of small material chips cut from the workpiece, is propelled away
from the workpiece by the motion of the cutter and the spraying of lubricant. Therefore, no
process cycle step is required to remove the scrap material, which can be collected and
discarded after the production.
FEATURES
● Minimize the number of setups that are required by designing all features on one side of the
workpiece, if possible
● Design features, such as holes and threads, to require tools of standard sizes
● Minimize the number of tools that are required
● Ensure that the depth of any feature is less than the tool length and therefore will avoid the
collet contacting the workpiece
● Lower requirements for tolerance and surface roughness, if possible, in order to reduce costs
● Design internal vertical edges to have a corner radius equal to that of a standard tool. If
another component with an external sharp edge must fit, then drill a hole to provide a relief
area
● Avoid very long and thin features
● Use chamfers rather than a corner radius for outside horizontal edges
● Avoid undercuts
APPLICATIONS:
● Aerospace and Power generation parts, Stainless Steels.
● Aerospace parts,CFRP and aluminium composite materials.
● Die casting molds
● Gold forging Dies.
SPECIFICATIONS:
XLTURN
Turning is a form of machining, a material removal process,
which is used to create rotational parts by cutting away
unwanted material. The turning process requires a turning
machine or lathe, workpiece, fixture, and cutting
tool. The workpiece is a piece of pre-shaped
material that is secured to the fixture, which itself
is attached to the turning machine, and allowed to
rotate at high speeds. The cutter is typically a
single-point cutting tool that is also secured in the
machine, although some operations make use of
multi-point tools. The cutting tool feeds into the
rotating workpiece and cuts away material in the
form of small chips to create the desired shape.
Turning is used to produce rotational, typically axi-symmetric, parts that have many features,
such as holes, grooves, threads, tapers, various diameter steps, and even contoured surfaces.
Parts that are fabricated completely through turning often include components that are used in
limited quantities, perhaps for prototypes, such as custom designed shafts and fasteners.
Turning is also commonly used as a secondary process to add or refine features on parts that
were manufactured using a different process. Due to the high tolerances and surface finishes
that turning can offer, it is ideal for adding precision rotational features to a part whose basic
shape has already been formed.
WORKING/OPERATION:
The time required to produce a given quantity of parts includes the initial setup time and
the cycle time for each part. The setup time is composed of the time to setup the turning
machine, plan the tool movements (whether performed manually or by machine), and install
the fixture device into the turning machine. The cycle time can be divided into the following
four times:
1. Load/Unload time
- The time required to load the workpiece into the turning machine and secure it to the
fixture, as well as the time to unload the finished part. The load time can depend on the
size, weight, and complexity of the workpiece, as well as the type of fixture.
2. Cut time
- The time required for the cutting tool to make all the necessary cuts in the workpiece for
each operation. The cut time for any given operation is calculated by dividing the total cut
length for that operation by the feed rate, which is the speed of the tool relative to the
workpiece.
3. Idle time
- Also referred to as non-productive time, this is the time required for any tasks that occur
during the process cycle that do not engage the workpiece and therefore remove material.
This idle time includes the tool approaching and retracting from the workpiece, tool
movements between features, adjusting machine settings, and changing tools.
4. Tool replacement time
- The time required to replace a tool that has exceeded its lifetime and therefore become
to worn to cut effectively. This time is typically not performed in every cycle, but rather only
after the lifetime of the tool has been reached. In determining the cycle time, the tool
replacement time is adjusted for the production of a single part by multiplying by the
frequency of a tool replacement, which is the cut time divided by the tool lifetime.
Following the turning process cycle, there is no post processing that is required. However,
secondary processes may be used to improve the surface finish of the part if it is required. The
scrap material, in the form of small material chips cut from the workpiece, is propelled away
from the workpiece by the motion of the cutting tool and the spraying of lubricant. Therefore,
no process cycle step is required to remove the scrap material, which can be collected and
discarded after the production.
WORKPIECE
● Select a material that minimizes overall cost. An inexpensive workpiece may result in
longer cut times and more tool wear, increasing the total cost
● Minimize the amount of turning that is required by pre-cutting the workpiece close to the
desired size and shape
● Select the size of the workpiece such that a large enough surface exists for the workpiece to
be securely clamped. Also, the clamped surface should allow clearance between the tool and
thefixture for any cuts
FEATURES
● Minimize the number of setups that are required by designing all features to be accessible
from one setup
● Design features, such as holes and threads, to require tools of standard sizes
● Minimize the number of tools that are required
● Ensure that the depth of any feature is less than the tool length and therefore will avoid the
tool holder contacting the workpiece
● Lower requirements for tolerance and surface roughness, if possible, in order to reduce costs
● Avoid undercuts
SPECIFICATIONS:
RAPID PROTOTYPING
Rapid prototyping is a group of
techniques used to quickly fabricate
a scale model of a physical part or
assembly using three-
dimensional computer aided
design (CAD) [Link] of
the part or assembly is usually done
using 3D printing or "additive layer
manufacturing" technology.
The first methods for rapid
prototyping became available in the
late 1980s and were used to
produce models and prototypeparts.
Today, they are used for a wide range of applications and are used to manufacture production-
quality parts in relatively small numbers if desired without the typical unfavorable short-run
economics. This economy has encouraged online service bureaus. Historical surveys of RP
technology start with discussions of simulacra production techniques used by 19th-century
sculptors. Some modern sculptors use the progeny technology to produce exhibitions. The
ability to reproduce designs from a dataset has given rise to issues of rights, as it is now
possible to interpolate volumetric data from one-dimensional images.
WORKING:
Rapid prototyping was introduced in 1987. This technology is an additive process. An additive
process builds an object by joining particles or layers of raw material. Other conventional
processes are subtractive and compressive. Materials used for the additive process are
photopolymers, thermoplastics, metal powders, and ceramic powders.
Stereolithography, which was one of the first rapid prototyping technologies, is a method that
uses photopolymer in a vat. A laser generates an ultraviolet beam that solidifies focused surface
areas of the photopolymer. The process begins with the vat filled with the photopolymer liquid.
The operator loads a three dimensional CAD solid model file into the system. The control unit
slices the model and supports into a series of cross sections from 0.004 to 0.020 inches thick.
The computer-controlled optical scanning system directs and focuses the laser beam so that it
solidifies a two -dimensional cross section on the surface of the photopolymer. The product
turns to cover the solid polymer with another layer of the liquid. This process continues,
building the part from the bottom up, until the system completes the product.
There are many other rapid prototyping technologies such as selective laser sintering (SLS),
fused deposition modeling (FDM), fused peposition modeling (FDM), etc.
SPECIFICATIONS FOR A 3D PRINTER:
Abbreviation: 3DP
Material type: Powder
Materials: Ferrous metals such as
Stainless steel; Non-ferrous
metals such as Bronze;
Elastomers; Composites;
Ceramics
Max part size: 59.00 x 29.50 x 27.60 in.
Min feature size: 0.008 in.
Min layer thickness: 0.0020 in.
Tolerance: 0.0040 in.
Surface finish: Rough
Build speed: Very Fast
Applications: Concept models, Limited
functional testing,
Architectural & landscape
models, Color industrial
design models, Consumer
goods & packaging
APPLICATIONS:
With the help of stereolithography a prototype was being made of a telescope for a
radiostation. The prototype was made at a scale of 1:200. With this prototype it was possible to
do some checks in the windtunnel. In this way the engineers could do some really important
measurements. A conventional prototype would have taken months to build.
A jewelmaker can also use this method very well. The prototypes build by rapid prototyping
were used to make molds. The expensive labourcosts went down because of the use of the
cost-effective prototyping!
A computer manufacturer made a computer inside a pen, the really personal computer. They
built the computer in a pen, but for better sales results they had to come up with more then
one packaging. Rapid prototyping helped them to design these different packagxings in a very
short time.