PROGRAMMING THE ROBOT
There are various methods which robots can be programmed to perform a given work cycle.
We divide this programming method into four categories.
1. Manual method
2. Walkthrough method
3. Lead through method
4. Off-line programming
Manual method:
This method is not really programming in the conventional sense of the world. It is more like
setting up a machine rather than programming. It is the procedure used for the simpler robots
and involves setting mechanical stops, cams, switches or relays in the robots control unit. For
these low technology robots used for short work cycles (e.g., pick and place operations), the
manual programming method is adequate.
Walkthrough method:
In this method the programmer manually moves the robots arm and hand through the motion
sequence of the work cycle. Each movement is recorded into memory for subsequent
playback during production. The speed with which the movements are performed can usually
be controlled independently so that the programmer does not have to worry about the cycle
time during the walk through. The main concern is getting the position sequence correct. The
walk through method would be appropriate for spray painting and arc welding.
Lead through method:
The lead through method makes use of a teach pendant to power drive the robot through its
motion sequence. The teach pendant is usually a small hand held device with switches and
dials to control the robots physical movements. Each motion is recorded into memory for
future playback during work cycle. The lead through method is very popular among robot
programming methods because of its ease and convenience.
On-Line/Lead -Through programming
Advantage:
Easy
No special programming skills or training
Disadvantages:
not practical for large or heavy robots
High accuracy and straight-line movements are difficult to achieve, as
are any other kind of geometrically defined trajectory, such as circular
arcs, etc.
difficult to edit out unwanted operator moves
difficult to incorporate external sensor data
Synchronization with other machines or equipment in the work cell is
difficult
A large amount of memory is required
Off- line programming:
This method involves the preparation of the robot program off-line, in a manner similar to
NC part programming. Off-line robot programming is typically accomplished on a computer
terminal. After the program has been prepared, it is entered in to the robot memory for use
during the work cycle. The advantaged of off-line robot programming is that the production
time of the robot is not lost to delay in teaching the robot a new task. Programming off-line
can be done while the robot is still in production on the preceding job. This means higher
utilization of the robot and the equipment with which it operates.
Another benefit associated with off-line programming is the prospect of integrating the robot
into the factory CAD/CAM data base and information system.
Robot Programming Languages
Non computer controlled robots do not require programming language. They are programmed
by the walkthrough or lead through methods while the simpler robots are programmed by
manual methods. With the introduction of computer control for robots came the opportunity
and the need to develop a computer oriented robot programming language.
The VALTM Language
• The VAL language was developed for PUMA robot
• VAL stands for Victors Assembly Language
• It is basically off-line language in which program defining the motion sequence is can
be developed off-line but various point location used in the work cycle are defined by
lead through.
• VAL statements are divided into two categories a) Monitoring command b)
Programming instructions.
• Monitor command are set of administrative instructions that direct the operation of the
robot system. Some of the functions of Monitor commands are
Preparing the system for the user to write programs for PUMA
Defining points in space
Commanding the PUMA to execute a program
Listing program on the CRT
• Examples for monitor commands are: EDIT, EXECUTE, SPEED, HERE etc.
• Program instructions are a set of statements used to write robot programs. One
statement usually corresponds to one movement of the robots arm or wrist.
• Example for program instructions are Move to point, move to a point in a straight line
motion, open gripper, close gripper. (MOVE, MOVES, APPRO, APPROS, DEPART,
OPENI, CLOSEI, AND EXIT)
The MCL Language
• MCL stands for Machine Control Language developed by Douglas.
• The language is based on the APT and NC language. Designed control complete
manufacturing cell.
• MCL is enhancement of APT which possesses additional options and features needed
to do off-line programming of robotic work cell.
• Additional vocabulary words were developed to provide the supplementary
capabilities intended to be covered by the MCL. These capability include Vision,
Inspection and Control of signals
• MCL also permits the user to define MACROS like statement that would be
convenient to use for specialized applications.
• MCL program is needed to compile to produce CLFILE.
• Some commands of MCL programming languages are DEVICE, SEND, RECEIV,
WORKPT, ABORT, TASK, REGION, LOCATE etc.
Textual Statements
Language statements taken from commercially available robot languages
1 The basic motion statement is:
MOVE P1
Commands the robot to move from its current position to a position and orientation defined
by the variable name [Link] point p1 must be defined.
The most convenient method way to define P1 is to use either powered lead through or
manual leads through to place the robot at the desired point and record that point into the
memory.
HERE P1
OR
LEARN P1
Are used in the lead through procedure to indicate the variable name for the point
What is recorded into the robot’s control memory is the set of joint positions or coordinates
used by the controller to define the point.
For ex, (236,157,63,0,0,0)
The first values give joint positions of the body and arm and the last three values(0,0,0)
define the wrist joint positions.
MOVES P1
Denotes a move that is to be made using straight line interpolation. The suffix‘s’ designates a
straight line motion.
DMOVE (4,125)
Suppose the robot is presently at a point defined by joint coordinates(236,157,63,0,0,0) and it
is desired to move joint 4from 0 to 125. The above statement can be used to accomplish this
move. DMOVE represents a delta move.
Approach and depart statements are useful in material handling operations.
APPROACH P1, 40 MM
MOVE P1
(Command to actuate the gripper)
DEPART 40 MM
The destination is point p1 but the approach command moves the gripper to a safe
distance(40mm) above the point.
Move statement permits the gripper to be moved directly to the part for grasping.
A path in a robot program is a series of points connected together in a single move. A path is
given a variable name
DEFINE PATH123=PATH(P1,P2,P3)
A move statement is used to drive the robot through the path.
MOVE PATH123
SPEED 75 the manipulator should operate at 75% of the initially commanded velocity. The
initial speed is given in a command that precedes the execution of the robot program.
For example,
SPEED 0.5 MPS
EXECUTE PROGRAM1
Indicates that the program named PROGRAM1 is to be executed by the robot at a speed of
0.5m/sec.
Interlock And Sensor Statements
The two basic interlock commands used for industrial robots are WAIT and SIGNAL. The
wait command is used to implement an input interlock.
For example,
WAIT 20,ON
Would cause program execution to stop at this statement until the input signal coming into
the robot controller at port 20 was in “ON” [Link] might be used in a situation where
the robot needed to wait for the completion of an automatic machine cycle in a loading and
unloading application.
The SIGNAL statement is used to implement an output interlock. This is used to
communicate to some external piece of equipment.
For example,
SIGNAL 20, ON
Would switch on the signal at output port 20, perhaps to actuate the start of of an automatic
machine cycle.
The above interlock commands represent situations where the execution of the statement
appears.
There are other situations where it is desirable for an external device to be continuously
monitored for any change that might occur in the device.
For example,in safety monitoring where a sensor is setup
to detect the presence of humans who might wander into the robot’s work [Link] sensor
reacts to the presence of humans by signaling the robot controller.
REACT 25, SAFESTOP
This command would be written to continuously monitor input port 25 for any changes in the
incoming signal. If and when a change in the signal occurs, regular program execution is
interrupted and the control is transferred to a subroutine called [Link] subroutine
would stop the robot from further motion and/or cause some other safety action to be taken.
Commands for controlling the end-effectors
Although end effectors are attached to to the wrist of the manipulator,they are very much like
external devices. Special command are written for controlling the end effector. Basic
commands are
OPEN (fully open)
and
CLOSE (fully close)
For grippers with force sensors that can be regulated through the robot controller, a command
such as ,
CLOSE 2.0 N
Controls the closing of the gripper until a 20.N force is encountered by the grippers.
A similar command would be used to close the gripper to a given opening width is,
CLOSE 25 MM
A special set of statements is often required to control the operation of tool type end effectors
.(such as spot welding guns, arc welding tools, spray painting guns and powered spindles ).
End Effectors
In the terminology of robotics, end effectors can be defined as a device which is attached to
the robots wrist to perform a specific task. The task might be work part handling, spot
welding, spray painting, or any of a great variety of other functions. The possibilities are
limited only by the imagination and ingenuity of the application engineers who design robot
systems. The end effectors are the special purpose tooling which enables the robot to perform
a particular job. It is usually custom engineered for that job, either by the company that owns
the robot or company that sold the robots. Most robot manufacturer has engineered groups
which design and fabricate end effectors or provide advice to their customers on end effectors
design.
For purpose organization, we will divide the various types of end effectors into two
categories: grippers and tools.
1. Grippers: are generally used to grasp and hold an object and place it at a desired
location. Grippers can be classified as
Mechanical grippers
Vacuum or suction cups
Magnetic grippers
Adhesive grippers
Hooks,
Scoops, and so forth.