Handbook of Industrial Robotics

1327 Pages·1999·53.001 MB·English

by  Shimon Y. Nof

HANDBOOK OF
INDUSTRIAL ROBOTICS
Handbook of Industrial Robotics, Second Editio n . Edited by Shimon Y. Nof
Copyright © 1999 John Wiley & Sons, Inc.
EDITORIAL BOARD
T. Arai H. Makino
University of Tokyo Yamanashi University
J. J. DiPonio G. Salvendy
Ford Motor Co. Purdue University
G. Seliger
Y. Hasegawa
IPK/IFW Berlin
Waseda University
K. Tanie
S. W. Holland
MEL Tsukuba
General Motors Corp.
K. Trostmann
S. Inaba Technical University Denmark
FANUC Inc.
Y. Umetani
A. C. Kak Toyota Technological Institute
Purdue University
H. Van Brussel
Catholic University of Leuven
S. K. Kim
Samsung Electronics
H.-J. Warnecke
Fraunhofer Institute
J.-C. Latombe
Stanford University
R. H. Weston
Loughborough University of
E. Lenz Technology
Technion—Israel Institute of
Technology D. Whitney
Massachusetts Institute of Technology
HANDBOOK OF
INDUSTRIAL ROBOTICS
Second Edition
edited by
Shimon Y. Nof
JOHN WILEY & SONS, INC.
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LibraryofCongressCataloging-in-PublicationData
Handbookofindustrialrobotics/editedbyShimonY.Nof.—2nded.
p. cm.
Includesindex.
ISBN0-471-17783-0(alk.paper)
1. Robots,Industrial—Handbooks,manuals,etc. I. Nof,Shimon
Y.
TS191.8.H36 1999
670.42(cid:1)72—dc21 98-8017
PrintedintheUnitedStatesofAmerica
10 9 8 7 6 5 4 3 2 1
This handbook is dedicated
to all of us who believe in
the wonders of human ingenuity
and robot servitude for the
betterment of our life
CONTENTS
Foreword xi
GuestForewords xiii
Preface xvii
Contributors xix
PART1 DEVELOPMENTOFINDUSTRIALROBOTICS
1. HistoricalPerspectiveandRoleinAutomation JosephF.Engelberger 3
2. RoboticsinJapan:EmergingTrendsandChallenges YojiUmetani,
YukioIwasa 11
3. RobotsandMachineIntelligence CharlesA.Rosen 19
4. EmergingTrendsandIndustryNeeds StevenW.Holland,ShimonY.Nof 31
PART2 MECHANICALDESIGN
5. ManipulatorDesign H.-J.Warnecke,R.D.Schraft,M.Ha¨gele,O.Barth,
G.Schmierer 43
6. KinematicsandDynamicsofRobotManipulators AndrewA.Goldenberg,
MohammadR.Emami 79
7. RobotHandsandEnd-Effectors KazuoTanie 99
8. MobileRobotsandWalkingMachines HagenSchempf 145
9. Teleoperation,Telerobotics,andTelepresence WayneBook,LonnieLove 167
10. Microrobotics ToshioFukuda,FumihitoArai 187
11. Nanorobotics AristidesA.G.Requicha 199
PART3 CONTROLANDINTELLIGENCE
12. DesignofRobotControllers HadiA.Akeel,AtsushiWatanabe 213
13. SensorsforRobotics C.R.Asfahl 245
14. StereoVisionforIndustrialApplications AkioKosaka,A.C.Kak 269
15. MotionPlanningandControlofRobots VijayKumar,Milosˇ Zˇefran,
JamesP.Ostrowski 295
16. IntelligentControlofRobotMobility RonaldC.Arkin 317
17. VirtualRealityandRobotics GrigoreC.Burdea,PhilippeCoiffet 325
PART4 PROGRAMMINGANDINTELLIGENCE
18. On-lineProgramming MichaelP.Deisenroth,KrishnaK.Krishnan 337
19. Off-lineProgramming Y.F.Yong,M.C.Bonney 353
vii
viii CONTENTS
20. Learning,Reasoning,andProblemSolvinginRobotics SpyrosG.Tzafestas,
ElpidaS.Tzafestas 373
21. Neuro-fuzzySystems C.S.GeorgeLee 393
22. Coordination,Collaboration,andControlofMultirobotSystems
MichaelJ.Shaw,NarendraAhuja,SethHutchinson 423
23. GroupBehaviorofRobots GeorgeA.Bekey,ArvinAgah 439
PART5 ORGANIZATIONALANDECONOMICASPECTS
24. IndustrialRoboticsStandards NicholasG.Dagalakis 449
25. OrganizationandAutomationImpactsonProductionWorkersQualification
(EuropeanExperience) H.-J.Bullinger,J.Pack 461
26. ManagementPoliciesofComputer-IntegratedManufacturing/Robotics
A.Gunasekaran 473
27. TheRoleofCIMandRoboticsinEnterpriseReengineering R.S.Maull,
S.J.Childe,J.B.Mills,P.A.Smart 495
28. RobotIntegrationWithinManufacturingSystems J.D.Gascoigne,
R.H.Weston 509
PART6 APPLICATIONS:PLANNINGTECHNIQUES
29. ProductDesignandProductionPlanning WilliamR.Tanner 529
30. OperationsResearchTechniquesforRoboticsSystems NicholasG.Hall 543
31. Computation,AI,andMultiagentTechniquesforPlanningRobotic
Operations VenkatN.Rajan,ShimonY.Nof 579
32. RobotErgonomics:OptimizingRobotWork ShimonY.Nof 603
33. HumanFactorsinPlanningRoboticsSystems Yee-YinChoong,
GavrielSalvendy 645
34. JustificationofRoboticsSystems JohnJ.Mills,G.T.Stevens,BrianHuff,
AdrienPresley 675
PART7 APPLICATIONS:DESIGNANDINTEGRATION
35. RoboticManufacturingCells J.T.Black,LaxmiP.Musunur 697
36. Reliability,Maintenance,andSafetyofRobots DavidR.Clark,
MarkR.Lehto 717
37. CADandGraphicSimulators/EmulatorsofRoboticSystems
JacobRubinovitz 755
38. Computational,AI,andMultiagentTechniquesforDesignofRobotics
Systems GeorgeL.Kova´cs 773
39. PrecisionandCalibration KlausSchro¨er 795
40. Robotics,FMS,andCIM H.VanBrussel,P.Valckenaers 811
41. AStrategyforImplementationofRoboticsProjects GearyV.Soska 825
PART8 ROBOTICSINPROCESSES
42. FabricationandProcessing J.T.Black 831
43. RoboticsinFoundries DougNiebruegge 859
44. SpotWeldingandLaserWelding MarioSciaky 867
45. ArcWelding Jose´ A.Ceroni 887
46. Painting,Coating,andSealing K.Sugimoto 907
47. FlexibleFixturing LaneA.Hautau,AllenC.Grzebyk,Jose´ A.Ceroni 927
48. WorkpieceHandlingandGripperSelection HadiAbu-Akeel,
AtsushiWatanabe 935
CONTENTS ix
PART9 ROBOTICSINOPERATIONS
49. MaterialHandlingandWarehousing YavuzA.Bozer 957
50. Assembly:MechanicalProducts DanielE.Whitney 975
51. Assembly:Electronics K.Feldmann,S.Krimi,M.Reichenberger,K.Go¨tz 997
52. QualityAssurance,Inspection,andTesting CharlieDuncheon 1013
53. MaintenanceandRepair LynneE.Parker,JohnV.Draper 1023
54. ProductRemanufacturing E.Zussman,G.Seliger 1037
55. Microassembly KarlF.Bo¨hringer,RonaldS.Fearing,KenY.Goldberg 1045
PART10 ROBOTICSINVARIOUSAPPLICATIONS
56. AutomotiveandTransportationApplications ValerieBolhouse,
BrianDaugherty 1069
57. Electronics,Instruments,andSemiconductorIndustry SungkwunKim 1081
58. RoboticsinSpace JohnG.Webster 1117
59. ApplianceIndustry ErichNiedermayr,JosephPo¨ssinger,NorbertRoth 1133
60. FoodandAgricultureRobotics YaelEdan 1143
61. Apparel,Wire,andWoodworkingIndustries ManfredSchweizer,
ThomasHo¨rz,ClausScholpp 1157
62. RoboticsinConstructionandShipbuilding KinyaTamaki 1167
63. ProcessIndustries ThomasD.Jerney 1185
64. Services GayEngelberger 1201
65. MedicalRoboticsandComputer-IntegratedSurgery RussellH.Taylor 1213
PART11 ROBOTICSAROUNDTHEWORLD
66. RoboticsAroundtheWorld Jose´ A.Ceroni,
Chin-YinHuang,MarcoA.Lara,NaRayeP.Williams,DonaldA.Vincent 1231
PART12 ROBOTICSTERMINOLOGY
RoboticsTerminology 1261
Index 1319
AbouttheCD-Rom 1349
FOREWORD
LOOKING AHEAD
In 1939, when I was 19 years old, I began to write a series of science fiction stories
about robots. At the time, the word robot had been in existence for only 18 years;Karel
Capek’splay, R.U.R., inwhichthewordhadbeencoined,havingbeenperformedforthe
first time in Europe in 1921. The concept, however, that of machines that could perform
tasks with the apparent ‘‘intelligence’’ of human beings, had been in existence for
thousands of years.
Through all those years, however, robots in myth, legend, and literature had been
designed only topointamoral.Generally,theyweretreatedasexamplesofoverweening
pride on the part of the human designer; an effort to accomplish something that was
reservedtoGodalone.And,inevitably,thisoverweeningpridewasovertakenbyNemesis
(as it always is in morality tales), so that the designer was destroyed, usually by that
which he had created.
I grew tired of these myriad-told tales, and decided I would tell of robots that were
carefullydesignedtoperformcertaintasks,butwithsafeguardsbuiltin;robotsthatmight
conceivably be dangerous, as any machine might be, but no more so.
In telling these tales, I worked out, perforce, certain rules of conduct that guided the
robots; rules that I dealt with in a more and more refined manner over the next 44 years
(my most recent robot novel, The Robots of Dawn, was published in October, 1983).
These rules were first put into words in a story called ‘‘Runaround,’’which appeared in
the March, 1942, issue of Astounding Science Fiction.
In that issue, on page 100, one of my characters says, ‘‘Now, look,let’sstartwiththe
threefundamentalRulesofRobotics...’’andheproceedstorecitethem.(Inlaterstories,
I took to referring to them as ‘‘the Three Laws of Robotics’’and other people generally
say ‘‘Asimov’s Three Laws of Robotics.’’)
I am carefully specific about this point because that line on that page in that story
was, as far as I know, the very first time and place that the word robotics had ever
appeared in print.
I did not deliberately make up the word. Since physics and most of its subdivisions
routinely have the ‘‘-ics’’suffix, Iassumed that ‘‘robotics’’wastheproperscientificterm
for the systematic study of robots, of their construction, maintenance, and behavior, and
that it was used as such. It was only decades later that I became aware of the fact that
the word was in no dictionary, general or scientific, and that I had coined it.
Possibly every person has a chance at good fortune in his life, buttherecan’tbevery
many people who have had the incredible luck to live to see their fantasiesbegintoturn
into reality.
I think sadly, for instance, of a good friend of mine who did not. He was Willy Ley
who,forallhisadultlifewasweddedtorocketryandtothedreamofreachingthemoon;
who in his early twenties helped found rocket research inGermany;who,yearafteryear
wrote popular books on the subject; who, in 1969, was preparing to witness the launch
ofthefirstrocketintendedtolandonthemoon;andwhothendiedsixweeksbeforethat
launch took place.
Such a tragedy did not overtake me. I lived to see the transistor invented, and solid-
state devices undergo rapid development until the microchip became a reality. I lived to
see Joseph Engelberger (with his interest sparked by my stories, actually) found Uni-
mation, Inc., and then keep it going, with determination and foresight, until it actually
constructed and installed industrial robots and grew enormously profitable. His devices
were not quite the humanoid robots of my stories, but in many respects they were far
more sophisticated than anything I had ever been equipped to imagine. Nor is there any
xi
xii FOREWORD
doubt that the development of robots more like mine, with the capacities to see and to
talk, for instance, are very far off.
I lived to see my Three Laws of Robotics taken seriously and routinely referredtoin
articles on robotics, written by real roboticists, as in a couple of cases in this volume. I
lived to see them referred to familiarly,eveninthepopularpress,andidentifiedwithmy
name,sothatIcanseeIhavesecuredformyself(allunknowingly,Imustadmit)asecure
footnote in the history of science.
I even lived to see myself regarded with a certain amount of esteem by legitimate
peopleinthefieldofrobotics,asakindofgrandfatherofthemall,eventhough,inactual
fact,Iammerelyachemistbytrainingandascience-fictionwriterbychoice—andknow
virtually nothing about the nuts and bolts of robotics; or of computers, for that matter.
But even after I thought I had grown accustomed to all of this, and had ceased mar-
veling over this amazing turn of the wheel of fortune, and was certain that there was
nothing left in this situation that had the capacity to surprise me, I found I was wrong.
Let me explain . . .
In 1950 nine ofmy storiesofrobotswereputtogetherintoavolumeentitledI,Robot
(the volume, as it happens, that was to inspire Mr. Engelberger).
On the page before the table of contents, there are inscribed, in lonely splendor The
Three Laws of Robotics:
1. Arobotmaynotinjureahumanbeing,or,throughinaction,allowahumanbeing
to come to harm.
2. A robot must obey the ordersgiven itbyhumanbeingsexceptwheresuchorders
would conflict with the First Law.
3. Arobotmustprotectitsownexistenceaslongassuchprotectiondoesnotconflict
with the First or Second Law.
And underneath, I give my source. It is Handbook of Robotics, 56th Edition, 2058
A.D.
Unbelievable. Never, until it actually happened, did I ever believe that I would really
live to see robots, really live to see my three laws quoted everywhere. And certainly I
never actually believed that I would ever really live to see the first edition of that hand-
book published.
To be sure, it is Handbook of Industrial Robotics, for that is where the emphasis is
now, in the early daysofrobotics—butIam certainthat,withthedevelopmentofrobots
for the office and the home, future editions will need the more general title. I also feel
that so rapidly does the field develop, there will be new editions at short intervals. And
if there are new editions every 15 months on the average, we will have the fifty-sixth
edition in 2058 A.D.
But matters don’t stop here. Having foreseen so much, let me look still further into
the future. I see robots rapidly growing incredibly more complex, versatile, and useful
than they are now. I see them taking over all work that is too simple, too repetitive, too
stultifyingforthehumanbraintobesubjectedto.Iseerobotsleavinghumanbeingsfree
to develop creativity, and I see humanity astonished at finding that almost everyone can
be creative in one way or another. (Just as it turned out, astonishingly, once public edu-
cation became a matter of course, that reading and writing was not an elite activity but
could be engaged in by almost everyone.)
I see the world, and the human outposts on other worlds and in space, filled with
cousin-intelligences of two entirely different types. Isee silicon-intelligence(robots)that
can manipulate numbers with incredible speed and precision and that can perform oper-
ations tirelessly and with perfect reproducibility; and I see carbon-intelligence (human
beings) that can apply intuition, insight, and imagination to the solution of problems on
the basis of what would seem insufficient data to a robot. I see the former building the
foundationsofanew,andunimaginablybettersocietythananywehaveeverexperienced;
andIseethelatterbuildingthesuperstructure,withacreativefantasywedarenotpicture
now.
Iseethetwotogetheradvancingfarmorerapidlythaneithercouldalone.Andthough
this, alas, I will not live to see, I am confident our children and grandchildren will, and
that future editions of this handbook will detail the process.
ISAAC ASIMOV
(1920–1992)
NewYork,NewYork
January1985