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SICE-ICASEInternationalJointConference2006Oct.18-21,2006inBexco,Busan,KoreaDevelopmentofIndustrialDualArmRobotforPrecisionAssemblyofMechanicalPartsforAutomobilesChan-HunPark,Kyoung-TaikParkandDae-GabGweon2IntelligentMachineSystemResearchCenter,KIMM,Taejeon,Korea(Tel:+82-42-868-7127;E-mail:chparkgkimm.re.kr)2DepartmentofMechanicalEngineering,KAIST,Taejeon,Korea(Tel:+82-42-869-3225;E-mail:dggweongkaist.ac.kr)Abstract:Generalindustrialrobotshavedefinitelimitsofapplicationbecausemostofthemhasonlyonearm.Somespecialindustrialrobotshavetwoarms,buteacharmdoesthejobsseparately,thatis,eacharmiscontrolledtoperformitsreferencetrajectorywithoutdeepconsiderationsofthecooperativejob,sotheydoverysimplecooperativejobsinpositionlevelasaresult.RecentlysomeJapaneseautomobilecompaniesareinterestedinusingdualarmrobotsforassemblyofmechanicalpartsofautomobilesofwhichrobotshavetohavetwoarmsandhavetheabilityofcooperationusingpositioncontrolandforcecontrol.Wearedevelopinganindustrialdualarmrobotforprecisionassemblyofmechanicalpartsforautomobilesofwhichdegreeoffreedomis6DOFperarmand3DOFintorso.Thepayloadwillbe10kg/armandtheout-reachbe1.5m.ThisspecificationwasdeterminedforspecialassemblyprocessesforWIACo.LtdandRobotValleyCo.Ltd.Thedesignconceptisintroduced.Keywords:DualArmRobot,Assembly,RealTimeOS,MotionController.1.INTRODUCTIONIndustrialrobotshavealreadyhadgoodrolesinvariousindustrialfieldsforscoresofyearssincetheyhaveappeared.Thetechnologyofrobotapplicationsforautomobileindustrieshasalreadyreachedveryhighlevel,sowecantconsidertheautomobileindustryandthecompanieswithoutrobots.But,untilnow,industrialrobotscanthavetheirrolesinthemanyfieldsinwhichanoperatordoesthejobwithhis/hertwoarms.Generalindustrialrobotshavedefinitelimitsofapplicationbecausemostofthemhaveonlyonearm.Somespecialindustrialrobotshavetwoarms,buteacharmdoesthejobsseparately,thatis,eacharmiscontrolledtoperformitsreferencetrajectorywithoutdeepconsiderationsofthecooperativejobs,sotheydoverysimplecooperativejobsinpositionlevelasaresult.RecentlysomeJapaneseautomobilecompaniesareinterestedinusingdualarmrobotsforassemblyofmechanicalpartofautomobilesinwhichrobotshavetohavetwoarmsandhavetheabilityofcooperationusingpositioncontrolandforcecontrol5.Wearedevelopinganindustrialdualarmrobotforprecisionassemblyof mechanicalpartsforautomobilesofwhichdegreeoffreedomis6DOFperarmand3DOFintorso.Thepayloadwillbe10kg/armandtheout-reachbe1.5m.ThisspecificationwasdeterminedforspecialassemblyprocessesforWIACo.LtdandRobotValleyCo.Ltd.Thedesignconceptisintroduced.Inthecaseofgeneralindustrialrobots,thepositionreferenceteachingwithateachingpendantisenoughbecausearobotcontrollercontrolsasinglearmwithjustpositionreference.Butinthecaseofdualarmrobot,positionreachingisnotenoughbecausetwoarmshavetodocooperativejobsforpartsassembly,thecontrollerhastoconsidertheinteractionforcebetweentwoarmsandmechanicalpartsforassembly.Off-lineProgram(OLP)canbeusedforthispurposebutweneed89-950038-5-598560/06/$10C2006ICASEmoreintuitiveteachingmethods.So,themaster-slaveconceptisadopted.Weusetwocommercialmasterdevices,eachofthemhas6DOFinput(position)and6DOFoutput(force).Inthisconcept,thecontrollerneedstocomputeinverse/forwardkinematicsfor15DOFslaverobotand12DOFmasterrobotin0.005-0.01secondinrealtime.Soverypowerfulcomputationalpowerisneeded.ThatisthereasonweadoptakindofPC-basedcontroller.WewillusePentiumDprocessors,windowsXPprofessional,acommercialmotionboardofMotionEngineeringCo.Ltd.andRealTimeExtensionSoftwareofArdenceCo.Ltd.Controllerconceptandstructureisintroduced.2.JOBDEFINITIONFORTHEDUALARMROBOTOurinterestistheautomation oftheprocessofassemblyofmechanicalpartsofanautomobilecompanyusingadualarmrobotsystem.Theassemblylinesofgeartransmissionandconstantvelocityjointsareourtargets.Thesetwoassemblyprocessesdefinitelyneedso-calledcooperativetaskoftwoarmsofaworker,sosinglearmrobotscantbeappliedtothesekindsofprocesses.Thisisoneofthereasonsthatthemajorautomobilecompanieskeeptheseprocessesnot-automated.Wearenotshowingthedetailsfortheassemblyofthetargetprocesses,butjustshowingthebriefpicturesofthem.Figure1showsthetransmissionassemblylinewhichiscomposedofsomanygearsandshaftsandFigure2showstheconstantvelocityjoints(CVJoint)whichiscomposedoftwouniversaljointsandshafts.InthecaseofWIACo.Ltd.whichisfinancingthisprojectwiththegovernment,mostofproductionlinesofautomobilepartshavealreadybeenautomatedwithoutsomespecialassemblylineswhichincludethesetwoprocesses.Thedualrobotisbeingdesignedforthese3059linestobeautomated.Thedualarmrobothastobereachedto1.5m,tohandlethepayload1Okgf,toovercomethetorque1ON-mandtomovewiththerotationalvelocityofthe150deg/s.Therequiredrepeatabilityis0.1mm.Table1summarizesthespecificationwhichthedualarmrobotssatisfiesforthetargetprocesses.Fig.IlransmissionAssemblyLineFig.2ConstantVelocityJointAssemblyLinekinematicstructureisverysimilartothepuma-likerobots,anditsactionisexpecteddifferentfromhumanoidrobot.Ourdualarmrobothastobeappliedtotransmissionassemblylinesandconstantvelocityjointassemblylines.Thesetaskneedstheend-effectersofarmshavetheabilityofrotationof360degreescontinuously.Ifthedualarmrobothasthekinematicstructureofthelefthandsideofthefigure3,thentheeacharmhastohavetherotationgripperadditionally.Thus,thepayloadwouldbereducedorthestrongermotorsystemwouldbeneeded.Thereforethekinematicstructureoftherighthandsideofthefigure3isselected,andthelastjointcanbeusedtodothescrewmotionofanendeffecter,rotating360degrees,fortheassemblylines.Thesecondbenifitoftheproposedkinematicstructureisso-calledkinematicdecoupling,theinversekinematicsisverysimplyexpressedwithclosedformsolutions12.Thesearethereasonstheproposedkinematicstructureisselected._0wJvHumanoidRobotsThedualarmrobotsunderdevelopmentFig.3Thedifferencebetweenhumanoidrobots andthedualarmrobotunderdevelopmentinthisresearch.Figure4showsthesimpledrawingtherightarmanditsdesignedtosatisfythespec.oftable1.Table1Thespecificationofthedualarmrobots.Out-reachPayloadMaxTorqueMaxspeedRepeatability1.5m1Okgf/arm5ONm150deg/s0.1mm3.ROBOTDESIGNTherearesomanykindofdualarmrobots,theyhavedifferentkinematicstructures,butmostofhumanoidrobotshave3DOF-torsoand6DOF-arms.Thedualarmrobotunderdevelopmentinthisresearchhasdifferentkinematicstructurefromthatofmostofhumanoidrobotseventhoughtheyhavethesamedegreeoffreedom.Figure3showthedifferencebetweenthem.Mostofhumanoidrobotshavethekinematicstructuresimilartohuman,butthekinematicstructureofourdualarmisdifferentfromthem.TheleftandrightarmsFig.4ThedesignoftherightarmFortheworkspaceanalysis,thedevelopmentofkinematicsolutionsandthevisualevaluation,thesimpledualarmanalysistoolisdeveloped.Thisprogramisunderconstruction,itwillhavetheabilityofkinematicevaluationandtheverificationofcontrolalgorithms,3060IT7etc.rig.3iiesigntoololaclUdlartEllrULot4.CONTROLLERDESIGNFigure6showstheoverallstructureofthecontrollerunderdevelopmentwhichiscomposedofthemainhost,thevisioncontroller,thetele-operationcontrollerandtherobotcontoller.AllthecontrollersarePC-based,andcontrollersareconnectedtoeachotherwithCANbustocommunicatetoeachotherwithrealtime.Offlineprogram,visionsystemandtele-operationisbeyondthescopeofthispaper.Here,onlytherobotcontrollerisintroduced.LmisteCAMERA-.i,Shn,+UOnuireSystemln(HardRealtiIa_.NlrwbirVanot1XI3Therearetwowaysforthedevelopmentoftherobotcontrollerfordualarmrobot,thatis,thedevelopmentofthespecialcontrolboardfordualarmrobotortheuseofthecommercialmotionboards.Inthisproject,akind ofPC-basedrobotcontrollerwithZMP-syncNetmotionboardofMotionEngineeringCo.Ltd.andIndustrialPCisdeveloped.MicrosoftWindosXPasOSandRTXofArdenceCo.Ltdforrealtimecontolareselected.ZMP-syncNetmotionboardisageneralmotionboard,itusesthecentralizedcomputationtechnique,itscontrolfrequencyisreducedwhenthemoreaxedarecontrolledatthesametime.Itcontrolthe4axeswith48khzatthesametime,anditcancontrol32axesatthesametime,with2khz.Theoneofthespecialfeatureisthatitusesthedigitalcommunicationtomotordrivers(AMPs)withtheprotocolSyncNetofMotionEngineering.ThesecondspecialfeatureisthatMotionEngineeringsupportsthedriversoftwareforRealTimeOS,RTLinux,RTX,etc.ThegeneralmotionboardwithoutthedriversforRealTimeOScantbeusedtocomposethePC-Basedrobotcontroller.RTXisakindofRealTimeExtensionforwindowsXP,itsinterruptlatencyisverysmall(10us).RTLinuxisknownasoneofthebestrealtimeOS,butitisverydifficulttodevelopsoftwareintheLinuxenvironmentforgeneralusers.ThisiswhyRTLinuxisnotselected.MostofPCusersusewindowXP,andsomanyusefulsoftwaredevelopmentkitshavebeendeveloped.Therefore,windowXPwouldbeoneofthebestOSwiththeconsiderationofthemarket.ButwindowsXPdoesntsupportrealtimecomputationanditsnotperfectlystablesystem.SoRTXwithwindowsXPisselected.RTXaddstheabilityofrealtimecomputationtothewindowXP.Figure7showsthefunctionofRTX4.Fig.6TheControllerstructureGeneralrobotcontrollersareveryusefulinthedevelopmentofrobotsystem.Theyhaveveryusefulframeforrobotkinematicparametersandcontrolparameters.Inthecaseofsimpleserialrobot,mostofgeneralrobotcontrollersareavailable.Butinthecaseofthedevelopmentofveryspecialrobots,almostgeneralrobotcontrollerisnotavailable.Becausetheydonthaveso-calledopenarchitecture.Userscantaccessthesourcecodeforthekinematicequations,sospecialcaseofrobotkinematicscantbeappliedtothegeneralrobotcontrollers.Inthemarket,thereisntanycommercialrobotcontrollerfordualarmrobots,thespecialrobotcontrollerforthedualarmunderdevelopmenthastobedeveloped.Fig.7RTXandwindowsArdenceCo.LtdsaysRTXsupportstheabilityoftheinterruptlatencyoflOusinthesingleCPUsystem.Buttheresultofourtestisdifferentfromtheiropinion.SothePentiumDprocessorwithdualcoreisselected.BecauseiftheCPUhasmorethandualcoreordualCPU,thenRTXcanuseonecoreoroneCPUfullywithouttheinterferencewithwindowsXP.Inthiscase,RTXguaranteestheinterruptlatencylessthan2usastheexperimentaltesteventhoughwindowsXPisshutdownwithbluescreen4.3061Tj61HostProesgirie1TmeFig.8RTXandmultipleCPUWhenthemotionboardwhichhastheitsowncontrolalgorithmandtheabilityofaxisinterpolationisusedtocomposedofPC-basedrobotcontroller,thesynchronizationbetweenthehostandthemotioncontrollerismostimportant.RTXusesitsownclock,andmotionboarduseditsownclock,too.Thus,thefunctionofthesnyqinterruptofZMP-syncnetboardisused3.ZMPmotioncontrollersofMotionEngineeringhavetheabilitytointerruptthehostataspecifiedfrequency,wherethefrequencyisamultipleofthecontrollerssamplerate.Thisboard-to-hostinterruptisreferredtoastheSyncInterrupt.Forsystemsthatneedtosynchronizewiththecontrollerandcalculatedatathatneedstobesenteverysample,the thefirmwareofZMPhasaflag.ThisflagiscalledtheHostProcessFlag.TheHostProcessFlagcanbeusedtotellthefirmwarethatthehostisprocessingdatathatisexpectedtobetransmittedtoZMP.TheHostProcessFlagissetbythehostafteritiswokenupbyaSyncInterruptandbeforetheprocessingofitsdataandtasks.TheHostProcessFlagisclearedbythehostwhenallprocessingisdoneandbeforegoingbacktosleepandwaitingforthenextSyncInterrupt.ThefirmwareofZMPcheckstheHostProcessFlageveryforegroundcyclejustbeforestartingitsowncontroljob.IftheHostProcessFlagisstillsetwhenitsownjobs(controlandinterpolation)start,thenthefirmwarewillsetastatusbitinthecontrolobjectindicatingthatthehostdidnotcompleteitstasksintime.Thefigure9sumarizeshowthehostPCandthemotionboard(ZMP)aresynchronizedusingsyncinterrupts3.Fig.9Synchronizationbetweenthemotionboardandthe hostACKNOWLEDGMENTSThisworkwassupportedbyMOCIE(MinistryofCommerce,IndustryandEnergyRepublicofKorea)andthelocalgovernmentofGyeongsangnam-do.REFERENCES1MarkW.Spong,M.Vidyasagar,Robotdynamicsandcontrol.Johnwiley&Sons,19892JohnJ.Craig,IntroductiontoRobotics,AddisonWesley,19893/Software-MPI/Topics/sync_interrupt.htm4RTXDatasheet,Ardence()55.CONCLUSIONThedualarmrobotwhichisbeingdesignedtobeappliedtotheprocessofassemblyof mechanicalpartsofautomobileanditscontrollerwhichiscomposedofanindustrialPC,theZMPmotionboardofMotionEngineering,windowsXPofMicrosoft,andRTXofArdenceareintroduced.Thedesignedconceptsandthekinematicstructureofthedualarmrobotareintroduced.ThemethodofsynchronizationbetweenthehostPCandtheZMPmotionboardandthemethodofthemostleastinterruptlatencyforRTXareintroduced.3062用于汽车零件组装的工业双臂机器人的开发摘要 一般的工业机器人由于只有单只手臂在工作运用中有一定的局限性。尽管某些特殊工业机器人有双臂，但它们是单独工作的。也就是说，每只手臂在控制下按照其基准弹道工作，对工作中的合作性不多以考虑，因此，它们在只能完成简单的合作工作。近来，一些日本汽车生产商对双臂机器人的使用产生了浓厚的兴趣，因为它们能组装汽车零件，而这需要机器人拥有双臂，并且通过位置控制和力控制下能协调合作。我们正致力于开发能组装汽车零件的双臂机器人，其手臂的自由度达6DOF，整体自由度达3DOF，手臂负荷达10kg，可触范围达1.5m。此参数是为实现WIA有限公司和机器人谷有限公司的汽车组装而设计的，并且融合了设计概念。关键词 ：双臂机器人 组装 实时操作系统 运动控制器1.简介自面世以来，工业机器人在各工业领域发挥着重要作用。机器人的应用在汽车行业更为显著，如果汽车行业和生产商没有机器人，那后果是无法想象的。但是，目前在很多领域仍没有工业机器人能代替人完成需要双臂操作的工作。一般的工业机器人由于只有单只手臂在工作运用中有一定的局限性。尽管某些特殊工业机器人有双臂，但它们是单独工作的。也就是说，每只手臂在控制下按照其基准弹道工作，对工作中的合作性不多以考虑，因此，它们在只能完成简单的合作工作。近来，一些日本汽车生产商对双臂机器人的使用产生了浓厚的兴趣，因为它们能组装汽车零件，而这需要机器人拥有双臂，并且通过位置控制和力控制下能协调合作5。我们正致力于开发能组装汽车零件的双臂机器人，其手臂的自由度达6DOF，整体自由度达3DOF，手臂负荷达10kg，可触范围达1.5m。此参数是为实现WIA有限公司和机器人谷有限公司的汽车组装而设计的，并且融合了设计原理。就一般工业机器人而言，用一个示教箱足以指导机器人定位操作，因为利用位置基准一个控制器只控制一只手臂。对于双臂机器人，由于双臂需合作完成零件组装，控制器必须考虑两只手臂以及组装零件产生的相互作用力，光用定位指导是远远不够。可以利用离线编程技术，但是我们需要更敏感的指示方法，因此采用了主从式技术。我们采用两个商业主设备，每个设备都能达到6DOF的定位输入和6DOF的力量输出。因此，控制器需及时在0.05-0.01s内为从机器人和主机器人分别提供15DOF和12DOF反向/正向动力。这也正是为什么我们采用基于电脑的控制器的原因。我们将采用运动工程有限公司和实时扩展软件产品有限公司的windows XP专业版奔腾处理器，引用控制器的原理和结构。2、双臂机器人的工件定义我们对汽车公司利用双臂机器人系统实现械零件组装的自动化非常感兴趣。而齿轮传动和等速万向接头的组装过程是我们的研究目标。毫无疑问，这两个过程均需要双臂合作才能完成，也就是所谓的“合作性工作”，所以，单臂机器人无法应用于这些过程。这也是大多数汽车公司在这些过程中未实现自动化的原因之一。在此，对于这两个过程我们不会详述，仅展示一些图片。图1显示的是装配输送线，它由很多齿轮和轴组成。图2显示的是等速万向接头生产线，它由两个万向接头和轴组成。在WIA有限公司，这些都是政府资助的。很多不包含着两个过程的汽车零件的生产线已经实现了自动化。双臂机器人是为实现这两个生产过程自动化而设计的。双臂机器人的高度需达1.5m以承受10kgf，克服转矩10N.m，使转动速度达150deg/s，这就要求可重复性达0.1mm。表1列举了双臂机器人要完成目标程序的参数要求。 图1 图2 表13、机器人设计双臂机器人多种多样，有不同的运动结构，但大多数人形机器人的躯干自由度达3DOF，手臂自由度达6DOF。本课题研究的双臂机器人与大多数人形机器人在运动结构上有所不同，虽然它们的自由度相同。图3显示了它们之间的区别。大多数人形机器人和人有类似的运动结构，但是我们所研究的双臂机器人的运动结构不同，它的双臂的运动结构和美洲狮的及其相像。我们期望它的动作和人类也不一样。 人形机器人 本研究设计的机器人 图3我们设计的双臂机器人要运用于传送组装线和等速万向接头组装线，这要求手臂的末端功能器能360度不停旋转。如果双臂机器人的运动结构如图3左边所示，那么每只手臂需有一个额外的旋转夹。这样，将会降低其负荷或者需要更强劲的马达系统。因此，选择了图3右边所示的运动结构，最后一个接头能使末端功能器实现螺旋运动，是组装线360度旋转。另外，这个运动结构还要一个优点，那就是所谓的“解耦”，反向运动在闭合形式方案下也得以简单表达。这都是我们选择这种运动结构的原因。 图4 图5 双臂机器人设计工具图4显示的是机器人右臂的简单草图以及符合表1所示参数的设计。为实现工作分析，预备了运动解决方案，并开发了目光鉴定仪和简单的双臂分析工具，以便在制造过程中能够进行运动评估和检查控制计算等。图5显示的是双臂机器人的设计工具。4、控制器设计图6显示的是控制器的总体构造，它由中心主机，可是控制器，遥控控制器和机器人控制器组成。所有这些控制器均基于电脑系统，并且每个控制器都通过CAN总线相互连接，控制器间可以实时交流信息。离线编程，视觉系统和遥控控制器不在本研究范围内，在此只介绍机器人控制器。 图6 控制器构造一般的机器人控制器在机器人开发系统中非常实用，它对机器人运动参数和控制参数都起到借鉴作用。相对简单的机器人而言，大多数普通机器人