With robotics investments typically ranging from tens of thousands to millions of dollars, it is important to make the right choice the first time and avoid common mistakes that can lead to unnecessary expenses or delays in tasks. To help engineers and designers avoid the worst mistakes, this article lists the top 10 pitfalls to avoid in robotics applications.
Myth #1: Underestimating Payload and Inertia
The number one mistake in robotics is underestimating payload and inertial requirements. This is usually caused by not including the weight of the tool at the end of the manipulator when calculating the load. Secondly, the cause of this error is the underestimation or neglect of the inertial force generated by the eccentric load.
Inertial forces may cause overloading of the robot axes. In robotics, overloading of rotating axes is common. If this problem is not corrected, it will also cause damage to the robot. Reducing the load or reducing the speed parameter can deal with this situation. However, reducing the speed will increase the cycle time, and as a return on investment, reducing a portion of the cycle time is the first in the purchase of robots. This is why load-related factors have been taken into account from the very beginning.
The effective load is very important. Some information given by the technical parameters of common robots has detailed instructions. The rated load is only effective at the rated speed. One of the important conditions for reaching the maximum load is to reduce the robot’s operating speed. In addition, , Excessive loads may also damage the precision of the robot.
Mistake #2: Trying to make a robot do too much
Sometimes, designers make robotic cells too complex by asking them to do too much work. This, once created, makes it difficult to determine the correct cycle time, or creates difficulties for disposal schemes, which will create substantial difficulties due to disposer speed limitations. And this kind of error is often magnified, and unplanned production shutdowns will lead to huge losses.
Another situation is that the use of robots and work cells exceeds the original design capabilities. It is easy to be disappointed when the added work is added after simulation. Especially if new simulations are not done before advancing the plan, then the regular cycle time may not be achieved. Therefore, to ensure that a cycle of the robot is within the specified time, then things that exceed the capabilities of the robot must be paid attention to.
Before using the robot, it is necessary to go through a simulation, according to the design requirements, to determine the stroke load and cycle time of the robot application.
Myth 3: Underestimating Cable Management Issues
As simple as it seems, and perhaps as simple as it seems, cable management is often overloaded. However, optimizing the access of cables or peripherals to the tool mounted on the end of the manipulator is very important for the movement of the robotic device. A lack of estimation of potential problems will lead to other movements of the robot to avoid cable entanglement and stress. Also, assuming no dynamic cables or reducing the stress on the cables can lead to damage to the wires and downtime.
The end-effectors of robots currently used are generally gas-driven or electrical-driven, and there will inevitably be corresponding gas pipes or cable connections. The gas circuit and electrical circuit of most industrial robots go outside, so you should pay attention to the time of robot motion control; there are also some industrial robots whose gas circuit and electrical circuit are built-in, which is convenient, only need to consider the arm and electrical circuit The relative motion of the end effector will do.
Misunderstanding 4: Questions to consider before choosing a robot
After considering the application of each scene, when the system is installed, you can determine whether the application is what you need, and avoid serious overload due to possible errors.
In addition, the working schedule of the robot is also one of the issues to be considered. The determination of the stroke should not only be determined according to the stroke of the robot’s technical parameters to determine whether the requirements can be met. It should be considered whether the trajectory of the robot after the end effector is installed can reach the required stroke. This is also one of the key reasons for simulating.
In different environments, there will be customized industrial robots. For example, the spraying industry needs industrial robots with explosion-proof capabilities, which are different from standard robots, as well as the use of clean rooms and so on. In addition, the reliability of the robot and its defect rate, power consumption, etc. are all issues that must be considered when selecting.
Myth #5: Misunderstanding accuracy and repeatability
An accurate machine is repeatable, but a repeatable machine is not necessarily accurate. Repeatability refers to the precise reciprocation performance of a robot in a predetermined position according to a regular working path.
Accuracy is represented by moving exactly to a calculated point along the work path. In the moving operation, the robot moves to some predetermined positions through calculation, using the precise performance of the robot. Accuracy is directly related to mechanical tolerance and precision of the robot arm.
Accuracy has a great relationship with the mechanical precision of the robotic arm. The higher the precision, the higher the precise speed. The robot reducer is an important key structure to ensure the precision of the robot.
Misunderstanding 6: Choosing a robot system only depends on the quality of the control system
Most robot manufacturers think more about the controller of the robot than the mechanical performance. But assuming once the robot is deployed, the uptime depends mainly on the durability of the machinery. Poor robot performance is most likely not due to poor controllers and electronics, but poor mechanical performance.
Often the choice of a robotic system is based on the operator's knowledge of the controller and software. Assuming that the robot also has excellent mechanical properties in this regard, then this will be a very competitive advantage. Conversely, assuming that the robot needs to be stopped for maintenance from time to time after installation, the time-saving advantage will be lost.
The mechanical part is the key to ensure the performance of industrial robots. Precision, speed and durability all have a great relationship with the mechanical part. The structure of the robot is relatively simple, usually a motor and a reducer. If the selected robot often needs to repair the reducer or other mechanical structures, it will be very troublesome.
Misunderstanding 7: Lack of correct robot knowledge reserve
Robot manufacturers and system integrators usually design a robot cell for only one application, but if the user does not have a reserve of robotics knowledge, they may face failure. The usage time of any equipment is closely related to how users use and maintain the equipment. It is not uncommon for some first-time robot users to refuse training. The crucial condition for the robot to continue to work normally is to fully understand the robot's capabilities and to use them optimally within the scope of work.
Industrial robots are very special equipment, and their operation complexity is no less than that of a CNC machine tool. Similarly, the use of robots requires familiarity with the basic knowledge of safe operation of industrial robots, otherwise it is very unsafe for equipment and people. Robot users must participate in the safety operation training of the manufacturer's system before they are allowed to work.
Misunderstanding 8: Neglecting related equipment for robot applications
Teach pendants, communication cables, and some special software are usually required, but can easily be forgotten during the initial order. This will lead to delays and over-budget of the entire production plan. When choosing robot-related equipment, you must consider your own comprehensive needs. A very common situation is that customers sometimes fail to integrate some key equipment and robots in order to save money, such as related equipment and software that need to be configured for the project. During the procurement process, the related products ordered are considered in accordance with the requirements of the project.
Myth #9: Over or Underestimating Robot Control Systems
Underestimating the capabilities of the robot control system will result in repeated system investment and over-budget costs. It is very common to use double backup on safety circuits. Excessively overestimating the capabilities of the control system will result in additional equipment costs, rework, and lost work costs, etc. Trying to control too many I/O ports and adding servo systems is a common misunderstanding.
Safety control is a very important issue. While considering safety, it is also necessary to optimize the safety logic signal of the application as much as possible. The repetition in the program is unnecessary.
Myth 10: Robotics is not considered at all
Financial constraints, lack of knowledge about robotics, and past attempts at using robots are reasons why many people stay away from robotics. But in order to win in the final competition in the market, this misunderstanding needs to be corrected, and the use of robotics can improve efficiency and save time in many cases. Especially for simple operations and repetitive work, robotics can be used to improve production efficiency. The use of robots in production can ensure the yield of products.
With the emergence of the seventh axis of the robot, it can better cooperate with the application of the robot, so that the robot can use more space and have more application scenarios, so it will be a matter of time before the robot replaces the manual.
