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Design of robot cell for gear manufacturing process

Article in International Journal of Applied Engineering Research · January 2015

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 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.55 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm

DESIGN OF ROBOT CELL FOR GEAR MANUFACTURING

PROCESS
1 2
Mirji Sairaj Gururaj, A. Arockia Selvakumar
1
Student, School of Mechanical and Building Science, VIT University Chennai
2
Associate Professor, School of Mechanical and Building Science, VIT University Chennai

Abstract
quenching press machine and place in palate board using end
In an industry it is the need to design and develop the robot cell
effectors [2].Computer simulation is used to assist in robot
for providing better flexibility, and to improve reconfigurable
selection and programming and to evaluate robotic work cell
computing capability of a system. This paper explains about the
layout which provides the user with an effective tool for
proposed design of robotic working cell layout which will be
planning new robot installations or modifying existing ones and
best suitable for the robot motion in order to provide the
also study is done on knowledge based robotic assembly cell,
optimised path and validation of robot position time according
motion controller [3,4]. The research work is done on helical
to the provided distances in the robot cell. Further, it helps to
gear manufacturing considering the structural analysis of the
make comparison between operator work time and robot
gear [5]. New technique is obtained to optimize the location of
position time. Comparison is carried out by considering a robot
assembly tasks in a manipulator’s workspace [6].The present
cell consisting of five machines such as hobbing, shaving, oil
research work is based on the evaluation of the robot cell layout
spinning, chamfering and DOP machines.
to optimise the robot path with incorporation of robot position
Keywords- Robot cell, Layout, Optimization. time which helps to make the gear manufacturing process more
efficient.
I.INTRODUCTION

II. ROBOT CELL LAYOUT PLANNING

Various methods are used to determine the machine layout in
CONSIDERATIONS
flexible manufacturing cell, and to find the feasible robot
The problem statement in the gear manufacturing process is to
configuration of the robot to achieve minimum cycle time
convert manual operated process to automation by which the
[1].Previously in an industry the operator required to stay at the
operator is replaced by robot by virtue of which pick and place
machine for picking and placing which surely leads to increase
operation can be automated. Here, five machines are considered
in cycle time. Hence integrated design of robotic work cell for
in the layout such as hobbing machine, oil spinning machine,
high quality machining is made which investigates the
DOP machine, chamfering machine, shaving machine and ID
possibility to extend the use of industrial robot to perform high
inspection unit as shown in Figure 1. Hence, the task is to
quality machining. The method is focused on advanced
design such a robot cell layout which should be reliable for
techniques for machining strategy and validation of automatic
robot motion to reach the working stations in less amount of
robot path generation. And also research is done on actual cycle
time.
time and estimated new cycle time to increase productivity and
increase the efficiency of industries by using C++ programming
and Matlab Software for Cartesian robot which pick gear in

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© Research India Publications; httpwww.ripublication.comijaer.htm

Table.1 Fanuc M20iA specifications

Robot Type Fanuc M20iA

Axes 6
Payload (Kg) 20
Reach (mm) 1811
Repeatability +/- 0.08

Motion Range J1 195

(degrees/sec) J2 175
J3 180
J4 360
J5 360
J6 550
Fig.1 Robot cell Model Weight (kg) 250

The following factors are taken into considerations while Temperature 0 to 45

designing a robot cell. (deg. Celsius)

A. Flow of materials between the machines:

The robot motion is highly influenced by the sequence of the

material flow. According to the robot reach various layouts are
evaluated and as per the robot convenience and material flow a
suitable robot cell layout is designed.

B. Characteristics of the robot operation:

As per the payload and robot reach the specific robot is selected
in the robot cell. The Fanuc M20iA robot is found to be suitable
for this problem statement. Since, the requirement of robot
reach, payload is fulfilled comfortably. The Fanuc
specifications are shown in Table 1, and Fanuc M20iA robot is Fig.2Fanuc M20iA Robot
shown in Figure 2.
C. Calculation of cycle time as per path planning:

The design of layout is to be such a way that the robot path

should be optimised for cycle time reduction. It is difficult to
make approximation for the real operating conditions since the
joint velocity and end effector velocity varies. In this paper, the
calculation of robot joint velocity is illustrated to give the

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© Research India Publications; httpwww.ripublication.comijaer.htm

approach for the validation of robot performance according to to convert measurement in meters to degrees. The entire cycle
the design of robot working layout. Here the robot position time time is difficult to calculate as the joint velocities and end
is calculated based on the path planning of the robot as shown effector velocities are different. In this work, only joint
in Figure 3. velocities (J1, J2 and J3) are considered to give the approach to
minimize the cycle time and to evaluate robot position time in
comparison with manual operation.

Fig.3Sequence of operation

D. Machine size and its operation time:

In the design of the robot cell layout the prime most focus is Fig.4Layout of Robot cell with dimensions
needed for the machine size that it should not disturb the robot
performance. To evaluate the cycle time of the entire process it
III.PROBLEM FORMULATION
is the need to find the machine operation time.

E. Comparison with the manual operation: A.Calculations of robot position time with respect to robot path:

The comparison of manual operation and robot operation should

From the Figure 5 and 6,the robot kinematics is used to
be made to validate the performance of the robot.
calculate the degree of motion for a particular distance. It is
The dimensions are calculated and the three stations are located quite difficult to show the relation between degree and
(air point) according to that robot follows the path as shown in meter. Hence, the links are simulated and according to the
Figure 4. There are five machines included and one ID required linear motion the angles are calculated.
inspection unit in the layout. The layout has three air point
For 700 m the J2 joint of robot will give the degrees of
(stations) for the robot, to perform the arm motion for the joints
motion= 36.80 degree and for 500 m the J3 joint of robot
(J2 and J3). As the Fanuc joints motion speed is in degree not in
will give the degree of motion = 80.17-27.52= 52.65 degree.
meter so if we have the data in the dimensions in the degrees
then it is easy to find the time accordingly. Hence, it is needed

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J1 (Position time)= 95/ 195 = 0.48 sec

Similarly by converting the dimension in meters into

degrees along X and Y- axis it is easy to find the robot
position time for that particular joints (J2 and J3). The robot
motion time is shown in table.2.

Table.2. Robot motion time for the joints J 2 and J3

Process Robot motion time for J2

and J3 joints
Fig.5 Robot link at 0 degree ID inspection from station 1 0.494

ID inspection to hobbing 1.334

machine
Hobbing machine to oil 1.948
spinning machine
Oil spinning machine to 2.037
chamfering machine
Chamfering machine to DOP 2.045
machine
DOP machine to shaving 1.742
machine
Shaving machine to oil spinng 1.734
Fig.6 Robot link at 36.80 degree machine
Oil spinning machine to DOP 1.25
machine
Similarly, all the calculations is done on the basis of this
relation. The cycle time of robot calculations are shown B. Calculation of machine operation time:
below.
The Machine operation for each machine is shown in Table 3,
Speed= Distance/ Time and sequence of operation is demonstrated in Labview as
shown in Figure7.
The motion speed of the robot in the Fanuc specifications
as per this data is taken into consideration and it is easy to Table3 Machine operation time

find the time if we have the dimensions in the degree.

Machines in operation Machine operation time
Example, if the robot moves from the station 1 to station 2 (sec)
as per the robot layout then the time will be calculated as per ID inspection 20
following method: Hobbing 290
Oil spinning 20
Degree between station 1 and station 2 = 95 degree
Chamfering 30
For the motion of the robot from station 1 to station 2 only DOP 10
need to focus on the joint J1 (twist pair).
Shaving 240

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Table 4 Robot - Machine operation time

Robot Machine Total robot-

motion time operation machine time (sec)
(sec) time (sec)
0.494 20 20.494
1.334 290 291.34
1.948 20 21.948
2.037 30 32.037
2.045 10 12.045
1.742 240 241.742
1.734 20 21.734
1.25 10 11.25
Total 652.584

Table5Man - Machine operation time

Operator Machine Total Man-

time (sec) operation machine time
time (sec) (sec)
10 20 30
50 290 340
5 20 25
10 30 40
Fig.7Machine cycle time representation in Labview 5 10 15
15 240 255
5 20 25
IV.RESULTS AND DISCUSSION 5 10 15
Total 745
The robot motion time is calculated based on the joints J 1, J2

and J3 of the robot; here the gripper motion time is not taken The operator timing is calculated by observing the motion of
into consideration. The arm motion contributes to the maximum the operator using stop watch at gear manufacturing
position time; hence, it is calculated to using a simple method company and comparison is made between robot motion
without simulation approach. After visiting to a gear time and operator time it is shown in Table 4. The gripper
manufacturing industry, it is noticed that operator needs calculations are not made but even though only by
maximum time to position the job, fit the job at the work considering the joint velocities the approach can be given to
stations. Operator has constraints like fatigue, loss of skills, loss validate the difference between manual operation and
of concentration etc. The automation technique is too much automation. The graph is shown in Figure 8, demonstrates
faster and leads to enhancement of productivity.
the difference between robot and manual operation and the
graph shown in Figure 8, demonstrates operation time for
the entire process in the robocell .

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© Research India Publications; httpwww.ripublication.comijaer.htm

machine operation time easily. As per the results obtained the

time reduction is about 92 second per unit job for one way
sequence of the process. Hence around 15 % productivity can
be increased compared to manual operation. This calculation is
based on the one way path planning of robot.

REFERENCES

1) Allan Tubaileh, Ibrahim Hammad, and Loay Al Kafafi,

“Robot cell planning”, International Journal of Mechanical,
Aerospace, Industrial and Mechatronics Engineering Volume 1,
Issue 2, 2007.

2) Pratik P Gandhi, “Performance of a Robot to reduce cycle

Fig.8 Total Robot-machine Time and Total Man-machine time
time estimation by C++ programming”, International Journal of
Mechanical Engineering and Robotics Research, Volume 2,
Issue 2, ISSN 2278-0149, April 2013.

3) H.A.EI Maraghy, “Robocell: A computer aided robots

modelling and work station layout system”, International
Journal of Advanced Manufacturing Technology, Volume 2,
Issue 2, 43-59, April 1987.

4) Dissanayake M and Gal J. A., “Work station planning for

redundant manipulators”, International Journal of Production
Research, Volume 32, Issue 5, 1105-1118, 1998.

Fig.9 Operation time for the entire process in the robocell

5) B.Venkatesh, “Design, Modelling and Manufacturing of
Helical gear”, International Journal of Applied Engineering
Research, Volume 1, Issue 1,ISSN-0976-4259, 2010.
V.CONCLUSION

The robot cell layout is designed with the development of oil 6) Mata. V.and Tubaileh, A., “The Machine Layout problem
spinning machine and DOP machines for the reliability of the of robot cells”, International Journals of Production Research,
robot. The layout is designed in such a way that the process Volume 36, Issue 5, 1273-1292.
time of the entire process of gear manufacturing in the robot cell
can be reduced providing a convenient path planning for the 7) Nelson B., Donath M., “Optimizing the location of assembly
robot, here the robot motion time is calculated with considering tasks in a manipulator’s workspace”, Journal of Robotics

joint velocity J1, J2 and J3 are calculated by virtue robot Systems, Volume 7, Issue 6, 791-811, 1990.

performance is validated by comparing with operator motion

time. In addition to that sequence of machine operation time is
represented using Labview by which the demonstration of

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