The Changing Face of Manufacturing: 9th Annual British Robot Association Conference

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The 9th Annual BritishRobot Association Con- ference was held in Stratford-upon-Avon, U.K. from May 13-14, 1986.

In introducing the conference, J.A. Collins, President of the British Robot Association and Chairman of the conference, pointed out that 1986 has been designated Industry Year to draw attention to the place of British industry in the life of the community as a whole. This, he said, has raised the political visibility of manufacturing industry. Collins noted that the subjects and speakers at the BRA-9 Con- ference dealt with as many aspects of invest- ment and robotics and its uses as time al- lowed.

We present below a description of the lec- tures delivered at this conference.

Managing Change

Cost Effectiveness

In a lecture entitled "Cost Effectiveness with New Technology", J.A.T. Stafford (Birds-Eye, Walls Ltd., U.K.) illustrated areas where technol- ogy can be effectively applied within the Food Industry. The presentation served as an oper- ational view of the need to become a low cost producer. Stafford demonstrated that technology is now not only available but useable and that it is an essential ingredient to remaining competitive.

Vision/Sensing in Manufacturing

Seam tracking Systems

According to G. Edling (ASEA Robotics A~, Sweden), the potential market of seam tracking systems for robot arc welding is very large. Over- simplified sensors and complicated programming

have, however, limited their practical use. Edling explained that a new generation of seam tracking systems, called LaserTrak, consists of an intelli- gent scanning optical sensor with advanced soft- ware support in the robot control system. The programmer programs tracking by just adding the argument "Track" and the type of joint to the robot positioning instruction. Track data such as offsets, track length and stop conditions are de- fined in track data fields. Edling further pointed out that all hand shakes and track sequences are then performed automatically when welding.

VICTER

R. Mills (BI~ Technology Ltd., U.K.) described and discussed an application of both robot and vision to automatically visually inspect the correct functioning of an automobile instrumentation panel. Mills included a description of selection criteria for the system equipment together with the approach used to control both the machine vision and the robot from a supervisory microcomputer. The problems encountered during the system de- velopment were also discussed in the presentation, entitled "VlCTER: Visual Inspection and Calibra- tion TEst by Robot".

Non-Contact Sensors

Increasing requirements for flexibility and more detailed measurements in automated metrology are being met through the use of non-contact sensors. In particular, the long linear CCD arrays developed recently for facsimile transmission are also very convenient, accurate and stable "rulers" for use in these flexible measuring systems. According to P.J.E. Aldred and C.J. Cooke (Tesa Metrology Ltd., U.K.), these arrays, exploited sim- ply as point measurement devices, thus avoiding the cost and time penalties of image analysis, can be used to explore the projected profile and surface

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finish of components at very high speed. This. the lecturers pointed out. is of particular advantage in FMS turning cells. The lecture Aldred and Cooke presented was entitled "Some Applications of Non-Contact Sensors in Automated Industrial Metrology".

Integrated Material Handling

Sensorized Manipulation System

S. Belforte, A. Romiti and M. Sorli (Polytech- nic of Turin, Italy) dealt in their presentation with the manipulation of delicate pieces in the food industry, in particular chocolates, by means of a sensorized hand with multiple vacuum grippers. A highly adaptable vacuum gripper is needed for chocolates of irregular shape; it was found that a closed cell neoprene sucker gives optimal perfor- mance when shaped according to opportune di- mensions. Belforte explained that the hand brings a set of vacuum grippers fit for loading a full chocolate box by one manipulation stroke. The sensors are included in the hand, and are able to signal the location of any chocolate missing or lost by the grippers. The inactive suckers are automati- cally disconnected from the vacuum circuit so that the grasped chocolates are kept attached to the hand and deposited into the box.

Automobile Factories

According to P. Miitzener (Schindler-Digitron AG. Switzerland), there are three main applications for FTS in automobile factories: (1) an automatic internal transport system, e.g. for supplying com- ponents to assembly lines, (2) in FMS for automati- cally supplying material to CNC machines in multi-shift production and collecting finished components, and (3) in FAS for transporting vehicles, subassemblies or aggregates during as- sembly. In a lecture entitled "VTS Applications in Automobile Factories", Miitzener showed how FTS robovehicles are used in a flexible assembly sys- tem.

Flexible Electronic Assembly

Achieving Objectives

R. Dalby (Ingersoll Engineers. Inc.. u.K.~ pointed out that the U.K. electronics industry is currently investing heavily in Flexible Manufac- turing Technology. However, despite the industry's enthusiasm, the evidence suggests that these in- vestments are not producing the hope for benefits. largely because of the way they are being carried out. In a lecture entitled "The Electronics In- dustry Achieving a Competitive Edge". Dalbv described the problem and showed a welt-proven route through many of the obstacles to the realiza- tion of the commercial objectives of flexible elec- tronics assembly.

PC Board Assembly

The two major changes impacting future elec- tronic assembly requirements are Surface Mount Technology and VLSI. According to D.A. Cowan (The Plessey Company plc, U.K.), surface mounted devices offer reliable increased density for a better product at lower cost and VLSI is constantly evolv- ing to produce more functions on a silicon chip. For the next 10 years most printed circuit boards are expected to contain a mixture of surface mounted and axial. DIL and radial components. It is anticipated that there will still be "odd form" components. Cowan described a system to assem- bly mixed componentry cost effectively. He pointed out that it can be integrated into a CIM strategy and the enabling technology of CAD. CAM, CAT. and CAW.

Electronics Sector

LB. Wilson (Handley-Watker Management Consultants Ltd.. U.K.) began his presentation by observing that Flexible Assembly is a must in a marketplace demanding product variety, high quality, reliability, timely deliveries and competi- tive costs, To date. there are still only a small number of Flexible Assembly Systems in oper- ation throughout the world, and not all of these are successful. In a lecture entitled "Achieving Flexibility in Assembly Through Technology and People". Wilson described a FAS being established in the electronics sector. He explained why it was

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needed, how it works and the benefits that can be achieved.

Robots

Robots are becoming extensively used in elec- tronics assembly for a wide variety of reasons. B.S. Barclay (Meta Machines Ltd., U.K.) examined the areas where they are being used and where they will be used and why, from trends within the electronics and robots industry to the financial implications. Barclay then looked at the compo- nents of flexible "through hole" assembly cell and gave some pointers for a successful installation. The lecture was appropriately entitled "Robots in Electronics Assembly".

Design for Automated Manufacture

Products Management

Many complex factors have to be considered in order to manufacture products profitably. Today's products incorporate a variety of technologies; they must link together to form systems and they must exploit market niches. Also, they must be manufactured as cheaply as possible. For any company, P.J. Deasley (Ingersoll Engineers Inc., u.K.) pointed out, products are a strategic issue. In his presentation Deasley considered some char- acteristics of modern products and discussed how they can be manufactured cheaply with prolonged life. Two management tools were introduced for this, called "Product Management" and "Compe- titive Manufacture". These tools are complemen- tary and must be utilized in parallel, not only to give the optimum results, but to enable the prod- uct to survive. Deasley also indicated that many of our classical ideas on organization must be re-for- mulated to ensure survival in tomorrow's industry.

From 1 4 Parts" to 6

While essentially a low volume manufacturing plant, NCR (Manufacturing) Ltd. has for many years sought ways to utilize advanced manufactur- ing technologies. K.D. Yuile (NCR Manufacturing Ltd., U.K.) discussed the changes in philosophy and approach to design that are necessary for maintaining a successful business. Illustrations of

the benefits available were drawn from a robotic assembly application. Yuile explained that by working with the product design team, the manu- facturing engineers were able to develop a more flexible, more productive cell than was originally possible. Yuile's lecture was entitled "From 14 Parts to 6: An Approach to Design for Manufac- ture".

Cost Effective Design on Silicon

According to N. Bragg (Cambridge Con- sultants Ltd., U,K.), an attractive way to reduce the assembly costs of electronic systems is to minimize the component count by investment in an Appli- cation Specific Integrated Circuit. In a lecture entitled "Cost Effective Design on Silicon", Bragg discussed approaches to ASlC specification and design which are particularly relevant to design- cost sensitive, low volume applications. Their rel- evance to the prototyping of high volume designs was also considered. Bragg suggested that the production volumes at which AS~Cs can cost-effec- tively be applied are often much lower than is generally appreciated.

Integration of the Manufacturing Business

A Realistic Approach

P. Moyes (Digital Equipment Company Ltd., U.K.) suggested in his presentation that for success with Computer Integrated Manufacturing it is necessary to combine "Technology Push" with "Management Pull". He illustrated the availability of the technology and computer " tools" for cIM by reference to DIGITAL'S portfolio of CIM prod- ucts. Moyes claims that the major obstacle to CIM lies in the management, planning and implementa- tion and cautions against underestimating what is involved in successful integration.

Causeway for Automation Swamp

According to P. Cornwell and P. Shaw (Texas Instruments Ltd., U.K.), a common problem found in proposed Flexible Manufacturing Systems is the difficulty of integrating equipment from several different suppliers. This difficulty, they said, largely results from the diverse communication

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standards in use and the need to link the equipment into a coherent whole. In their lecture Cornwell and Shaw discussed the root of the problem and current long term approaches for integration of new equipment. They then described a novel low cost alternative which is widely applicable both to the new and existing equipment.

Product Automation in Britain

R. Lucas (Marconi Microsystems, U.K.) pre- sented the findings of a major survey of British manufacturing automation. He examined the con- sequences of large investment in this area and the lessons learned by companies that have recently automated. It was found that most problems expe- rienced are the result of basic failings which may easily be avoided if a small number of fundamen- tal precautions are taken. For this reason Lucas concluded by presenting a series of strategic rec- ommendations, which may significantly increase the chance of a successful automation program.

tive and simple solution. Added benefits include pre-assembly checks and final quality checks. Champaneri referred to two applications with the ICOS vision system.

R O K I 2 ~

ROKI 200 is a small precision servo-controlled robot, suitable for robotized assembling in the electronic and electrochemical industry. B. Solar, L Verdenik (Edvard Kardelj University, Yugo- slavia) and Z. Debeljak (Iskra Kibernetika Kranj, Yugoslavia) discussed the basic robot characteris- tics and applications. Robotized rectifier bridge assembling is based on experience gained by sensor dependable positioning work cells. Robotized as- sembling of the thin film hybrid circuits is another application demonstrating the power of robot con- troller. The robot is used in designing and assem- bling, as well as in circuits testing processes. The robotized assembling of sapphire bearing was de- scribed as another application of the ROKI 200 industrial manipulator.

Supplementary Lectures

Programmer's Planning Assistant

D.J. Williams, N.E.S. Bugg and E. Chu (Uni- versity of Cambridge, U.K.) indicated in their pre- sentation some of the areas of likely application of Artificial Intelligence techniques in manufacturing systems engineering. In a lecture entitled "A Manufacturing System Programmer's Planning Assistant", they outlined a programmer's planning assistant technique to help in the generation of system control software.

Machine Vision

A machine vision based automatic alignment package for use in assembly and manufacturing was described by D. Champaneri (Filtrona Instru- ments and Automation Ltd., U.K.). A change in manufacturing technology such as Ic technology in the PCB field requires a change in requirements from today's robots. Positioning, Champaneri pointed out, now becomes even more critical. Problems generally stem from variations in feed- ings and picking mechanisms. He claimed that vision systems would present the only cost effec-

Joint Trajectories

Q. Zhigang, IV. Lin and C. Dinghua (Harbin Institute of Technology, China) presented a new method of solution of approximate joint trajecto- ries for control of an arc welding robot along a Cartesian path. The continuous position, veloci- ties, and accelerations on joint trajectories can be obtained by resolved-acceleration control. The in- verse Jacobian transformation is omitted in order to reduce the on-line computational burden. Al- though a fifth degree polynomial is used to inter- polate adjacent intermediate knots, calculation of a system of only 3 linear equations is required for the solution of an approximate function of a joint trajectory. The lecturers have written a program to implement the calculations. Results were illus- trated by means of a numerical example.

Multisensory Feedback System

In a lecture entitled "A Robot Multisensory Feedback System", S.R. Ruocco ,and R. C Seals (Middlesex Polytechnic, U.K_) described the work currently being carried out at Middlesex Polytech- nic to integrate an overhead (or " 'panoramic") camera, an eye-in-hand rangefinder and a tactile

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sensor within the control system of an industrial robot to attain the full potential flexibility of a 2nd generation robot. They described the control strategy together with some preliminary results. These show the suitability of such a multisensory system for interface with an industrial robot and the potential increase in flexibility thus obtained.

Robot Post-Processor

S. Andrews and R.W. Cliffe (Bristol Polytech- nic, U.K.) described the development of a robot post-processor which converts cLdata, the tso standard for the output format of CAM facilities, into a robot program. With the aid of the post- processor, computer aided design information may be translated into a robot program for tasks such as welding and materials handling using existing off-line NC machine tool programming systems. According to Andrews and Cliffe, this method of robot programming offers the advantages of a low cost step towards off-line robot programming and the integration of robot programming and CAM facilities. In addition, the system supports the proposed German DIN standard for robot pro- gramming information IRdata. Use of the system was illustrated with a materials handling applica- tion involving the unloading of a CNC punch press.

Grinding of Surfaces

When using robots for processes like grinding, burring, milling, etc., the components of mecha- nics, control and sensors do not meet the require- ments. K.-H. Wurst (University of Stuttgart, F.R.O.) used the example of grinding surfaces to show one means necessary for automation. The aim is to provide automation in a technically not too complicated way and at a low cost. Wurst explained that when planning a new concept for a modular design of any kinematic construction of a robot, the user is able to adapt the mechanical construction to the process. He showed that a complete description of the process in the robot control (robot cyc ) and sensors adapted to the process allows any use for the task of tooling.

Fabric Panels

The task described by P.M. Taylor and P. Bowden involves the accurate placement of one

piece of fabric on top of another prior to sewing or bonding. Medium resolution solid state cameras are incorporated into a vacuum based gripper and these enable highly accurate location of fabric panel features, typically a notch, corner or edge. Taylor and Bowden (University of Hull, W.K.) pointed out that the movements of the robot are then modified to compensate for imprecision in the original location of the parts. In their pre- sentation, entitled "Accurate Picking and Placing of Fabric Panels for Subsequent Joining", ex- amples were given of applications to shirt collar assembly and to part of underwear production.

Target Tracking System

Advanced robotic systems require integration of vision sensory mechanisms to achieve flexibility and to improve interactive performance. M.B. Zaremba (University of Quebec, Canada), M.A. Poissant and O.L. Hageniers (Diffracto, Canada) presented a microprocessor system for real-time control of the Cincinnati Milacron T3 robot equipped with a vision sensor. The vision system represented the industrial application of the pho- togrammetric technology developed by the Na- tional Research Council of Canada. Zaremba dis- cussed two different schemes for robot guidance: the closed-loop system and the predictive scheme. The implementation showed the advantages of the prediction-based control, such as stable oper- ations, simplicity and fast execution of the control algorithms.

Other Lectures Presented

Modular Approach to FA S

The use of swivel-arm robots for assembly pur- poses has increased considerably in the past two years. More and more problem solutions are being conceived using this type of robot instead of "con- ventional" handling techniques. According to J. Berndt and H. Kaufrnan (Robert Bosch GbmH, F.R.~.), robot systems using swivel-arm robots per- mit extremely cost-efficient and highly flexible solutions to production problems. They can be used not only for insertion processes, but also for manufacturing process stations. Bern& and Kauf- man believe that these are but a few of the reasons

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which will lead to a more than pronounced pro- liferation of the swivel-arm robots in the future. Their lecture was entitled "A Modular Approach to Flexible Assembly Systems (EASy'.

Automatic Materials Handling System

In November 1985. Perkins Engines Ltd. un- veiled a £2.5 million new automated parts store in Peterborough, O.K. Codenamed SPAR by the devel- opment team, this new system is. according to M. Vaughan (Perkins Engines Ltd.. U.K), one of the most sophisticated component handling facilities in Europe. Featuring extensive use of micro- processor minicomputer-controls and robotics, the new system represents the latest phase in a £50 million investment program aimed at further as- sisting the company m building high-quality en- gines at a competitive price for the benefit of 500 customers around the world. Vaughan described the system m his lecture and pointed out that the results of this investment is a totally efficient service, tailored to individual customer needs.

Automation at IBM Greenock

A.A.C. Wilson (IBM Ltd.. U.K.) described the evolution towards automation in manufacturing processes taking place at IBM United Kingdom Limited's Manufacturing Plant at Greenock, Scot- land. The specific goals of the strategy have been to develop competitive in-house manufacturing of display terminal products, to allow the shipment of the volumes required for a rapidly expanding marketplace, and to constantly improve the pr ice /per formance ratio and quality of the shipped product. Wilson demonstrated IBM'S commitment to meet the challenges for all high volume low cost manufacturers by moving in a phased and con- trolled manner towards automation.

Vehicle Industry

According to R.A. Dover (Land Rover. Ltd.. U.K.), the vehicle industry continues to lead in the application of technology. Dover examined the reasons for this and gave examples of Land Rover's approach to the increasing pace of change. He analyzed the lessons learned from the successful implementation of change. His presentation was entitled "Management of Technological Change in the Vehicle Industry".

JCB Experience

J.L Lewis IJC Bamford Excavators Ltd. U.K.~ provided insight into how the JOB Company has adapted to the nature of change and has taken on many forms of automation. In the most elemen- tary sense. PLCS now control conveyors, processes like shotblasting, painting and similar equipment. NC and CNC is much in evidence in all the processing departments. FM cells have also been installed and a fully automated FMS. with four separate CN¢ machines linked by conveyors and gantries is now being installed. Lewis pointed out that if the company had not made changes and had not introduced new processes, it would have failed. Changes were required which were far reaching and had an impact on management pro- duction and the workforce.

Making Waves

In his presentation D. Paterson (TI Creda Manufacturing Ltd., U.K.) first described the sort of robotic installations at Ti Creda Manufacturing Limited. He explained the motives behind the introduction of robots at the company. Paterson believes that we must examine our real motives in proposing a robot for a particular application. When a robot needs to be installed to establish better working conditions and a more reliable result, then this is the case where a product de- signed for robotic manufacture will really shine. according to Paterson.

Spark Plug Electrode Inspection System

Electronic Automation Ltd. has designed and built a turn-key visual inspection system which can carry out a required task at production line speeds and with consistent and reliability inspec- tion. P. Naylor and A. Rae (Electronic Automa- tion Ltd., U.K.) described the complete stand-alone visual inspection system which feeds, inspects, and sorts spark plug electrodes according to a number of criteria governing their use.

Automated Order Picking

According to A.J. Williams (PW International Ltd., U.K.), within materials handling there re- mains one major application area relatively un-

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touched by advanced automation technology. This is the field of order picking or, stated in general terms, " random item selection and collation". Williams reviewed current state-of-the-art solu- tions in terms of what is available "off the shelf" and their successful implementation. He also re- viewed deve lopment and concept designs throughout Europe which hold commercial prom- ise, i.e. those that offer the potential to satisfy reasonable financial return criteria. Finally, Wil- liams examined the commercial potential for fully computer controlled and integrated materials handling systems.

Consumer Appliances

"Design for Manufacture" is a philosophy which, if adopted by management, requires that considerable thought be addressed not just to- wards the company's product range, but towards the very manufacturing system already in the com- pany. To successfully design for manufacture, S.P. Walsh pointed out, one first needs to develop a manufacturing strategy. Walsh (TI Domestic Ap- pliance Division Ltd., u.K.) outlined the objectives of such a strategy. Two examples of design for manufacture were given in the presentation. The first explains briefly how a new kettle model af- fected the manufacturing process around which a factory was based. The second example reports on work done jointly by Yl and Cranfield Institute of

Technology to develop a technique of flexible assembly using robotics.

Business Revolution

According to P.G. Stokes (Arthur D. Little Ltd., u.K.), the widespread introduction of manu- facturing technologies will fundamentally alter the stage upon which industries will compete, will alter the basis of business policy, and will have social implications, too. Perhaps the most signifi- cant change, Stokes noted, is that in some in- dustries, notably but by no means only electron- ics, firms will be forced to become non-specialist. The new technologies will allow them to produce a wide range of products previously produced by different specialist companies. Those that fail to grasp this nettle, Stokes contended, will lose un- acceptable amounts of business. To be successful, companies must look more widely than at the cost reduction benefits of the technologies. The stra- tegic implications of the company's approach to the market must be given serious consideration also. Stokes expressed his views in a presentation entitled "Business Revolution in the Making".

The Proceedings of this conference are available from the British Robot Association, 28-30 High Street, Kempston, Bedford MK42 7A J, U.K. 1986. 356 pages. ISBN 0-948507-29-2.