Abstract
Traditionally, six axis robots have not been used in electronic surface mount assembly. However, the need for more flexible production systems that can be used for low to medium production builds, means that these robots can be used due to their high degrees of flexibility. This research investigated the application of an articulated robot to assemble a multi component PCB for an electronic product. To increase the potential of using this method of automation, a genetic algorithm was used to improve cycle time and condition monitoring was performed to assess the vibrations within the robot structure, during operation. By also studying the motion types the robot movements can be optimized in order to minimize the cycle time and maximize the production throughput with reduced vibrations to improve the accuracy of the assembly process. The study utilised a robotics assembly cell and a robot programmed with different velocities. Vibrations were present throughout out the assembly cycle and by analysing when these large vibrations occur and for which types of motion, an optimal selection could be made. The point-to-point motion type running at 50% speed had a faster assembly time and significantly lower accelerations and oscillations than the other motion types. The spline-linear motion type running at around 30% speed was best for the component insertion due to its linear nature and improved repetition accuracy.
Highlights
Electronics manufacturing has evolved over the past years from a labour-intensive activity to a highly automated one
The assembly operation of the printed circuit board can be achieved using a variety of placement technologies; the main focus of this paper is to present the procedure of finding the best solution for articulated type robots with six rotary joints
The genetic algorithm was used to find the shortest and longest paths. These represent the “best” and “worst” solutions. Between these solutions there is over a 2 second improvement per cycle for the Spline Linear (SLIN) motion type, which is commonly used in this sort of operation (Table 2)
Summary
Electronics manufacturing has evolved over the past years from a labour-intensive activity to a highly automated one. Electronic components need to be placed into position, on the PCB, and the use of automation and robotics provides accuracy, repeatability and efficiency to this process, when compared to manual assembly. The test part is a Eurorack Serge filter with variable resonance This electrical product lends itself to mass production systems that traditionally would have used production lines with high manual costs and more recently high investment specialised automation. To further optimise the assembly process, this paper contributes a study into the motion types available for use in the KUKA robotics system with the aim of addressing the following: Correct motion type selection for fastest cycle time, assuming the build route and work space orientation have already been optimised
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