Integrated Industrial

Servo Driven Approach in Robotic DispeDsiDg System

Akihiro Yanagita Product Manager Application Products Division F ANUC Robotics North America, Inc

Integrated Servo Driven Dispensing approach integrates the dispense control together with the robot control, and utilizes the unique double acting shotmeter design. the benefit is more closely coupled dispensing control, reduced system components, increased reliability in overall system, higher quality dispense result, and total process solution. (Patent pending)

Introduction As robotic dispensing system is applied to wide variety of dispensing application, the robot often need to move along a complicated dispensing seam trajectory. In such cases, it is inevitable for the robot to slow down at sharp corners within the trajectory. In order to keep the same constant bead width throughout the dispensing seam, it is necessary to dynamically modulate the dispensing material flow rate based on the speed of the robot Tool Center Point (TCP) relative to the workpiece on which the material is to be dispensed. To achieve this goal, the robot controller has a mechanism to predict the actual TCP speed ahead of time (US patent 005373221 A), and sends the flow rate command to the dispensing controller based on the predicted TCP speed value. In a typical conventional dispensing system, the dispensing controller receives the flow rate command from the robotic controller as the analog signal. Based on the flow rate analog signal, the dispensing controller adjusts the material dispensing flow rate dynamically during the dispensing process.

.Shot size reduced for largest seam . The dispense rate is controlled by the speed of piston displacement. acting shotmeter The double acting meter operation is based on a reciprocating piston driven by a servo motor. but also the dispenser unit using the same servo control structure. Because of its bulkiness.Improved dispensing process result .Common servo control with robot for precise dispense control . etc.Closely coupled precise control between robot and dispenser .RobOt mounting allows shorter response time for better dispense control The Integral Servo Dispensing (ISD) system is the new innovative approach to integrate the dispensing control into the robot control so that the robotic controller controls not only the robot arm. This unique design of shotmeter provides the following benefits. the size of one shot is required to be big enough for one entire job. positive and precise volumetric metering. low shear handling for low density sealer material. Because of the length of the material supp(y pipe. system . the unit is not mounted on the robot arm. that is primarily due to its single acting design that needs some time to fill the material into the metering chamber. therefore. the shotmeter unit is often inevitably bulky.Simplified wiring in overall. This technology is. the response time of the system is long. . The dispensing system that is introduced here utilizes the double design and the integral servo dispensing (ISD) control system. The characteristics of the shotmeter technology are. On the other hand. Fluid flow through the meter is controlled by a valving arrangement that fills one side of the piston from the fluid supply while the other side of the piston displaces fluid out of the meter to the applicator mounted on the robot end of arm tooling. able to provide good quality dispense result for the applications that requires rather constant dispensing flow of materials.The shotmeter dispensing technology is often utilized in the robotic dispensing application. This system provides the following advantages.Reduced number of system components for increased reliability .Reduced physical size accommodates Robot mounting .Double acting design eliminates "Fill" time . and therefore. The servo motor and valving arrangement work together changing the direction of the piston travel when required. but is mounted at a remote location from the robot. precise pressure control prior to start dispensing. and therefore it is difficult to be able to modulate the flow rate quickly enough for the job.

Fluid flow through the meter is controlled by a valving arrangement that fills one side of the piston from the fluid supply while the other side of the piston displaces fluid out of the meter to the applicator mounted on the robot end of arm tooling. Though the system is capable of controlling other styles of metering devices. the double acting shotmeter is the primary device the integral servo dispensing system controls. . From Material Supply FANUC R-J2 Robot Controller Analog and Digital 1/0 Unit DispenseTooi Control Software (Robot and Dispenser Control) Servo Control Unit (for Dispenser) Servo Control Unit (for Robot Arm) Figure-1 Integral Servo Dispenser System Configuration Double Acting Shotmeter Dispensing Unit The hardware for this system consists of the fluid metering device. The servo motor and valving arrangement work together changing the direction of the piston travel when required.Integral Figure-1 Servo shows Dispensing the system System configuration Configuration of Integral Servo Dispensing system. The double acting meter operation is based on a reciprocating piston driven by the servo motor.

(Patent pending) . dispensing in positive meter direction. Pressure dispense Figure-2 Double Acting Shotmeter Operation The unique "Fill while dispensing" design of double acting meter eliminates the time for reloading the dispenser.The dispense rate is controlled by the speed of piston displacement. and recirculation of material between the two chambers. and it has become possible for the shotmeter device to be mounted on the shoulder of the robot arm. The physical size of the shot meter unit is also reduced. dispensing in negative meter direction. improves the flow control response due to the shorter length in the material delivery system to the dispensing gun. The condition of these valves defines the modes of meter operation. and therefore. transducers are located in the valving manifold to monitor supply and pressures. This. The valve assembly consists of four pneumatically controlled valves. in turn. enables the size of one shot to be optimized to the largest seam instead of the entire job.

the DispenseTool software controls not only the robot arm. driving the meter in the proper direction. The meter speed is set by the flo. the meter will drive in reverse decompressing the sealer to achieve the proper pressure. During each mode the robot controller utilizes the necessary inputs and outputs to control the meter. and therefore. The system uses a sophisticated control algorithm. If the meter hits the meter stroke limit during dispensing. the system software is capable of predicting the robot TCP speed ahead of time (prediction time user definable). the dispenser is controlled in closely coupled manner with the robot control. Each mode of operation is described below. If the set point is lower that the current pressure. (Patent pending) Because of its highly integrated design. the meter will drive forward compressing the sealer to achieve the proper pressure. . By adjusting the prediction time to be the response time of the material delivery system. but also the servo motor to drive the dispenser.R-J2 Robot controller and DispenseToolTM System Control Software DispenseToolTM is the robotic operating system software that runs on the FANUC system R-J2 controller. The prepressure function uses the prepressure set point value specified in the job program. and continues dispensing. If the meter hits a stroke limit during prepressurization/depressurization the servo will stop. the constant bead thickness may be maintained throughout the robot path. This improves the timing accuracy of dispensing control relative to the robot motion creating constant smooth dispensing result. With the Integral Servo Dispensing control feature. Integral Servo Dispensing System Operation Overview The meter system has several modes of operation. the system posts a warning message. When the user job program is run. If the setpoint is higher than the current pressure. and adjusts the dispensing flow rate based on the predicted TCP speed value. the robot control and dispenser control system shares the same servo control system. This function drives meter and opens the dispense gun to apply sealant or adhesive.wrate command that is specified in the job program. reverses the meter motion direction. and is calculated in conjunction with the predicted robot TCP speed value. PRE-PRESSURE CONTROL This mode is normally used to prepare for the next dispensing process after a dispensing process has finished. The meter can resume dispensing at the next dispensing process. and the system will post a warning message. to reach the set point. DISPENSE CONTROL This mode is used between the starting of dispensing process and the end of the process defined in the user job program.

The time to be able to change the pre-pressure value is important for the shorter cycle time in the actual production system.The lines indicate +1-10% of specified pressure difference Figure-3 Pressure Control Characteristic . this chart indicates robustness of the integral servo dispensing system. The control system uses the positional information from the servo motor pulse encoder to determine the current position of the meter. Although the characteristic of the pressure control system greatly depends on that of the material delivery system.REPOSITION CONTROL The meter has its own operation stroke range. In this example the system is tuned with 10% overshoot as an allowable pressure tolerance for faster pressure transition. An offset value can be defined to place the meter at some distance from the stroke limit allowing the meter to move backwards towards the meter stroke limit in an effort to reduce the pressure trapped between the meter and the gun. .:. showing the response to a step command input of the pressure setpoint change from 300psi to 600psi.3 shows the characteristics of the pressure control system. Re-positioning is the operation to bring the meter to closest stroke limit preparing for the next dispensing process with full chamber of dispensing material. and quick pressure change within 250msec transition time from one pressure to another. Performance The figure.

. A system with reduced amount of hardware. increased reliability.Conclusion In this paper we have described some significant advancements in the robotic dispensing system. We hope that the integral servo dispensing system will contribute to the rapid progress in the robotic dispensing application for wide variety of industrial dispensing needs. and improved dispensing process result.

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