Applied Innovations in Industrial Robotics: Increasing Operational Range through Structural Modifications and Control System Analysis

By, MSc. Orges BESHKU

Abstract

This article focuses on the studying and improving of the capabilities of a Fanuc M-900iB, 6 degree of freedom industrial robot arm. The main objective is to increase its reach and expand its workspace in situations where parallel production lines in automated industries can use one robot with a wide work frame instead of two robots per each line. In order to achieve these objectives, a complete engineering study of the structural, mechanical, electrical, electronic and software components has been carried out. To make this analysis, evaluation and improvement, the maintenance and construction manuals of this robot, the computer program used in real life as well as its physical study and computer simulation were used as reference. In the mechanical aspect, the structure is studied with all the constituent components such as the base, the joints, the end effector and the links between them with the weight of each component, electrical consumption, ranges of motion, angular velocities, moments of inertia as well as internal components have been considered while the second part of the mechanics covers the kinematics and dynamics in mathematical aspects and computer simulations of the trajectory of its movement, considering the inertia created in the minimum and maximum capacity. In the electrical/electronic aspect, the configuration has been studied in detail including the control unit, main board, servo amplifier, servo motors, power supply unit and transformer. In the second part, the electronic control method, general control block diagrams as well as specific position, speed, and current control block diagrams are presented, explaining the filters and amplifiers associated with each, Bode diagrams, and characteristics of  open and closed systems. In conclusion links 1 and 3 were extended by 0.3m and 0.25m, offering us a much wider and effective working frame of the robot in the workplace. According to the simulations performed the forces required by the change are affordable and within the safety factor for the supply unit with power, amplifier and servo motors.