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Article
Publication date: 28 December 2021

J. Norberto Pires, Amin S. Azar, Filipe Nogueira, Carlos Ye Zhu, Ricardo Branco and Trayana Tankova

Additive manufacturing (AM) is a rapidly evolving manufacturing process, which refers to a set of technologies that add materials layer-by-layer to create functional components…

837

Abstract

Purpose

Additive manufacturing (AM) is a rapidly evolving manufacturing process, which refers to a set of technologies that add materials layer-by-layer to create functional components. AM technologies have received an enormous attention from both academia and industry, and they are being successfully used in various applications, such as rapid prototyping, tooling, direct manufacturing and repair, among others. AM does not necessarily imply building parts, as it also refers to innovation in materials, system and part designs, novel combination of properties and interplay between systems and materials. The most exciting features of AM are related to the development of radically new systems and materials that can be used in advanced products with the aim of reducing costs, manufacturing difficulties, weight, waste and energy consumption. It is essential to develop an advanced production system that assists the user through the process, from the computer-aided design model to functional components. The challenges faced in the research and development and operational phase of producing those parts include requiring the capacity to simulate and observe the building process and, more importantly, being able to introduce the production changes in a real-time fashion. This paper aims to review the role of robotics in various AM technologies to underline its importance, followed by an introduction of a novel and intelligent system for directed energy deposition (DED) technology.

Design/methodology/approach

AM presents intrinsic advantages when compared to the conventional processes. Nevertheless, its industrial integration remains as a challenge due to equipment and process complexities. DED technologies are among the most sophisticated concepts that have the potential of transforming the current material processing practices.

Findings

The objective of this paper is identifying the fundamental features of an intelligent DED platform, capable of handling the science and operational aspects of the advanced AM applications. Consequently, we introduce and discuss a novel robotic AM system, designed for processing metals and alloys such as aluminium alloys, high-strength steels, stainless steels, titanium alloys, magnesium alloys, nickel-based superalloys and other metallic alloys for various applications. A few demonstrators are presented and briefly discussed, to present the usefulness of the introduced system and underlying concept. The main design objective of the presented intelligent robotic AM system is to implement a design-and-produce strategy. This means that the system should allow the user to focus on the knowledge-based tasks, e.g. the tasks of designing the part, material selection, simulating the deposition process and anticipating the metallurgical properties of the final part, as the rest would be handled automatically.

Research limitations/implications

This paper reviews a few AM technologies, where robotics is a central part of the process, such as vat photopolymerization, material jetting, binder jetting, material extrusion, powder bed fusion, DED and sheet lamination. This paper aims to influence the development of robot-based AM systems for industrial applications such as part production, automotive, medical, aerospace and defence sectors.

Originality/value

The presented intelligent system is an original development that is designed and built by the co-authors J. Norberto Pires, Amin S. Azar and Trayana Tankova.

Details

Industrial Robot: the international journal of robotics research and application, vol. 49 no. 2
Type: Research Article
ISSN: 0143-991X

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Article
Publication date: 1 September 2002

J. Norberto Pires, John Ramming, Stephen Rauch and Ricardo Araújo

Force/torque sensing is very important for several automatic and industrial robotic applications. Basically, if precise control of the forces that arise from contact between tools…

1782

Abstract

Force/torque sensing is very important for several automatic and industrial robotic applications. Basically, if precise control of the forces that arise from contact between tools and parts is required to successfully complete the automatic task, then a force/torque sensor is needed along with some force/torque control technique. In this paper we focus on force/torque sensing aspects applied to industrial robotic tasks. Concentrating on a particular type of force/torque sensor, we demonstrate how to use them and how to integrate them into force/torque control applications using robots. Finally, an industrial application is presented where force control was fundamental for the success of the task.

Details

Sensor Review, vol. 22 no. 3
Type: Research Article
ISSN: 0260-2288

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Article
Publication date: 16 April 2018

J. Norberto Pires and Amin S. Azar

This paper aims to introduce the ideas of practical implications of using industrial robots to implement additive/hybrid manufacturing. The process is discussed and briefly…

2264

Abstract

Purpose

This paper aims to introduce the ideas of practical implications of using industrial robots to implement additive/hybrid manufacturing. The process is discussed and briefly demonstrated. This paper also introduces recent developments on human–machine interface for robotic manufacturing cells, namely the ones used for additive/hybrid manufacturing, as well as interoperability methods between the computer-aided design (CAD) data and material modeling systems. It is presented – using a few solutions developed by the authors – as a set of conceptual guidelines discussed throughout the paper and as a way to demonstrate how they can be applied and their practical implications.

Design/methodology/approach

The possibility to program the system from CAD information, which is argued to be crucial, is explored, and the methods necessary for connecting the CAD data to material modeling systems are introduced. This paper also discusses in detail the main requirements (also from a system point-of-view) needed for a full implementation of the presented ideas and methods. A few simulations to better characterize the interactions from heat conduction and physical metallurgy were conducted in an effort to better tune the additive manufacturing process. The results demonstrate how the toolpath planning and deposition strategies can be extracted and studied from a CAD model.

Findings

The paper fully demonstrates the possibility to use a robotic setup for additive manufacturing applications and shows the first steps of an innovative system designed with that objective.

Originality/value

Using the aimed platform, unsupervised net-shaping of complex components will substitute the cumbersome processes, and it is expected that such a visionary concept brings about a significant reduction in cost, energy consumption, lead time and production waste through the introduction of optimized and interactive processes. This can be considered as a breakthrough in the field of manufacturing and metal processing as the performance is indicated to increase significantly compared to the current instruction-dependent methods.

Details

Industrial Robot: An International Journal, vol. 45 no. 3
Type: Research Article
ISSN: 0143-991X

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Article
Publication date: 1 April 2002

J. Norberto Pires, A. Loureiro, T. Godinho, P. Ferreira, B. Fernando and J. Morgado

Associating robot manipulators with industrial welding operations is common and maybe one of the most successful applications of industrial robots. Nevertheless, it is far from…

529

Abstract

Associating robot manipulators with industrial welding operations is common and maybe one of the most successful applications of industrial robots. Nevertheless, it is far from being a solved technological process, mainly because the welding process is not fully understood but also because robots are still at an early satge of development, being difficult to use and program by regular operators. This is also true for Human Machine Interfaces (HMI), which are not intuitive to use and are therefore unsatisfactory. In this paper we discuss these problems and present a system designed with the double objective of serving our R&D efforts on welding applications, but also our need to assist industrial partners working with welding setups. Frequently industrial partners are not happy with available commercial systems, requiring tailored solutions that could be adapted to several robots and robot controllers. The developed system is explained in some detail, and demonstrated using two test cases which reproduce two situations very common in industry: multi‐layer butt welding (used on big structures requiring very strong welds) and multi‐point fillet welding (used for example on structural pieces for the construction industry).

Details

Industrial Robot: An International Journal, vol. 29 no. 2
Type: Research Article
ISSN: 0143-991X

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Article
Publication date: 9 January 2009

J. Norberto Pires, Germano Veiga and Ricardo Araújo

The purpose of this paper is to report a collection of developments that enable users to program industrial robots using speech, several device interfaces, force control and code…

869

Abstract

Purpose

The purpose of this paper is to report a collection of developments that enable users to program industrial robots using speech, several device interfaces, force control and code generation techniques.

Design/methodology/approach

The reported system is explained in detail and a few practical examples are given that demonstrate its usefulness for small to medium‐sized enterprises (SMEs), where robots and humans need to cooperate to achieve a common goal (coworker scenario). The paper also explores the user interface software adapted for use by non‐experts.

Findings

The programming‐by‐demonstration (PbD) system presented proved to be very efficient with the task of programming entirely new features to an industrial robotic system. The system uses a speech interface for user command, and a force‐controlled guiding system for teaching the robot the details about the task being programmed. With only a small set of implemented robot instructions it was fairly easy to teach the robot system a new task, generate the robot code and execute it immediately.

Research limitations/implications

Although a particular robot controller was used, the system is in many aspects general, since the options adopted are mainly based on standards. It can obviously be implemented with other robot controllers without significant changes. In fact, most of the features were ported to run with Motoman robots with success.

Practical implications

It is important to stress that the robot program built in this section was obtained without writing a single line of code, but instead just by moving the robot to the desired positions and adding the required robot instructions using speech. Even the upload task of the obtained module to the robot controller is commanded by speech, along with its execution/termination. Consequently, teaching the robotic system a new feature is accessible for any type of user with only minor training.

Originality/value

This type of PbD systems will constitute a major advantage for SMEs, since most of those companies do not have the necessary engineering resources to make changes or add new functionalities to their robotic manufacturing systems. Even at the system integrator level these systems are very useful for avoiding the need for specific knowledge about all the controllers with which they work: complexity is hidden beyond the speech interfaces and portable interface devices, with specific and user‐friendly APIs making the connection between the programmer and the system.

Details

Industrial Robot: An International Journal, vol. 36 no. 1
Type: Research Article
ISSN: 0143-991X

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Article
Publication date: 24 April 2007

J. Norberto Pires, Gabriel Afonso and Nelson Estrela

The main objective of this paper is to report the development of an indirect force control strategy designed to operate with industrial robotic deburring applications. More…

744

Abstract

Purpose

The main objective of this paper is to report the development of an indirect force control strategy designed to operate with industrial robotic deburring applications. More specifically, the system reported here is developed to debur high‐quality knives that incorporate innovative design from well‐known authors (fashion designers). Therefore, these products are very difficult to manufacture and have quality requirements incompatible with human‐based deburring, since humans introduce too many unacceptable deviations as a consequence of their incapacity to maintain concentration for long periods of time.

Design/methodology/approach

Since a good model of the environment is difficult to obtain, namely on industrial applications, a simple strategy was designed to obtain the relevant parameters leading to an acceptable performance. Consequently, the system implements an indirect force control strategy as a way to use actual robot controllers, explore the computing power of external personal computers, and the advanced features of modern force‐torque sensors. The proposed strategy is presented in some detail and further discussed using a few test‐case experiments.

Findings

Experiments show a usable setup for contour following which is very useful to obtain the work‐piece profile. A good selection of the path step seems to be, as expected, one of the most important variables to achieve good results: the smaller the increment over the trajectory the more regular is the resulting force profile. Low speeds also seem to lead to better results. The strategy implemented to maintain contact with the object and keep contact force at a certain level seems to result over surfaces with a smooth and large radius continuity, although there are significant force variations on impact with objects (which is not important since impacts can be planned), especially at the higher speeds, and even more significant near object edges. The desired contact force is also a parameter that should be tested. In the presented experiments, a contact force of 10 N was selected and oscillations of 1 N were observed around this value. In an industrial environment, more exposed to noise and vibrations, a higher contact force may be required. On the other hand, the increase of the contact force also increases the flexion of the sensing tool what brings more uncertainty to the calculated contact point. Large force oscillations imply more uncertainty of the obtained work‐piece contour. Like in any industrial process selected parameters are the ones that show acceptable results at higher execution speeds.

Practical implications

The objective of the presented setup is to find the better compromise for a particular industrial application, achieving acceptable operational cycle times.

Originality/value

The obtained results are encouraging and the ability to perform contour recognition under a specified contact force can be very useful with the automatic deburring system being developed. In fact, this feature enables the system to acquire the exact contour of the working piece in the exact same conditions that will be used for the subsequent deburring task. This will contribute to minimize error and increase the process speed.

Details

Assembly Automation, vol. 27 no. 2
Type: Research Article
ISSN: 0144-5154

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Article
Publication date: 1 September 2006

J.N. Pires, F.J. Caramelo, P. Brito, J. Santos and M.F. Botelho

Implant surgery is generally accepted as the best technique for complete teeth replacement. However, it is also the most demanding technique to implement and the most onerous to…

676

Abstract

Purpose

Implant surgery is generally accepted as the best technique for complete teeth replacement. However, it is also the most demanding technique to implement and the most onerous to the client. It would be helpful to reduce costs and simplify procedures in order that the general public could benefit from implant dentistry. This paper reports a robotic system developed with the objective of studying stress/strain distribution caused by implants inserted in blocks of a polymer. The polymer exhibits the same mechanical properties of the human mandible bone.

Design/methodology/approach

The system includes an industrial robot manipulator, a data acquisition board, strain gauges for stress/strain evaluation and a force/torque sensor (equipped with accelerometers) placed on the robot wrist. The objective is to optimize the number of implants and their placement/orientation, contributing in this way to reduce the overall cost of implant surgery. The system is presented in detail and explored for drilling and implant insertion.

Findings

The preliminary results are encouraging and indicate the usefulness of the system. The three presented situations correspond to general clinical procedures and, as can be concluded from the preliminary results, the intensity of the applied forces increase with the inclination of the drilling tool. Since, the depth of the holes is the same, it can be also concluded that the dissipated energy is superior in the 30° hole. Apart from inclination all the other properties remain constant during the force evaluation; therefore, we expected that during the perforation of the 30° hole the temperature should raise more than in the other types of holes. This aspect will be addressed in detail in the near future (just by carefully monitoring the temperature) because living tissues should not be submitted to temperatures greater than 42°C. The observed fluctuation in the modulus of the force during a drilling cycle suggests that the material is not homogeny. The results indicate that the strain is larger in the vertical load. This might be related with the fact that inclined applied forces imply a distribution of the strain/stress forces at least for two directions.

Research limitations/implications

Further work will include more sensors to obtain all the data.

Practical implications

This will be of interest to the implant industry, since low prices will significantly increase the market and consequently the need for implant products. Currently, implant surgery as well as teeth replacements are based on a few general rules that, very often, do not take into account the specific needs of the patient. This happens independently of clinician expertise, which does not have enough biomechanical information to plan the number, location and orientation of implants in a specific surgery. Consequently, in most of the cases the needs are overestimated, to guarantee long‐term success, which implies expensive procedures and more discomfort for patients.

Originality/value

This work reports on a robotic system to simplify implant procedures.

Details

Industrial Robot: An International Journal, vol. 33 no. 5
Type: Research Article
ISSN: 0143-991X

Keywords

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Book part
Publication date: 14 October 2019

Stanislav Ivanov and Craig Webster

Purpose: The purpose of this chapter is to elaborate on the major conceptual and practical considerations of the use of robots, artificial intelligence and service automation…

Abstract

Purpose: The purpose of this chapter is to elaborate on the major conceptual and practical considerations of the use of robots, artificial intelligence and service automation (RAISA) in travel, tourism, and hospitality companies (TTH).

Design/methodology/approach: The chapter develops a conceptual framework of the major issues related to the use of RAISA in the travel, tourism and hospitality context.

Findings: The findings indicate that while there is a creeping incursion of RAISA into TTH, there are major concerns that the TTH industry has to consider in regard to automating TTH services.

Practical implications: In a practical sense, the chapter identifies the decisions that TTH industry professionals need to take when dealing with RAISA technologies. Furthermore, the chapter elaborates on the impacts RAISA have on business operations, marketing management, human resources and financial management of TTH companies. The TTH industry has to adjust its practices and communicate with its workforce in ways as not to increase Luddite tendencies and resistance among employees.

Social implications: The analysis shows that there is an upcoming era in which automation of services will be so advanced that wealthy countries may not need to import labour to make up with its own aging workforce, suggesting that RAISA and its further development has the potential for disrupting society and international relations.

Originality/value: This chapter provides a comprehensive review of the issues related to the use of RAISA in the TTH industry, including the drivers of RAISA adoption in tourism, advantages and disadvantages of RAISA technologies compared to human employees, decisions that managers need to take, and the impacts of RAISA on business processes. It shows how macroenvironmental pressures shape the microeconomic decisions to use RAISA in a TTH context.

Details

Robots, Artificial Intelligence, and Service Automation in Travel, Tourism and Hospitality
Type: Book
ISBN: 978-1-78756-688-0

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Article
Publication date: 23 October 2007

J.N. Pires, T. Godinho and R. Araújo

Interaction with robot systems for the specification of manufacturing tasks needs to be simple since the paper targets the widespread use of robots in small and medium enterprises…

678

Abstract

Purpose

Interaction with robot systems for the specification of manufacturing tasks needs to be simple since the paper targets the widespread use of robots in small and medium enterprises (SMEs). In the best case, existing practices from manual work could be used, to ensure current employees a smooth introduction to robot technology as a natural part of their work. The aim of the paper is to simplify the robot‐programming task by allowing the user to simply make technical drawings on a sheet of paper. Craftsmen use paper and raw sketches for several situations: to share ideas, to get a better perspective of the problem, or to remember the customer situation. Currently these sketches have to be either interpreted by the worker when producing the final product by hand, or transferred into CAD files using an appropriate software tool. The former means that no automation is included, the latter means extra work and considerable experience in using the CAD tool.

Design/methodology/approach

The approach is to use a digital pen and paper, both based on the Anoto technology, as input devices for SME robotic tasks, thereby creating simpler and more user‐friendly alternatives for the programming, parameterization and commanding actions. To this end, the basic technology has been investigated and fully working prototypes have been developed to explore the possibilities in the context of typical SME applications. Based on the encouraging experimental results, it is believed that drawings on digital paper will, among other means of human‐robot interaction, play an important role in manufacturing SMEs in the future. Consequently, a fully working test‐case welding example is presented and explained, allowing a complete demonstration of all the developed features.

Findings

This paper explores the utilization of digital pens for the task of programming industrial robot manipulators, i.e. the possibility of obtaining robot programs from technical drawings on a sheet of paper. A practical implementation was presented to demonstrate how to use digital pens and CAD applications to program industrial robots. The results clearly show that the digital pen based on Anoto technology, integrated with CAD interfaces and code generation interfaces, is very useful and powerful for the planned task. The next steps will be to adopt a software infrastructure and develop the necessary services to allow system integrators to consider this type of device as an advanced user‐friendly robot‐programming method.

Originality/value

This is the first time that digital pens have been used to program robot manipulators.

Details

Industrial Robot: An International Journal, vol. 34 no. 6
Type: Research Article
ISSN: 0143-991X

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Article
Publication date: 1 March 2004

J. Norberto Pires, Tiago Godinho and Ricardo Araújo

In this paper, a small revision on force control strategies is presented, stressing the implementation requirements of each strategy with the objective of clarifying the reasons…

651

Abstract

In this paper, a small revision on force control strategies is presented, stressing the implementation requirements of each strategy with the objective of clarifying the reasons of their poor practical utilization in industry. Furthermore, recognizing that direct force control approaches require system changes on actual robot control systems, which calls for manufacturer cooperation, an indirect force control approach is presented. The controller is introduced along with implementation description. The system is tested with an industrial deburring application that is also briefly introduced. Research experimental results of the proposed controller obtained in the laboratory, and experimental results obtained with the industrial deburring application are presented and discussed.

Details

Sensor Review, vol. 24 no. 1
Type: Research Article
ISSN: 0260-2288

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