Introduction to Machine Design

Introduction to Machine Design

Machine design is the application of science and Cnc machining technology to devise new or improved products for the purpose of satisfying human needs. It is a vast field of engineering technology which not only concerns itself with the original conception of the product in terms of its size, shape and construction details, but also considers the various factors involved in the manufacture, marketing and use of the product.

People who perform the various functions of machine design are typically called designers, or design engineers. Machine design is basically a creative activity. However, in addition to being innovative, a design engineer must also have a solid background in the areas of mechanical drawing, kinematics, dynamics, materials engineering, strength of materials and manufacturing processes.

As stated previously, the purpose of machine design is to produce a product which will serve a need for man. Cnc machining Inventions, discoveries and scientific knowledge by themselves do not necessarily benefit people; only if they are incorporated into a designed product will a benefit be derived. It should be recognized, therefore, that a human need must be identified before a particular product is designed.

Machine design should be considered to be an opportunity to use innovative talents to envision a design of a product is to be manufactured. It is important to understand the fundamentals of engineering rather than memorize mere facts and equations. There are no facts or equations which alone can be used to provide all the correct decisions to produce a good design. On the other hand, any calculations made must be done with the utmost care and precision. For example, if a decimal point is misplaced,

an otherwise acceptable design may not function.

Good designs require trying new ideas and being willing to take a certain amount of risk, knowing that is the new idea does not work the existing method can be reinstated. Thus a designer must have patience, since there is no assurance of success for the time and effort expended. Creating a completely new design generally requires that many old and well-established methods be thrust aside. This is not easy since many people cling to familiar ideas, techniques and attitudes. A design engineer should constantly search for ways to improve an existing product and must decide what old, proven concepts should be used and what new, untried ideas should be incorporated.

New designs generally have “bugs” or unforeseen problems which must be worked out before the superior characteristics of the new designs can be enjoyed. Thus there is a chance for a superior product, but only at higher risk. It should be emphasized that if a design does not warrant radical new methods, such methods should not be applied merely for the sake of change.

During the beginning stages of design, creativity should be allowed to flourish without a great number of constraints. Even though many impractical ideas may arise, it is usually easy to eliminate them in the early stages of design before firm details are required by manufacturing. In this way, innovative ideas are not inhibited. Quite often, more than one design is developed, up to the point where they can be compared against each other. It is entirely possible that the design which ultimately accepted will use ideas existing in one of the rejected designs that did not show as much overall promise.Cnc machining Psychologists frequently talk about trying to fit people to the machines they operate. It is essentially the responsibility of the design engineer to strive to fit machines to people. This is not an easy task, since there is really no average person for which certain operating dimensions and procedures are optimum.

Another important point which should be recognized is that a design engineer must be able to communicate ideas to other people if they are to be incorporated. Initially the designer must communicate a preliminary design to get management approval. This is usually done by verbal discussions in conjunction with drawing layouts and written material. To communicate effectively, the following questions must be answered:

(1) Does the design really serve a human need?

(2) Will it be competitive with existing products of rival companies?

(3) Is it economical to produce?

(4) Can it be readily maintained?

(5) Will it sell and make a profit?

Only time will provide the true answers to the preceding questions, but the product should be designed, manufactured and marketed only with initial affirmative answers. The design engineer also must communicate the finalized design to manufacturing through the use of detail and assembly drawings.

Quite often, a problem well occur during the manufacturing cycle. It may be that a change is required in the dimensioning or telegramming of a part so that it can be more readily produced. This falls in the category of engineering changes which must be approved by the design engineer so that the product function will not be adversely affected. In other cases, a deficiency in the design may appear during assembly or testing just prior to shipping. These realities simply bear out the fact that design is a living process. There is always a better way to do it and the designer should constantly strive towards finding that better way.

Fundamentals of Mechanical Design

Fundamentals of Mechanical Design

   Cnc machining  Mechanical design means the design of things and systems of a mechanical nature—machines, products, structures, devices, and instruments. For the most part mechanical design utilizes mathematics, the materials sciences, and the engineering-mechanics sciences.

 The total design process is of interest to us. How does it begin? Does the engineer simply sit down at his desk with a blank sheet of paper? And, as he jots down some ideas, what happens next? What factors influence or control the decisions which have to be made? Finally, then, how does this design process end? 

 Sometimes, but not always, design begins when an engineer recognizes a need and decides to do something about it. Cnc machining  Recognition of the need and phrasing it in so many words often constitute a highly creative act because the need may be only a vague discontent, a feeling of uneasiness, of a sensing that something is not right. 

 The need is usually not evident at all. For example, the need to do something about a food-packaging machine may be indicated by the noise level, by the variations in package weight, and by slight but perceptible variations in the quality of the packaging or wrap. 

 There is a distinct difference between the statement of the need and the identification of the problem. Which follows this statement? The problem is more specific. If the need is for cleaner air, the problem might be that of reducing the dust discharge from power-plant stacks, or reducing the quantity of irritants from automotive exhausts.    Definition of the problem must include all the specifications for the thing that is to be designed. The specifications are the input and output quantities, the characteristics of the space the thing must occupy and all the limitations on these quantities. We can regard the thing to be designed as something in a black box. In this case we must specify the inputs and outputs of the box together with their characteristics and limitations. The specifications define the cost, the number to be manufactured, the expected life, the range, the operating temperature, and the reliability. 

 There are many implied specifications which result either from the designer's particular environment or from the nature of the problem itself. The manufacturing processes which are available, together with the facilities of a certain plant, constitute restrictions on a designer's freedom, and hence are a part of the implied specifications. A small plant, for instance, may not own cold-working machinery. Knowing this, the designer selects other metal-processing methods which can be performed in the plant. The labor skills available and the competitive situation also constitute implied specifications. 

 After the problem has been defined and a set of written and implied specifications has been obtained, the next step in design is the synthesis of an optimum solution. Now synthesis cannot take place without both analysis and optimization because the system under design must be analyzed to determine whether the performance complies with the specifications.

  The design is an iterative process in which we proceed through several steps, evaluate the results, and then return to an earlier phase of the procedure. Thus we may synthesize several components of a system, analyze and optimize them, and return to synthesis to see what effect this has on the remaining parts of the system. Both analysis and optimization require that we construct or devise abstract models of the system which will admit some form of mathematical analysis. We call these models mathematical models. In creating them it is our hope that we can find one which will simulate the real physical system very well.

  Evaluation is a significant phase of the total design process. Evaluation is the final proof of a successful design, which usually involves the testing of a prototype in the laboratory. Here we wish to discover if the design really satisfies the need or needs. Is it reliable? Will it compete successfully with similar products? Is it economical to manufacture and to use? Is it easily maintained and adjusted? Can a profit be made from its sale or use? 

  Communicating the design to others is the final, vital step in the design process. Undoubtedly many great designs, inventions, and creative works have been lost to mankind simply because the originators were unable or unwilling to explain their accomplishments to others. Presentation is a selling job.

 The engineer, when presenting a new solution to administrative, management, or supervisory persons, is attempting to sell or to prove to them that this solution is a better one. Unless this can be done successfully, the time and effort spent on obtaining the solution have been largely wasted. 

 Basically, there are only three means of communication available to us. There are the written, the oral, and the graphical forms. Therefore the successful engineer will be technically competent and versatile in all three forms of communication. A technically competent person who lacks ability in any one of these forms is severely handicapped. If ability in all three forms is lacking, no one will ever know how competent that person is!

  The competent engineer should not be afraid of the possibility of not succeeding in a presentation. In fact, occasional failure should be expected because failure or criticism seems to accompany every really creative idea. There is a great to be learned from a failure, and the greatest gains are obtained by those willing to risk defeat. In the find analysis, Cnc machining  the real failure would lie in deciding not to make the presentation at all.

PLC control of the knife random mode of election

PLC control of the knife random mode of election

 Common methods of automatic election knife

 Cnc machining Automatic control of the knife CNC refers to the system after the implementation of user instructions on the knife library automation process, including the process to find knives and automatic tool change . CNC Machining Center device (CNC) directive issued by the election knife , a knife, the tool required to take the knife position, said the election automatic knife. automatically elected knife There are two ways: random sequence election knives and knife election method.

 order election knife 

 Tool Selection order is Cnc machining  the process tool according to the sequence of the insert knife, the use of knives in order to take place, used knives back at the original knife, can also order Add Block, a knife. In this way, no need Tool identification devices, and drive control is a relatively simple, reliable and can be used directly from the points of the knife machinery to achieve. But the knives in each of the tool in different processes can not be reused, if the tool is installed in accordance with the order of the knife, there will be serious consequences. The need to increase the number of knives and knife the capacity of the tool and reduce the utilization of the knife.

 Random election knife 

  Random election under the knife is arbitrary instructions to select the required tools, then there must be tool identification devices. Tool knife in the library do not have the processing in accordance with the order of the workpiece can be arbitrary storage. Each of the tool (or knife blocks) are for a code, automatic tool change, the rotary cutter, every tool have been the "tool identification device" acceptable identification. When CNC tool code and the code in line with directives of the tool selected, the rotary cutter knives will be sent to the ATC position, waiting to grab manipulator. Random knife election is the advantage of the cutter knife in the order has nothing to do with the processing sequence, the same tool can be used repeatedly. Therefore, the relatively small number of knives, knife the corresponding smaller. Random elections knife on the tool must be coded to identify. There are three main coding.  

   1. Tool coding. Adopt special knife handle structure coding, the drawbars on the knife handle back-end packages such as spacing of the coding part of the lock-nut fixed. Coding diameter ring diameter of a size two, respectively, said that binary "1" and "0" to the two rings are different, can be a series of code. For example, there are six small diameter of the ring can be made to distinguish between 63 (26-1 = 63) of the coding tool. All of 0 normally not allowed to use the code, to avoid the cutter knife Block did not confuse the situation.     

 2. Knife Block coding. On the knife Block coding, coding tool, and tool into line with the number of knives in the Block. ATC knife when the rotation, so that each knife seats followed through knowledge knife, knife found blocks, knives stopped the rotation. At this time there is no knife handle encoding part of the knife handle simplified.   

  3. Annex coding methods. This style of coding keys, Cnc machining coded cards, coding and coding-disc, which is the most widely used coding keys. First toknives are attached to a tool of the show wrapped coding keys, and when the cutter knife to the store at knife in, so put the number of keys to remember knife Block Road, will be inserted into key to the coding Block next to the key hole in the seat for the knife to the numbers.

  

Daidao system for the automatic tool change

Daidao system for the automatic tool change 

cnc milling machine  Figure 2.4 shows the knife and the whole machine tool CNC machine tools for the appearance of Fig.  

   

 Figure 2.5 shows the knife and split-type machine to the appearance of CNC machine tool plans.     

  

 At this point, knife storage capacity, cnc milling machine  a heavier tool can, and often additional transport unit to complete the knife between the spindle and cutting tool transport.   Daidao the knife from the ATC, the election knives, automatic loading and unloading machine tool and tool exchange institutions (manipulator), composed of four parts, used widely. 

    Tool Automatic Tool Change the manipulator system, the whole process more complicated ATC. We must first used in the processing of all installed in the standard tool on the knife handle in the machine outside the pre-size, according to a certain way Add to the knife. ATC, selected first in the knife knife, and then from ATC, from the knife from the knife or spindle, exchange, the new knife into the spindle, the old knife back into the knife.    

 ATC, as the former two knives to accommodate a limited number can not be too many, can not

  meet the needs of complex parts machining, CNC machine tool Automatic Tool Change Daidao the use of the automatic tool change devices. The knife has more capacity, both installed in the spindle box side or above. As for the automatic tool change Daidao device CNC machine tool spindle box only a spindle, spindle components to high stiffness to meet the machining requirements. The number of establishments in larger knife, which can meet the more complex parts of the machining processes, significantly improving productivity. Daidao system for the automatic tool change applied tocnc milling machine   drilling centres and CNC machining centers. The comparison drawn Daidao automatic tool change system is the most promising.

ATC head-turret installed

 ATC head-turret installed

 With rotating CNC machine tool often used such Cnc machiningATC devices, with a few turret head spindle, each with a spindle on both knives, the first tower interim process can be automatic tool change-realization. The advantage is simple structure, tool change time is short, only about 2 s. However, due to spatial constraints, the number of spindle can not be too much, usually only apply to processes less, not to high precision machine tools, Cnc machining  such as the NC drill, such as CNC milling machine. In recent years there has been a mechanical hand and the turret head with a knife for the automatic tool change ATC devices, as shown in Figure 2.3. It is in fact a turret head ATC, and the knife-ATC device combination. The principle is as follows:

  5 turret on the first two tool spindle 3 and 4, when using the tool spindle 4 processing tool, the manipulator 2 will be the next step to the need for the tool does not work on the tool spindle 3 until after the completion of this process , the first rotary turret 180 º, ATC completed. ATC most of their time and processing time coincidence, the only real tool change time  Cnc machiningturret transposition of the first time, this approach mainly used for ATC and NC NC drilling file bed.

ATC, the main types, characteristics, and the scope of application

ATC, the main types, characteristics, and the scope of application 

 Auto Rotary Tool

  Rotary  Cnc machining Tool automatically on the use of CNC machine tool is a simple installation of automatic tool change, the Quartet and 47.60 Turret Tool various forms, such as rotary turret were installed on four, six or more of the Tool , NC instructions by ATC. Rotary Tool has two vertical and horizontal, relatively simple structure, applicable to economic CNC lathe.   

   Rotary Tool in the structure must have good strength and stiffness, resistance to bear rough Cutting Tool in the cutting force and reduce the role of deformation and improve processing accuracy. Rotating Tool to  choose  reliable  positioning  programme structure and reasonable position, in order to ensure that each rotary turret to a higher position after repeated positioning accuracy (typically 0.001 to 0.005mm). Figure 2.1 shows the spiral movements of the Quartet Turret.  

 Auto Rotary Tool in the simplest of ATC, is 180 º rotary ATC devices, as shown in Figure   ATC instructions received, the machine control system put ATC spindle control to the designated location at the same time, the tool movement to the appropriate location, ATC, with the rotary axis and at the same time, the knives matching tool; drawbars from Spindle Cutting Tools rip, ATC, will be the tool from their position removed; ATC, 180 º rotary tool spindle and the tool and tool away; ATC, the Rotary At the same time, the tool refocusing its position to accept Spindle removed from the cutting tool; Next, Cnc machining   ATC, will be replaced with the cutter knives were unloaded into the spindle and tool: Finally, back to the original ATC, "standby" position. At this point, ATC completed procedures to continue to run. This ATC, the main advantage of simple structure, the less movement, fast tool change. The main disadvantage is that knives must be kept in parallel with the axis of the plane, and after the home side compared to the tool, chip and liquid-cutting knife into the folder, it is necessary to the tool plus protection. Cone knife folder on the chip will cause ATC error, or even damage knife folders, and the possibility of spindle. Some processing centre at the transfer, and the tool side. When the ATC command is called,  Cnc machining  the transfer-cutter knives will be removed, the machine go forward, and positioning with the ATC, in line with the position. 180 º "Rotary ATC devices can be used horizontal machine,can also be used for vertical machining centers.

Control of the knife

Control of the knife  

  (1) Cnc machining the knife as a system to control the positioning axis. In the ladder diagram in accordance with the instructions for computing T code comparison of the output angle and speed of instructions to the knife the knife servo drive servo motor. Tool storage capacity, rotation speed, and / deceleration time, and other system parameters can be set in such a manner free from any outside influence positioning accurate and reliable but the cost is higher.   

 (2)Cnc machining  knife from the hydraulic motor drives, fast / slow the points, with proximity switches count and positioning. In comparison ladder diagram of the current storage system knife (knife spindle) and goals knife (pre-knife) and computing, then output rotation instructions, judging by the shortest path rotation in place. This approach requires sufficient hydraulic power and electromagnetic valve knife the rotational speed can be adjusted through the throttle. But over time may be oily hydraulic, oil temperature and environmental factors impact the change in velocity and accuracy. Not generally used in large and medium-sized machine tool change frequently.   

 (3) Cnc machining the knife from AC asynchronous motor driven cam mechanism (Markov institutions), with proximity switches count, which means stable operation, and generally accurate and reliable

positioning cam used in conjunction with a mechanical hand, ATC fast-positioning.

Tool storage capacity and options

Tool storage capacity and options 

  Tool storage capacity of the first Cnc machining to consider the needs of processing, from the use of point of view, generally 10 to 40 knives, knife will be the utilization of the high, and the structure is compact.

 Tool options  

 (1) choose to order processing tool according to the order, followed Add to the knife every knife in the Block. Each tool change, the order of rotation of a cutter knife on location, and remove the need knives, has been used by the cutter knife can be returned to the original Block, can also order Add Block, Cnc machining a knife. However, as the knife in the tool in different processes can not be repeated use of the knife must increase the capacity and lower utilization rate.   

  (2) most of the arbitrary choice of the current system of using arbitrary NC election knives, divided into Daotao coding, coding and memory-cutter, three. Daotao coding tool code or knives or Daotao need to install the code used to identify, in accordance with the general principle of binary coding coding. Tool knife election coding method uses a special knife handle structure, and each of the coding tool. Each of the tool has its own code, thereby cutting tool can be in different processes repeatedly used, not to replace the tool back at the original knife, the knife capacity can be reduced accordingly. Memory-election this paper knife, in this way can knives and knife in the position corresponding to the Daotao memory of the PLC in the NC system, no matter which tool on the Inner knife, tool information is always there in mind, PLC . On the knife with position detection devices, will be the location of each Daotao.Cnc machining  This tool can be removed and sent back to arbitrary. On the knife is also a mechanical origin, every election, the nearest knife selection.

   

The functions of the knife and Common types

The functions of the knife and Common types

  knife The is the role of reserves Cnc machining  a certain number of tools, machine tool spindle in hand to achieve the fungibility a disc cutter knife is the type of library, the chain knives, and other means, in the form of the knife and capacity according to the Machine Tool to determine the scope of the process.

 Common types 

 The knife is a tool storage devices, the common knife mainly in the following forms: 

  (1) the turret knife 

   Including the first level turret vertical turret and the first two, see Figure 2.6 a) and b):

   

 2) the disc cutter 

  Disc knife in the library with discoid knife, cutting tool along See how vertical arrangement (including radial and axial from knife from knife), along See how radial array into acute or arranged in the form of the knife. Simple, compact, more applications, but are ring-cutter, Cnc machining low utilization of space. Figure 2.7 a) to c).

   

   If the knife storage capacity must be increased to increase the diameter of the knife, then the moment of inertia also increased correspondingly, the election campaign long knife. Tool number not more than 32 general. Cutter was multi-loop order of the space utilization knife, but inevitably given the knife from complex institutions, applicable to the restricted space Machine Tool storage capacity and more occasions. Two-disc structure is two smaller capacity knife on both sides of the sub-spindle place, more compact layout, the number of certificates corresponding increase knife, apply to small and medium-sized processing center.   

  (3) the chain knife     

   Including single-and multi-ring chain ring chain, chain link can take many forms change, see Figure 2.8 a) to c), the basic structure shown in Figure 2. 8 do  Features:

       

  knife apply to the larger capacity of the occasion, the space of the small number of generally applicable to the tool in the 30-120. Only increase the length  of the chain tool will increase the number should not be increased circumferential speed of its

moment of inertia of the knife does not increase the disc as large.  

      

  (4) linear combination knife and the knife library

The linear knife simple structure in Figure 2.9, tool single order, the capacity of small knife, used for CNC lathe and drill press on. Because the location of fixed knife, ATC completed action by the spindle without manipulator. The cutter knife is generally the turret combination turret with a combination of the disc cutter knife and the chain combination. Every single knife the knife certificates of smaller, faster tool change. Cnc machining There are also some intensive drum wheel, and the lattice-type magazine for the knife, the knife-intensive though. Small footprint, but because of structural constraints, basically not used for single processing center, the concentration used for single processing center, the concentration ufor FMS for the knife system.

Electrical Control System

Electrical Control System

  This tool storage systems is the Cnc machining main electrical control their shelves for operational control and position control. Operational control equipment, including operation of the start of braking control. Position Control is the main location and address of the shelves for testing. Control

   

                       system as shown in Figure 1

  1) Electric Transmission horizontal rotary tool storage systems are the mechanical movements are repeated short-term work system. And the run-time system needs some speed, speed transmission needs,Cnc machining  the system will use VVVF method can be used simple structure, reliable operation of the motor and frequency inverter. 

 2) Control of the system is divided into two kinds of manual control and automatic control, manual control as a general reserve and debugging methods of work; ways to the system control computer (IPC) and the control unit (inverter contactor , etc.) consisting of a control system. 

 3) location and positioning accuracy of the system automatically identify the site and location using a detection device as proximity switches, relays through the plate-point isolation and the number plate recorded close to the switching signal acquisition and operation of Hutchison with a Optimal Path addressable identify the current location and shelves of the purpose of the shelf location. In order to enable a more accurate positioning system,Cnc machining adopted two photoelectric switches, to detect the two shelves of the two films.

Cnc machining,cnc milling machine,precision parts,cnc machining parts,

System components and control structure

System components and control structure

 The entire system, including the structure and electrical machinery control systems.      

  Mechanical structure and working principle

    Tool from the stent, drive, cnc milling machine drive system, Turret, shielding, control system, and electrical components. Support from the column, beam, the upper and lower guide Central track, and track support component. 

   1) Drive for the system chosen VVVF method. Cone used brake motors, with VVVF by Cycloid

reducer through sprocket drive. 

  2) Drag a variable frequency drive system and control technology. VVVF adopted, will speed drive shaft in the normal range adjustment to control the speed rotary turret to 5 ~ 30mm in, the drive shaft into two,  cnc milling machine two under through sprocket, the two profiled rollers Chain driven rotating shelves. Expansion chain adopted by the thread tight regulation swelling, swelling the regular way. - Conditioned, under the same chain-of-conditioning, so that the chain of uniform. 

 3) Turret and shields the entire total of 14 independent Turret. 13 of them as a socket-Turret, as a drawer-Turret, each Turret back through the pin and, under the conveyor chain link chain plate, installed at the bottom roller, chain driven rotating turret rotation along the track. Outlet-Turret and BT50-BT40 Turret Turret two kinds of forms. To strengthen management, security, landscaping modeling, shelf peripherals and shields.  cnc milling machineTurret-drawer drawer placed at six other Des Voeux a knife, can be categorized with some of knife auxiliary equipment, such as bits, such as turning tools.

Design Of Tool Machine Prop

Design Of Tool Machine Prop 

    The original knife machine control cnc milling machine

  Automatic knife in the knife election, in the computer memory knife-election on the basis of using the Siemens 840 D features, and the election procedures knife more concise, and complete the space Daotao View. ATC use the knife rapid completion of STEP-7 programming, and have been tested in practice. In the positioning of the knife, PLC controlled modular design method, which future production of similar machines will be very beneficial, it is easy to use its other machine. Automatic tool change systems will be faster growth, reduced tool change time, increase the positioning accuracy tool is an important means to help NC technology development.    

   Tool and inventory components of modern production is an important link in the management, especially for large workshop management. The traditional way of account management, and low efficiency, high error rate, and not sharing information and data, tools and the use of state can not track the life cycle, are unable to meet the current information management needs. With actual production, we have to establish a workshop tool for the three-dimensional tool storage system to meet cnc milling machine  the knife workshop with auxiliary storage and management needs.    

   The system uses optimization technology, a large number of computer storage inventory information, timely, accurate, and comprehensive tool to reflect the inventory situation. The entire system uses a graphical interface, man-machine dialogue tips from the Chinese menu, select various functions can be realized and the importation of all kinds of information. Management system using online help function. Through the workshop management, network management and sharing of information. Have automated inventory management, cnc milling machinewarehousing management tool, a tool for the management and statistical functions.

  

Rodney Brooks ?iRobot

Rodney Brooks ?iRobot

   Roomba is made by Massachusetts-based iRobot, cnc milling machine  one of many companies planning to launch a host of new robots over the next few years. New robotics products that will soon be introduced include autonomous floor cleaners and industrial tools built to do boring, dirty and dangerous work like inspecting oil wells. Of course, autonomous oil well inspectors aren't as thrilling as the robotic servants that some visionaries have predicted. But robotics and artificial intelligence are working their way into everyday life, albeit in less dramatic ways. 

   Rodney Brooks, Director of thecnc milling machine  MIT Artificial Intelligence Laboratory and Chairman of iRobot Corporation, has been involved in this transformation for decades. His latest book "Flesh & Machines" explores many themes related to life with robots. The book centers on Brooks' own passion for creating what he calls "situated creatures" which we can eventually regard as our teachers and companions.

     Brooks' MIT A.I. Lab is filled with robotic machines, from mechanical legs to humanoids that use human-like expressions and gestures as intuitive human-robot interfaces ?something Brooks believes will be critical to people accepting robots in their lives. The first generation of relatively mundane versions of these machines is already marching out of the lab. 

    Rodney Brooks has a vision of a post-PC future in which sensors and microprocessors are wired into cars, offices and homes and carried in shirt pockets to retrieve information, communicate and do various tasks through speech and gesture interfaces. He insists that the age of smart, mobile machines is already beginning. You just have to know where to find them in oil wells, medical labs, financial services and construction companies.  

 Military & defense applications 

  Now iRobot has a US Defense contract to build a robot, about the size of a suitcase, which can climb stairs, crawl over ditches, survive three-story falls. Instead of carrying bombs, this robot has eyes and ears, transmitting what it sees and hears over a wireless link. This is a "Packbot" which can be thrown into a vehicle and then

hurled through windows of buildings where the enemy may have hostages. 

In general, robotic systems are of great interest to the Department of Defense because they offer the ability to perform military actions at greater stand-off distances, allow dangerous missions to be performed with minimal risk to people.  

  The Defense Advanced Research Projects Agency (DARPA) is the central research and development organization for the Dept. of Defense. The DARPA "Distributed Robotics Program" seeks to work with qualified companies to develop tiny, biologically-inspired robot designs and new methods of robot control for military applications. DARPA is particularly interested in micro-miniature robots because they can be produced at relatively low unit cost and offer unique mission advantages. They can be carried and deployed by individuals and small teams to augment human capability, perform hazardous missions, and accomplish tasks that previously could not be unimagined.  

  Potential applications include surveillance, reconnaissance, path finding, deception, weapon delivery, and small-scale actuation. For minefield detection, small sensors are mounted on hopping robots. Small robots can be sent into city pipelines for intelligence gathering. Robots used in large numbers can be used as decoys. Extremely small robots might be injected into small spaces to pick door locks.

   Because micro robots are similar to small animals and insects, biologically inspired designs (jumping, climbing, crawling, slithering, etc.) coupled with the use of MEMS and smart materials offer possibilities for novel and unique locomotion mechanisms. MEMS technology enables the integration of mechanical and electronic functions on a single silicon chip. Advanced microelectronic packaging using multi-chip modules and incorporating mixed signal electronics allows development of new ideas, integrating robotic form and function. 

   Robots for military applications can either be fully controlled by humans, semi-autonomously controlled, or operate autonomously. cnc milling machine To allow miniature robots to perform for extended periods of time in varied environments, innovative methods are needed to reduce power requirements, regulate energy use and provide rapid recharging.

  

Industrial robots

Industrial robots  

    The vast majority of robots cnc machining are used by the manufacturing industry, for repetitive tasks such as painting autobodies and simple assembly. Some 100,000 new robots were installed worldwide in 2000, nearly half of them in Japan, the biggest user. There were nearly 800,000 industrial robots in existence at the end of 2002 and this is likely to rise to almost 1 million by the end of 2004.  

  In the last decade the performance of robots has increased radically while at the same time prices have been plummeting. Today, manufacturing robots have a payback period as short as 1-2 years. In N. America, the price of robots relative to labor costs have fallen to 26, and as low as 12 if quality improvements are taken into consideration.  

Sales of industrial robots have risen to record levels and there is huge, untapped potential for domestic chores like mowing lawns and vacuuming carpets.

  New robot applications abound 

  As robot intelligence increases, and as sensors, actuators and operating mechanisms become more sophisticated, other applications are now multiplying. There are now thousands of underwater robots, demolition robots and even robots used in long-distance surgery. 

  Dozens of experimental search-and-rescue robots scoured the wreckage of the World Trade Center's collapsed twin towers. Teams of robotics experts were at Ground Zero operating experimental robots to probe the rubble and locate bodies. During the war in Afghanistan, robots were being used by the US military as tools for combat. They were sent into caves, buildings or other dark areas ahead of troops to help prevent casualties.

  After the recent anthrax scares, work has been ongoing to replace postal workers with robots. Indeed, there is huge potential to mechanize the U.S. postal service and some 1,000 robots were installed last year to sort parcels. The U.S. postal service has estimated that it has the potential to use up to 80,000 robots for sorting work, although existing models are not suitable for sorting letters.

  A giant walking robot is used to harvests forests, moving on six articulated legs, advancing forward and backward, sideways and diagonally. It can also turn in place and step over obstacles. 

 At UC Berkeley, a tiny robot called Micromechanical cnc machining Flying Insect has wings that flap with a rhythm and precision matched only by natural equivalents. The goal is to develop tiny, nimble devices that can, for example, surreptitiously spy on enemy troops, explore the surface of Mars or safely monitor dangerous chemical spills.

 A big increase is predicted for domestic robots for vacuum cleaning and lawn mowing. Robots to do these chores are practical today. An inexpensive house-cleaning robot was recently introduced a little battery-powered vacuum cleaner that scurries around the floor, sweeping up dust and dirt as it travels. cnc machining Called Roomba, it costs just $199 and, by all accounts, is selling very well.