What is the detailed process of developing industrial robots what do you need to learn?

In chronological order, the development of a mass-produced robot product consists of the following processes:

1. Requirements analysis product definition.

At this stage, product managers collect market information, visit customers, learn about competitors, finally summarize a product demand, as well as the typical industries typical processes that the demand targets. According to the market, they propose market expectations, how many units can be sold per year, the target price range, the current status development trend of the target industry application, etc.

According to the needs, a product performance target is proposed, the expected product is described quantitatively specifically at the product function level, such as the application environment, working range, maximum speed, rated load, time to complete a typical process track, IP level, power supply type, weight limit, service life, which certifications standards need to be complied with, etc.

The skills required here are comprehensive understanding of the industry, market, cost, strategy, other development links production processes, as well as business sensitivity.

2. Preliminary research feasibility analysis For the product performance targets proposed in the previous step, engineers in the fields of mechanics, simulation, drive, electrical, software begin to evaluate the targets their respective technical perspectives. They mainly focus on technical feasibility cost, the help of procurement production personnel is also needed during this period.

The goal is to determine whether there is a profitable balance between technology cost. Another important part of this stage is to conduct a detailed analysis of similar products of competitors try to transform the experience of competitors into the advantages of your own products. After this stage, a conceptual plan will be obtained, the development cycle cost will be estimated.

These contents will be output documents in the form of feasibility analysis report, project plan, cost analysis, risk assessment, etc. for management to decide whether to officially start the development project. At this stage, senior engineers will participate in each field. The knowledge skills involved in each field will be introduced in other development stages later.

3. Calculation simulation Although the previous conceptual plan lacks most of the details, it is possible to roughly model simulate the product based on the approximate size, load, speed, typical process trajectory other information. The kinematic model of the robot can be established according to the geometric information in the conceptual plan. On this basis, the external load is defined, the mass load friction are estimated based on experience, so that the dynamic model can be further obtained.

The dynamics simulation with target speed trajectory as input obtains two important data:

a. Torque of each drive shaft; b. Force of each joint;

The former is the basis for the development selection of the drive system, while the latter is the basis for the mechanical structure planning. Simulation calculation work is the interface between the system layer the component layer in the robot development process. The performance indicators for product functions are converted into the performance parameters of each component for technical completion. At this stage, classical mechanics multi-body dynamics simulation are particularly required, a deep understanding of the comprehensive knowledge of mechanical systems, electrical systems control theory is required. It is necessary to be proficient in the use of simulation calculation tools, Matlab/Simulink, Modelica, Adams, various software in the field of robots.

4. Drive system selection development The drive system includes a series of components power supply, servo drive, motor, to reducer, more commonly known as powertrain. Because the scope of different components varies greatly, it is usually completed by engineers in three fields: power electronics, servo motors, reducers. According to the speed torque requirements obtained through simulation calculation, the existing standard types the products in the above three categories, optimize them based on the standard types, develop new types.

The three components designed here, driver, servo motor, reducer, are the three core parts of industrial robots , carrying most of the key skills of the physical layer accounting for the bulk of the component costs. All three components are commonly used in industrial systems, but their performance requirements are higher than those of other applications (except precision machining aerospace).

Because the installation space is limited closed, the requirements for compactness heat management are particularly high. At this stage, engineers need to have a deep understanding of the knowledge in related fields, such as power electronics, motor drive control  (based on space vectors), motor (mainly brushless permanent magnet motor) design, motor-related electromagnetism, various reducer design application, bearings lubrication, etc. If you do involve component development but only selection, you need to have a deep understanding of the performance parameters of various components have a lot of application experience.

5. Mechanical planning Conventional motion system mechanical planning.

The design input includes the following aspects: first, the performance indicators of the mechanical subsystem (length, spatial motion range, weight) calculated through simulation; second, the force analysis of each node; third, the installation requirements of the drive system; fourth, the requirements for the installation method application environment in the functional performance indicators.

Summarizing these inputs, mechanical engineers need to appropriate materials design reasonable structures to achieve the above requirements. The mechanical analysis results are used as the input of finite element analysis, mechanical engineers perform finite element calculations on the design to verify the strength of the structure. Knowledge structure: mechanical design, materials, finite elements, familiarity with relevant standards, understanding of various processing technologies (casting, die casting, plastic molding, sheet metal, welding), proficiency in the use of CAD software (ProE, UG, Catia, Inventor), finite element calculations.

6. Control cabinet planning Typical industrial drive control system electrical cabinet planning.

The cabinet provides an environment for installation, operation, protection for the power supply starter in the drive system, the industrial control computer in the control system (most manufacturers choose industrial control computers instead of PLC plus motion controller solutions), the communication bus system. Layout, heat management,  the implementation of relevant design standards (IEC, UL, GB, CE) are key. Knowledge system: low-voltage electrical system design, servo drive system application, electrical cabinet air duct heat dissipation design, physical safety, field bus connection, various design standards.