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The purpose of this paper is to analyse teleoperation of an ABB industrial robot with an ABB IRC5 controller. A method to improve motion smoothness and decrease latency using the existing ABB IRC5 robot controller without access to any low-level interface is proposed.

The proposed control algorithm includes a high-level proportional-integral-derivative controller (PID) controller used to dynamically generate reference velocities for different travel ranges of the tool centre point (TCP) of the robot. Communication with the ABB IRC5 controller was performed utilising the ABB PC software development kit. The multitasking feature of the IRC5 controller was used to enhance the communication frequency between the controller and the remote application. Trajectory tracking experiments of a pre-defined three-dimensional trajectory were carried out and the benefits of the proposed algorithm were demonstrated. The robot was intentionally installed on a wobbly table and its vibrations were recorded using a six-degrees-of-freedom force/torque sensor fitted to the tool mounting interface of the robot. The robot vibrations were used as a measure of the smoothness of the tracking movements.

A communication rate of up to 250 Hz between the computer and the controller was established using C# .Net. Experimental results demonstrating the robot TCP, tracking errors and robot vibrations for different control approaches were provided and analysed. It was demonstrated that the proposed approach results in the smoothest motion with tracking errors of < 0.2 mm.

The proposed approach may be employed to produce smooth motion for a remotely operated ABB industrial robot with the existing ABB IRC5 controller. However, to achieve high-bandwidth path following, the inherent latency of the controller must be overcome, for example by utilising a low-level interface. It is particularly useful for applications including a large number of short manipulation segments, which is typical in teleoperation applications.

Using the proposed technique, off-the-shelf industrial robots can be used for research and industrial applications where remote control is required.

Although low-level control interface for industrial robots seems to be the ideal long-term solution for teleoperation applications, the proposed remote control technique allows out-of-the-box ABB industrial robots with IRC5 controllers to achieve high efficiency and manipulation smoothness without requirements of any low-level programming interface.

This study aims to report the development of a provisional robotic cell for additive manufacturing (AM) of metallic parts. To this end, the paper discusses cross-disciplinary concepts related to the development of the robotic cell and the associated command and control system such as the Computer-Aided Design (CAD) interface, the slicing software and the path planning for the robot manipulator toward printing the selected workpiece. This study also reports the development of a virtual production cell that simulates the AM toolpath generated for the desired workpiece, the adaptation of the simulation environments to enable AM and the development of a user application to setup, command and control the AM processes. If a digital twin setup is efficiently built, with a good correlation between the simulation environment and the real systems, developers may explore this functionality to significantly reduce the development cycle, which can be very long in AM applications where metallurgic properties, part distortion and other properties need to be monitored and controlled.

To generate the robot manipulator path, several simulation programs were considered, resulting in different solutions to program and control the robot of choice [in this study, Kuka and Asea Brown Boveri (ABB) robots were considered]. By integrating the solutions from Slic3r, Inventor, Kuka.Sim, Kuka.Officelite, RobotStudio and Visual Studio software packages, this study aims to develop a functional simulation system capable of producing a given workpiece. For this purpose, a graphical user interface (GUI) was designed to provide the user with a higher level of control over the entire process toward simplifying the programming and implementation events.

The presented solutions are compatible with the simulation environments of specific robot manufacturers, namely, ABB and Kuka, meaning that the authors aim to align the developments with most of the currently realized AM processing cells. In the long-term, the authors aim to build an AM system that implements a produce-from-CAD strategy i.e. that can be commanded directly from the CAD package used to design the part the authors are interested in.

This study attempts to shed light on the industrial AM, a field that is being constantly evolved. Arguably, one of the most important aspects of an AM system is path planning for the AM operation, which must be independent of the robotic system used. This study depicts a generic implementation that can be used with several robot control systems. The paper demonstrates the principle with ABB and Kuka robots, exploiting in detail simulation environments that can be used to create digital twins of the real AM systems. This is very important in actual industrial setups, as a good correlation between the digital twins (simulation environment and real system) will enable developers to explore the AM system in not only a more efficient manner, greatly reducing the development cycle but also as a way to fully develop new solutions without stopping the real setup. In this research, a systematic review of robot systems through simulation environments was presented, aiming to emulate the logic that is, used in the production cell development, disregarding the system brand. The adopted digital twin strategy enables the authors to fully simulate, both operationally and functionality, the real AM system. For this purpose, different solutions were explored using robots from two different manufacturers and related simulation environments, illustrating a generic solution that is not bound to a certain brand.

Using specific programming tools, fully functional virtual production cells were conceived that can receive the instructions for the movements of the robot, using a transmission control protocol/internet protocol. Conversion of the CAD information into the robot path instructions for the robot was the main research question in this study. With the different simulation systems, a program that translates the CAD data into an acceptable format brings the robot closer to the automatic path planning based on CAD data. Both ABB and Kuka systems can access the CAD data, converting it to the correct robot instructions that are executed. Eventually, a functional and intuitive GUI application capable of commanding the simulation for the execution of the AM was implemented. The user can set the desired object and run a completely automatic AM process through the designated GUI. Comparing ABB simulation with the Kuka system, an important distinction can be found, namely, in the exportation of the programs. As the Kuka program runs with add-ons, the solution will not be exported while maintaining its functionality, whereas the ABB program can be integrated with a real controller because it is completely integrated with modules of the virtual controller.

To conclude, with the solutions exploited, this study reports a step forward into the development of a fully functional generic AM cell. The final objective is to implement an AM system that is, independent of any robot manufacturer brand and uses a produce-from-CAD strategy (c.f. digital manufacturing). In other words, the authors presented a system that is fully automatic, can be explored from a CAD package and, consequently, can be used by any CAD designer, without specific knowledge of robotics, materials and AM systems.

Describes how Jaguar Cars in the UK is using robots to manufacture aluminium car bodies for its new XK sports car that is being built in the company's plant in Castle Bromwich, UK.

Describes the major production line techniques that are used in the manufacture of the body‐in‐white structure. These include self‐piercing rivets (SPRs), self‐tapping screws, MIG welding and adhesives.

The use of SPRs and self‐tapping screws are proving essential in the joining of aluminium components manufactured as extrusions, castings and pressings.

The introduction of SPRs and self‐tapping screws, adhesive bonding and MIG welding of cosmetic aluminium skin panels is the result of considerable research work on the part of Jaguar engineers and the company's suppliers, as well as Warwick University. Three of these techniques require the services of robots with their integrated controls. This work is likely to continue in order to reduce cycle times and improve overall product performance, both to the benefit of manufacturer and end‐user – the customer. This paper provides a unique insight into the development of a facility with islands of automation to produce aluminium body shells.

It is likely that arising out of development work into new techniques, processes and standards that will be used throughout the Ford organization, including other companies that form the Premier Automotive Group. Aston Martin, Land Rover and Volvo could all benefit from the technologies developed at Jaguar Cars.

This is the first time Jaguar Cars has used ABB robots in significant numbers to apply SPRs and self‐tapping screws to join aluminium components. ABB robots are also used for body shell inspection and MIG welding aluminum skin panels.

To report some successful applications of vision‐controlled robots in picking and packing of foodstuffs.

The design and capabilities of ABB's two picking robots are explained, and the specialist software that integrates vision guidance and product inspection. Then two food‐picking applications are described in detail.

The delta robot design combines low weight with high stiffness, giving very fast picking capability. The Cognex‐based vision system also produces high speed and precision, and is able to guide the robot and perform 100 per cent inspection in real time. Hygienic robot design allows it to handle open food.

ABB's FlexPicker robot has moved from being a niche product to a volume product, bringing high‐speed picking capability to a wider market.

Showcases the capability and flexibility of a powerful vision‐guided high‐speed robot.

ABB has launched a new robot controller, the fifth generation IRC5. One of its major features is MultiMove, a function that enables fully coordinated control of up to 36 axes, equal to four six‐axis robots plus work positioners or other servo devices. This opens up new application areas with a combination of handling and processing robots, including balanced welding and multiple robot manipulation to increase lifting capacity and/or protect large flimsy workpieces. Benefits are higher relative speeds, minimal in‐cycle waiting and improved weld quality. Other features of the IRC5 are its modularity, with a logical split of control and axis drive functions and simple two‐cable connection, and a completely new ergonomically designed interface unit running under Windows CE.NET with full colour touch screen and Windows menus and icons.

Looks at refurbishment services which can increase the life expectancy of robots. The services range from a thorough inspection and cleaning to a complete factory‐certified mechanical reconditioning program. At the same time robots can be upgraded to take advantage of current technological advancements such as new software equipment, accessories and expanded memories. Describes an exchange service where worn robots are immediately replaced by reconditioned units which saves money and minimizes production line disruption. Concludes that refurbishing is an increasingly successful business area that can also offer opportunities for manufacturing companies by either exchanging or buying previously owned robots.

Research has shown that companies focus their internal processes when they adopt enterprise resource planning (ERP) systems. However, the ERP systems need to expand their functionality to include customers and suppliers (with e-commerce functionality) to reach their full potential. The purpose of this paper is to consider business relationships as a resource but also a limitation when companies strive to get an extended ERP system.

The paper presents an illustrative case study of an industrial company's process of developing an extended ERP and how the company's portfolio of business relationships has affected the solution. The analysis is supported by the markets-as-networks theory.

The process of developing an extended ERP system needs to incorporate the company's business partners (customers and suppliers). It is a simultaneously bottom-up and top-down process given that the operative frontline staff hold the knowledge about the company's business relationships while the corporate management has the means of extending the ERP system functionality and align it with the focal company's strategy.

Companies need to consider the fact that the technological and financial status of their customers and suppliers differ. Thus, an effective and flexible extended ERP system needs to include both a high-end and low-end solution as well as understand that a full interorganizational integration might not be realistic.

The paper puts forth business relationship portfolios as an important factor to consider when extending the ERP system functionality in the supply chain and toward customers.

To review manufacturing automation products and technology on show at Interplas 2005, the UK's premier exhibition of equipment for the plastics and rubber industry.

Some of the automation products on display at the show are highlighted, particularly the take‐out or beam‐type robots favoured by several of the injection moulding machine (IMM) manufacturers who produce their own version of these robots, including Arburg and Negri Bossi. Descriptions are also given of products from some independent automation equipment manufacturers including ATM, Geiger Handling and Wittmann. Beam‐type and articulated arm robots are described as well as end‐of‐arm tooling including CaviGrip exhibited by ATM, which through cooling within the tool can achieve dramatic savings by reducing the cycle time of IMMs. The contrasting benefits of beam‐type and articulated arm robots tending IMMs are debated. Also revealed is new articulated arm robot hardware and software technology developed by ABB specifically for plastics manufacturing automation. Finally, a brief case study is presented of a robot cell at Characteristix, a UK manufacturer of injection mouldings for the entertainment industry, which has helped it compete against the Far East.

There are manufacturing automation products available to the plastics industry that can help lift it out of recession. Articulated arm robots can add significant value to injection moulded products.

Presents a review of the manufacturing automation technology now available to the plastics manufacturing industry.

Describes the development and application of the ABB IRB 140 industrial robot. This robot is characterised by its small size (120cm high) and high load carrying capacity (5kg). Applications covered include welding, die spraying, machine tending and clean room.

This paper aims to illustrate how robots can form an efficient, versatile and cost‐effective component in assembly operations.

The applicability of robots is illustrated by two integrated confectionery‐packing solutions, followed by a description of a portioning machine specially developed for floppy meats. The particular advantages of ABB's FlexPicker robot are described.

ABB's Global Partner Programme encourages the use of robots in automation, and such robots can achieve a rapid pay‐back, even in the low‐pay food‐packaging industry.

The paper brings to the attention of assembly engineers the possibility of incorporating robots in the assembly line.