Optimum path planningof manipulator arms in assembly applicationsinvolves the selection of the optimum combination of the robot control variables under the constraints imposed by the robot's physical capabilities and the condition of the working area. The present paper describes an approach based on numerical optimization techniques to plan collision-free paths, and on Taguchi parameter design methodology to optimize the control parameters of the pick-and-place operation that would yield minimum cycle time.
I. IntroductionThe ability to plan and optimize a collision-free path in pick-and-place operations is essential in order to improve both productivity and cost effectiveness of robotic assembly operations. Optimum path planning of manipulator arms in assembly applications involves the selection of the optimum combination of the robot control variables under the constraints imposed by the robot's physical capabilities and the condition of the working area (presence of obstacles). The path planning optimization in the assembly applications has two objectives. The first one involves the determination of the shortest path ofthe manipulator's end effector from a pick position (feeders and magazines carrying individual components) to the place position (assembly fixtures), such that it avoids collisions with obstacles in the assembly area. The second objective is concerned with the determination of the levels of the robot control variables that will yield the minimum cycle time in order to increase productivity.The problems associated with path planning and optimization in robotic applications have been emphasized in the past (Kant and Zucker 1988, Lin et al. 1983, Reif 1979, Wu 1989. Most of the reported solutions to these problems involve complex, nonlinear iterating procedures (Freund and Hoyer 1984, Kim and Shin 1985, Luh and Lin 1981, Trabia 1989. Furthermore, these solutions were reported to lack the accuracy required in many applications such as assembly and thus they are limited to applications where precise path planning is not critical. Different methods for off-line cycle time estimation and optimization have been developed. Almost all methods reported use empirical formula or approximation techniques, such as a 'rule ofthumb' method for estimating the time required by each element of the motion, i.e. one second per move, 0·5 second to open or close the gripper, etc. (Tanner 1980). This method was