Otobüs kapak üretim prosesinin robotik otomasyonla optimizasyonu ve triz metodolojisine uygulanması
Optimisation bus lid production with robotics automation and triz implementation
Yazar: ÖMER ZURNALI
Danışman: PROF. DR. CEVAT ERDEM İMRAK
İstanbul Teknik Üniversitesi / Fen Bilimleri Enstitüsü / Makine Mühendisliği Ana Bilim Dalı / Konstrüksiyon Bilim Dalı
Derece: Yüksek Lisans, 2019
Konu: Makine Mühendisliği = Mechanical Engineering
Dizin: Robot sistemleri = Robot systems ; İstanbul Teknik Üniversitesi = Istanbul Technical University

Özet:
Bütünleşen dünya düzeninde yüksek verim, düşük maliyet ve zaman tasarrufu hemen hemen her konuda ön plana çıkmaktadır. Artan rekabet içinde, kar marjlarının günden güne düşmesi ile birlikte artık daha ucuza daha kaliteli ve hatasız iş yapmak firmalar için bir zorunluluk haline gelmiştir. Rekabete ayak uydurmak ve serbest piyasa içinde yer edinebilmek için üretim yöntemlerinin doğru ve en optimum şekilde kullanılması gerekmektedir. Bunu sağlamak için teknolojiyi ve bilimsel gelişmeleri güncel olarak takip etmek ve yapılan işe devşirmek büyük önem arz etmektedir. Endüstriyel anlamda teknolojiye ayak uydurmak, kapasite artışı yaparken çevrim sürelerini indirmek ve daha ucuz ama kaliteli ürünler piyasaya sürmek için optimizasyon, haberleşme ve robotik otomasyon sistemlerinin kullanılması büyük önem arz etmektedir. 1970'lerden sonra özellikle ağır sanayide kaldırma ve iletme amaçlı kullanılan robotlar, bilgi çağı ile birlikte yazılımların öne çıkması ve son olarak Endüstri 4.0 anlayışı ile birlikte daha hassas işler yapmakta ve endüstriyel hayatı rahatlatmaktadır. Özellikle Endüstri 4.0 ve ilerleyen versiyonları ile birlikte karanlık fabrika diye bilinen ışıkların söndürüldüğü tamamıyla otomatik sistemler vasıtasıyla üretim yapılan anlayışın artacak olması robotların ve robotik yapıların fabrikaları tamamen kaplaması kaçınılmaz bir son olarak görülmektedir.
Bu çalışmada robotlar, robotik yapılar ve robotik otomasyon ile ilgili bilgiler derlenmiştir.Literatür araştırması olarak daha önce konu ile ilgili çalışmalar incelenmiş ve kısa bilgiler verilmiştir. Robotik hatların kurulumu ve yardımcı ekipmanları ile ilgili bilgi verilmiş olup robotların programlanması ve haberleşme sistemlerine değinilmiştir.  Yaklaşık yüz yıldır toplu taşımada önemli bir yere sahip olan otobüslerin tarihi hakkında kısa bilgi verilmiş, otobüs ve otobüs kapak üretimi (bagaj, aks üstü kapağı vb.) için gerekli koşullar ortaya konulmaya çalışılmıştır. Robotik otomasyon sistemlerini kullanarak; mukavemeti sağlayan ve otobüs iskelet yapısına montajı kolaylaştıran birbirine kaynak ile bağlanan profillerden meydana gelen bir iç iskeletten ve ihtiyaca göre değişiklik gösteren çeşitli boyutlardaki saç plakalardan oluşan otobüs kapağı üretiminde daha dar bir alanda,  hızlı, kaliteli, iş sağlığı ve güvenliği açısından uygun bir çözüm sunulmaya  çalışılmıştır. Mevcut otobüs üretim hatları hakkında bilgi verilmiş olup; robotik otomasyon ile otobüs üretim hatlarında kurulacak çözümler üzerinde durulmuştur. Robotik otomasyon çözümünde mevutta olan veya ortaya çıkabilecek olası sorunları çözmek veya etkilerini en aza indirmek için akılcı problem çözme metodlarından biri olan triz metedolojisi kullanılmış ve sonuçları tartışılmıştır. Sonıç olarak robotik otomasyonun üretim hatları üzerindeki etkisi gösterilmeye çalışılmış ve bilim ile endüstriye katkı sağlanmaya çalışılmıştır.

Abstract:
In the order of the world which has been integrated, high efficiency, low cost and saving of time have come into prominence almost on every topic. In the increasing competition, doing cheaper, more qualified and accurate work is inevitable with decreasing profit margins for companies.  Production and lean manufacturing methods should be used in an efficient and optimum way to keep up with the competition. In order to achieve this, it is of great importance to follow technologic and scientific developments and adapt them to the current workflow. The optimization of workflows and using communication and robotic automation systems are very important to reduce cycle times and bring cheaper but quality products to the market. 
History of robotic studies which has been improved by human being dates back to the first industrial revolution age. In fact that, it has based on antique ages and mediaeval. Robot is a machine driven by motors and it is made up of several joints. Robots are designed to fulfill one or many tasks at the same time. The fact remains that industrial robots are a kind of robot for using manufacturing area. They are capable of doing welding, hemming, packaging, mounting, painting, palletizing, testing and, inspecting. Robots generate creative solutions aid of people depending on using area. With  control systems, It can be cheched out from remote area. 
After the 1970s, industrial robots have been used in especially transportation purposes for heavy industry. Robots have been doing more sensitive work along with the information age and finally with the understanding of the industry 4.0. Especially with Industry 4.0 and its progressive versions, increasing the dark factory which has just automated systems and there is no people at the production line, understanding is seen as an inevitable end. Robots and robotic structures will completely cover  to the factories at the near future. Robots will be on everywhere both industry and social life, they will be seen at home in fact that have already been. Studies about improving robots and robotic structures have been lasted in order to create more sensitive and creative ones.
In this study, a piece of general information about robots, robotic structures and robotics automation were given. Brief information about the history of the buses was given. Parts which have been used on robotic lines were introduced and given some information on controller and remote control systems.  Literature of robots, robotic science, robotic structures and, methodology of Triz were examined. Elaborated information was given about industrial robots and put emphasis on how robot structures and lines have been constructed. Some comparations were done with robotic structures and, graphics were exhibited association with it. Lean manufacturing methods were operated with possible causes on triz and trying to find solution. It was mentioned about agile manufacturing on behalf of human – machine relationship.
Firstly, when it comes to say about industrial robots, they have worked with some necessary equipment as integrated such as fixtures, positioners, controllers, I/O modules, valves, drivers. Positioners have applied synchronic motion so that robots could be done their implementations well. Workpieces which oparated by robots are aligned owing to fixtures. Controllers are separated by two as robot cabinet and system controller. I/O modules provide communication as pneumatical, hydraulics or electrical. Drivers carry out the motion of robot arms. Robot manipulators do not do anything by itself so appropriate conditions are supposed to provided for them as like necessary equipments, sofware, communication and so on. If it needs to accelerate the system, inverter which is used for increasing or aligning the system speed could be utilized. For communication perception, encoder which has some sensor types, by generating signals can be necessary in order to count product and give information to the system.
There are many remarks to be paid attention when robots have been utilized or robotic optimisation lines have been installed such as programming. It is very important for robots since to-do is taught to the robot and can be controlled by the programmer, whether it is active or passive, could be done everything that is in its limits. While passive programming can be done with aid of an operator, active programming can be created with teach pendant or softwares which have been done off-line programming for robots. Off-line programming provides some advantages such as simulation and, installation is not necessary in this method. However, programming technics have been developing and people are still learning them more than ever before. 
Remote control systems in broad scale robotic automation or in dark factory could be vital for tracking everything which has been in the area. Controllers provides many oppurtunities and advantages for the systems so that everything can work properly and anything can be detected when it happened. About everything which has happened in the system, controllers have informations and, they keep it long time on database in order to compare, determine which product was produced, point out which station at and what time it was produced at. 
Buses are kind of public transportation systems. They have been in human life for a long time. Buses have importance since reducing CO2 emissions in comparison with using personal cars. Bus production lines have made progress in the last years so, robotic lines have started to integrate, although bus production lines have big scale parts and, tolerances are wide. Nowadays, as cost reduction and innovation on products are almost everything thus, alternative materials and optimisations have gained importance. Even though bus and bus lid which has been utilized for storage, maintenance on bus, productions systems are traditional, robots have been beginned to be used in.
Selection criteria of robots are very crucial since these criteria specify how many kilograms a robot could carry. Thus, it is given information about kinematic equations, accuracy, repeatability, angular velocity and payload capacity of robots. Type of kinematic equations are forward and reverse kinematics. Forward direction kinematics with joint variables calculates the position and orientation of the main frame. The transformation matrix of the first joint defines the relationship between the first joint and the main frame; the transformation matrix of the last joint refers to the relationship between the end function and the last joint. When the position and orientation of the robot's end function according to the main frame is known, it is necessary to determine the necessary joint variables for the manipulator to reach this position and orientation with reverse kinematics. Accuracy and repeatability can be evaluated together because when one of them is deficient, robot operations would not be succesfully. Payload capacity of robot is pointed out according to optimum conditions which robot do not have any burden at sixth DOF (Degree of Freedom) by robot producers. So this option could be taken into consideration while prefering for a robot. 
A comparison with robots payloads and mass moments of inertias on joints was done between two robots which have different payloads by calculating mass moment of inertias. Some graphics related to static and dynamic behaviours of robots were showed up. It is seen that when payload is heavy for robot, it does not carry the payload or it does not open its arms so much.
A brief history and classification of buses according to regulations, instructions and directives were explained. Robots which are used in buses production lines and their technical features and some anticipations were given on the robotics industry about buses. Bus modeling were introduced about some modules. Robots which have been using on bus production line and their improvement were mentioned.
In order to achieve and accomplish all stage of the study and enlighten everyone who want to build robotic lines, essential regulations, instructions and obligations on commissioning robotic optimisation lines were examined and listed. These regulations are critical to installing robotic lines because governments and international institutions inspect all firms which have a production with conventional or robotic automation lines. These regulations have been built up with growing experiences over the years. It has taken spent many years to provide optimum production conditions. By using robotic automation systems, bus lid productions can be applicable in a narrower area with better quality and more suitable in terms of work safety. 
Triz is a kind of metodology of problem solving. However, it has some difference such as it does not show the solution way, it just give the opinion how to solve the problem. That is, Triz is a mentor. Triz metodology have composed of examining and evaluating lots of patents. In this thesis, Triz metodology was used to solve some obstacles and issues. It has showed that the opinion way as like brain storming.
The process of bus and lid production is a significant matter in this thesis. Therefore, structures of buses and lids were expressed in detail. About body construction, material selection and using materials on buses were explained. The former process and production steps, requirements for safety and flow and, acquisitions have been mentioned. Firstly, appropriote robots (according to mass moments of inertia) and equipments were selected then, in order to verify the selections simulation studies were done. İt was seen that robots and equipments were suitable for the system which was planned. Programming were implemented according to the plan. All stages about robotic automation line was explained and made a comparison between traditional method and robotic automation metdod. Differences between them were explained and tried to show with some graphics.
Bus lid production lines with robotic automation system will supplant by traditional one in the near future. In this study, bus lid production line which installed with robotic automation was explained in deteail as like what robots do to operate the parts and, what operator do to proceed the system and, how  the system can be developed. New type of line was tried to express with figures. 
When this system was installed and carried out comissioning the process, what kind of problem could be taken place and how could be solved , all of them was examined on Triz applicaiton and trying to find out any solution with Triz's guideness aid of lean and agile manufacturing tools. Triz showed the way to find opinion with its contradicts matrix how mechanic or physical problems are solved on line. Lean manufacturing tools provide the great advantages to overcome possible causes and failures. For sure, robotic automation system will show many key product indicators in time as it will be used in production line. 
This study can be improved and advocated with other kind of problem solving methods. The same study can be implemented other part of bus or automotive production areas. Robot motions can be showed at some language of programming like Phyton, Matlab, Mathcad, Robot Studio, Cosimir Robotics, Robcad  instead of Sim.pro which is used in this study in the future. Problems, failures will be seen in time and again try to use triz.
The possible problems that would be arised in the robotic automation systems were evaluated and discussed with triz methodology which is one of the rational problem-solving methods, in order to eliminate the problems that may be existed. 
The purpose of this thesis was to contribute to industry and explain how to use robotic optimisation against traditional production. All phases of aim were fulfilled and it can be developed in time with more opputunites.
As a result of this study is to show how to install any robotic line and how to solve possible causes which would be taken place, with Triz metodology.