JPRS ID: 10478 JAPAN REPORT

• Document Type: CREST
• Collection: JPRS
• Document Number (FOIA) /ESDN (CREST): CIA-RDP82-00850R000500050054-2
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• Original Classification: U
• Document Page Count: 84
• Document Creation Date: November 1, 2016
• Sequence Number: 54
• Content Type: REPORTS

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JPRS L/ 10478
23 April 1982
Ja an R~ ort
p p
(FOUO 25/82)
FBIS FOREIGN BROADCAST INFORMATION SERVICE
FOR OFFICIAL USE ONE.Y
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JPRS I,/10478
23 April 1982
I
~
. JAPAN REPORT
~ . (~ovo 25/821
,
CONTENTS
~ MILITARY ~
Recent Defense-Related Induatry Activities Reported
(D1IHItEI SANGYO SIiIMBiJN, vaxious dates ) . . . . . . . . . . . . . . . . . . . : . . . 1
Engine for MTX
Model 88 Tank
Mitsubishi To Remodel F-1+
Optical Communications Military Application s
Domestic Missile Development
Development of F-1's Successor
Value of NEC Contracts
Remodeling Pha.ntoms
I SCIEL~TCE AND TECHNOLOGY
Industrial Robot Production '"Pahnology Discussed
(DENSHI GIJUTSU, Jan 82) 14
1981 Industrial Rob ot Fair , by Ryoauke Masu~a, Takashi Mizutar.i
Kawr~saki Heavy Industries' PUMA, by Yasuhiro Kubota
Toshiba Steel's TOSMAN-300, by Nobuo Taguchi
Sanl~yo Seiki's SKILAM, ~by Yukio Oguchi
Yasukawa Electric's 'Motoman', by Sei~i Horikawa
Shinmeiwa Industry's 'Robel J', by Shigeo Kawabe
Hitachi Limited's 'Mr Aros',by Hitoshi Yosbhida
Creative Science, Technology Promotion Program Being Set Up
(NIHON KOGYO SHIMBUN~ 6~Tat~e 12 Feb 82~ 79
Outline of Program
ResearcM Setup
-a- [III -ASIA-111~'OUO]
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MILITARY
RECENT DEFENSE-RELATED INDUSTRY ~CTIVITIES REPORTED
Engine for MTX
Tokyo NIKKEI SANGYO SHIMBUN 3n Japanese 22 Jan 82 p 9
[TextJ Ishikawajima-Harima Heavy Industries has recently delivered to the
Dzfense Agency the first and second prototype F3 c:*~gines to be mounted in
the MTX. The Defense Agency appropriated approximately 9 billion yen in
FY-80 and FY-~81 for development of thia e.^gine by Ishikawajima-Harima. After
testing, the Defense Age*~cy will examine and compare its price and pe~for-
' mance to that of candidat~ engines from Garrett of the United States and
~ Snecma of France. By this October, a final decisiot~ is expected to be made
on whether or not the F3 engine will be used in the MTX.
MTX development was begun last fall by Kawasaki Heavy Industries as the main
contractor. It is the earnest wish of both the Defense Agency and the industry
that a fuselage as well as an engine be developed in Japan. Concerning the
F3 engine, five prototypes were ordered from Ishikawa~ima-Harima during FY-80,
1 year before the fuselage. Furthermore, four additional prototypes are to
be ordered by the end of FY-81.
Ishikawajima-Harima has delivered two out ot five prototype engines ordered
in FY-80. By this summer it expects to deliver the remaining three engines.
These prototype engin~s already fulfill the performance requirement of genera-
ting 1.6 tons of thru.st. The Defense Agency is planning to conduct tests
in high-altitude experiment facilitiea in the United States where humidity
and atmospheric pressure are ad~usted to simulate actual flying conditions in
July through September. In the ~aantime, it is also planning to conduct vari-
ous perfo~mance t~sts within Japan by mounting F3 engines in a modified C1
transport plane.
Examining the results of these tests, the Defense Agency is supposed to make
a final decision on whether or not the F3 engine will be used for the MTX
in October. Because Garrett and Snecma are also in the process of developing
engines of this class as a derivative of other engine types, it is expected
that the F3 engine will be chosen if its cost can meet the target of 100-150
million yen apiece in 1980 prices.
The development of the MTX is expected to be cempleted by FY-87. The A~.r
Self Defense Force plans to order about 200 MTX's. Since two engines are
mounted in each MTX, the total number of engines ordered will be about
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500 including spares. If the F3 engine is chosen, as of FY-8~ the con~ractor
is supposed to start manufacturing engines which will actually be mounted
on the MTX on a trial basis.
COPYRIGHT: Nihon Keizai Shimbunsha 1982
Model 88 Tank
Tokyo NIKKEI SANGYO SHIMBUN in Japanese 6 Feb 82 p 6
[Text] The Defense Agency will start basic 3esign work and manufacture of
prototypes for parts such as the turret in order to develop a new tank that
will succeed the model 74 tank as of FY-82. The Defense Agency has formulated
a 3-year plan to produce a first-phase ~rototype of a new tank starting in
FY-82, and a partiai budget was appropriated for items such as basic design in
the govern~ent's budget draft for FY-82. Since a new tank is targeted for a
final decision (on development) in 1988, the new tank is called the model 88
tank. It will be developed by M~tsubishi Heavy Industries as the inain contrac-
tor. The turret will be developed by Japan Steel Works, Ltd. The technical
develapment headquar*_ers of tt~ese corporations and the Defense Agency have
been making prototy~es of parts such the engine one by one. This stage
of research and prototype parts produc~ion was completed at the end of FY-81.
Therefore, they will start a substantial portion of the development of the
new tank as of FY-82. They intend to develop a tank of the world's highest
standards by improving the firepower and mobility.
According to the Defense Agency's development plan, the first phase prototype
of the tank will be completed in FY-82 through FY-84 and the second-phase
prototype in FY-85 and FY-86. Then, the Defense Agency will conduct practical
applic~tion tests and decide formally to deploy it in units in 1988. Althou~h
the Defens~ Agency requested approximately 7 billia!1 yen as development
expenses far an entire tirst-phase prototype, only approximately 1.3 billion
yen (for the 2 years Fv-82 and FY-83) was approved in the government' budget
draft as expenses for basic design of the entire tank and for production of
prototypes of some parts such as the turret. The Defense Agency, however,
hopes to proceed with the development plan as ori.ginally scheduled by request-
ing additional appropriations in the bLdgets after FY-83.
The outline of the model 88 tank will be determined in consideration of a
balance between firepower, mobility, and protectability. As for firepuwer,
the 105 mm turret of the model 74 tank will be replaced with a 120 mm turret.
As for the engine to be mounted, the agency is planning to use a 10-cylinder
water cooled engine with 1,500 horsepower, which is alm~st twice as powerful
as the engine of the model 74 tank. An increase in running speed and applica-
tion of compound bulletproof structures are also subjects of study. The number
of crewmen will be reduced from the four in the model 74 tank to three.
The Defense Agency has been producing prototypes parts by contracting with
Mitsubishi Heavy Industries for bodies and engines and with Japan Steel Works
for turrets. It will bring these prototype parts together to assemble a tank
as of FY-82. The prototype turret, for which prototype production has been
provided in the FY-82 budget, ia suppoaed to be 3esigned so that ammunition
will be interchangeable with that of U.S. forces.
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Mitsubishi Heavy Industries, the main contractor, is seriously preparing for
_ development of the model 88 tank in hopes of increasing fuel efficiency by
improving engine performance and reducing total weight, while trying to make
various apparatua~, work efficiently by applying mechatronics technology.
Because the budget for the entire first-phase prototype was not approved in
the government's budget draft, there are some areas where Mitsubishi Heavy
Industries has to invest in advance. Therefore, it plans to work out the
details with the Defense Agency in the near future.
COPYRIGHT: Nihon Keizai Shimbunsha 1982
Mitsubishi To Remodel F-4
Tokyo NIKKAN KOGYO SHIMBUN in Japanese 25 Feb 82 p 11
[Text] The Defense Agency has decided to sign a contract
with Mitsubishi Heavy Industries (Soichiro Suenaga, presi-
dent) in March for a portian of the service life prolonga-
tion plan (ASIP) of the trial remodeling pra~ect of the
F-4 Phantom (EJ) fighter-interceptor aircraft, which has
been an object of dispute in the Diet. Because the execu-
tion of the FY-81 budget has been suspended for tr~e
capability impr~vement portion of the plan, the De.fense
Agency and Mitsubishi Heavy Industries will sign a con-
tract only for the service life prolongation portion of
the plan. Immediately after signing the contract,
Mitsubishi Heavy Industries will purchase 25 VGH (velocity,
gravity, and height) data recorders with the budgeted
700 million yen. Then, it plans to extend the present
3,000-hour (hours in the air) lifespan of the F-4 by
about 2,000 hours to make a 5,000-hour lifespan. The
ASiP requires that records of actual use of each F-4
compiled by a load frequency meter and information fram
a VGH data recorder be processed by camputer. After
examining the degree of wear and the limits of each
aircraft, the agency will formulate a remodeling plan.
As for the capability improvement plan, as soon as the
suspension of the budget is removed, the Defense Agency
hopes to select a contractor quickly. .
Mitsubishi Heary Industries started licensed production of the F-4EJ in 1970.
It manufactured a total of 140 F-4EJ's by May 1981, when it delivered the
last aircraft to the Defense Agency. Other aircraft manufacturers are
Kawasaki Heavy Industries and Fuji Heavy Industries. However, in the case
of the ASIP for the F-4, Mitsubishi Heavy Induetries was chosen as contractor
because of its past experience of dealing with F-4's.
According to the ASIP, a VGH data recorder, which analyzes the aircraft body's
degree of safety, will be installed in one of every six of the 132 F-4EJ's
currently held by the Defense Agency. Then, information from VGH data
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recorders will be processed by computer along with records of actual use
(C/A data) compiled by 1"._zd frequency meters installed in every F-4EJ. rrom
the computer, (1) the present condition and future prospect of wear in each
aircraft and (2) limits of wear of related structural parts will be obtained
in order to gather basic materials for checkups and repairs. The Defense
Agency is studying the possibility of domestically producing a part of the
software needed for computer processing. Mitsubishi Electric Co and Tokyo
Precision Instrument Co are under consideration as possible contractors. The
software will be prepared from FY-81 through FY-83. Employment of the ASIP
will begin after the completion of software preparation in FY-84.
The lifespan of an aircraft used to be determined as the time when a representa-
tive aircraft of the type was wrecked. Owing to the progress of nondestructive
and other testing technologies, however, it has become possible to determine
the lifespan of individual aircraft. The conception of an ASIP was original]y
formulated in the United States in 1972, and it was first applied to the
F-4E. The Air Self Defense Force sent a study team to the United States in
FY-80 to see whether or not supply of the ASIP software by the United States
was possible.
In the case of aircraft, load is imposed on win~ joints and outside shell plates,
and these parts wear. The ASIP is intended to find worn parts and replace them
with new parts. According to the Defense Agency, although the degree of wear
differs in each aircraft, the plan is to extend the life of aircraft from the
present 3,000 hours to 5,000 hours.
The ASIP and capability improvement are two sides of the F-4EJ trial remodeling
project. The capability improvement plan includes replacemeiit of the 'J.S.
Westinghouse APQ 120 fire control system with the Westinghouse APG 66, which
has been installed in the small F-16 fighters, and installation of a new
central computer (made by IBM of the United States), which has been installed
in F-15's. As the result, the missiles carried by the aircraft will be the
most advanced AIM-7F's and AIM-9L's. In addition, the remodeled F-4EJ's will
carry anti-ship air-to-surface missiles and posses a bombing capability. The
execution of the budget has been suspended for the capability improvement plan
due to a dispute in the Diet over Mr Masuda's (former director general of the
Defense Agency) statement in 1968 that "Fighter aircraft should not be equipped
with bombing capabilities."
Judging that the suspension on the expenditure of 1.3 billion yen for design
costs will be removed soon, the Defense Agency hopes to hasten selection of a
contractor. Although Mitsubishi Heavy Industries is most likely to g~t a
contract for the capability improvement plan as in the case of the ASIP,
the company appears to need technical assistance from electrical manufacturers
in the fields of fire control systems, central computers, headup displays,
and inertial navigation systems.
COPYRIGHT: Nikan Kogyo Shimbunsha 1982
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Aptical Communicatione Military Applications
Tokyo DENPA SHIMBUN in Japanese 27 Feb 82 p 2
[TextJ According to information revealed by a concerned source on 26 February,
Mitsubishi Heav3 Industries and Mitsubishi Electric Company, the largest
defense contractor and the defense co~itractor ranking high in the amount of
orders received, respectively, have started to develop ortical communications
systems for military uses in order to prepare for the a~~plication of optical
communications to information processing in fighter air.craft and warships
of the Self Defense Forces.
Due to a sharp increase in computers and electronic apparatuses installed
in fighters and warships, all wiring requirements cannot be handled by the
presently used copper cables. Therefore, they have decided to hasten research
and development of optical communications systems for military applications.
On the other hand, the First Research Laboratory of the Technical Research
Headquarters of the Defense Agency has been studying military applications of
optical communications together with manufactuers of optical communications-
related apparatus.
For this reason, military uses of highly advanced optical communications ,
technologies, such as the high-speed digital cou~unications that have been
developing rapidly in nondefense sectors, are expected to progress at a
rapid pace hereafter.
According to the source, Mitsubishi Heavy Industries and Mitsubishi Electric
have formed an engineer-level committee which has been studying military appli-
cations of optical co~unications. They are trying to build up a system within
a short time in order to be able to respond at any time if the Self Defense
Forces decide to use optical communications systems for information processing
in fighters and warships.
Various electronic apparatuses such as central computers, inertial navigation
systems, and fire control systems have been installed in the newest fighters
and warships. Thus, they have become, so to speak, "a mass of electronic
apparatuses." Accompanying this tendency, the volume of internal information
has grown enormously and cannot be handled by copper cables any more. This
is why the two companies have started seriou~ study of military applicat~ons
of optical communications. ~
If optical communication systems are used, data communications can be increased
in volume and concurrently reduced in weight. In addition, there are merits
such as elimination of electromagnetic waves and facilitation of highly dense
wiring.
- Figliters and other military aircraft have, among other things, been highly
computerized. The size of missile control and other fir,~ control devices
and inertial navigation equipment has become very small. Instrument panels
in front of the pilot's seat have been in a process of digitalization.
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Within the limited space of an aircraft, communications circuits connecting
these electronic apparatuses are bulky as well as heavy. Consequently, the
future use of optical communications is inevitable in fighters. The United
States has also begun experiments to apply optical communications in fighters.
F'or this reason, on the assumption that. "the age of optical communications"
for fighters and warships will come in Japan, both companies have begun serious
study of systems development and related parts usable in military applications
such ~s optical cables, light-emitting elements, and optical connectors, and
the checking of their durability and reliability.
Until now, the only instance of military application of optical communications
in Japan has been the use of a very short optical fiber as part of the radar
equipment. However, if plans for a ground support fighter (FSX) to reFlace
the F-4 Phantom, which will be greatly reshaped by installation of the most
advanced electronic apparatuses and plans for an improved mobility aircraft
(CCV), which is under development as a fighter of the future, are reali.zed,
large-scale application of optical communications can be foreseen.
COPYRIGHT: Denpa Shimbunsha 1982
Domestic Missile Development
Tokyo NIHON KEIZAI SHIMBUN in Japanse 1 Mar 82 p 10
[Text] The Defense Agency and defense equipment
manufacturers have been actively engaged in develop-
ment of missiles. As of FY-82 the Defense Agency
will start development of an anti-ship surface-to-
surface missile (Mitsubishi Heavy Industries in
charge) and a middle-range anti-tank missile (Kawasaki
~ Heavy Industri_t:- and Nippon Electric Company in
charge). In ad.~ition, Mitsubishi Heavy Industries
has started research and developmenr_ of an air-to-
air missile commissioned by the Detense Agency.
Tokyo Shibaura Electric Company also started develop-
ment of a h~nd-carried SAM (surface-to-air missile).
Domestic missile development proj~cts are jostling
with one another. All of them are intended to be
employed after 1985. If the Defense Agency formally
decides to employ them, several tens of billions of yen
in orders are expected. Consequently, the manufacturers
developing them are highly motivated. Because electronic
technologies for nondefense use can be applied to guidance
equipment and other components, missiles and considered
"a weapon suitable for Japan. For this reason, they
seem to be the core of defense equipment development.
Makers Expect To Receive Several Tens of Billions of Yen in Orders
The anti-ship surface-to-surface missile which will formally become a Defense
Agency development project as of FY-82 is a missile to attack from land enemy
ships which try to reach the shore. Based on the technology used to develop
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the ASM-1--an anti-ship air-to-surface missile--Mitsubishi Heavy Industries
is planning to develop an anti-ship surface-to-surface miasile. It expects
to complete development by FY-87.
The middle-range anti-tank missile is for attacking tanks. One of its
characteristics is the application of a new system whereby a missile radiatea
laser beams toward enemy tanks a~d chases the reflected light. Kawasaki Heavy
Industries, the main contractor, and Nippon Electric Company in charge of
guidance equipment, have been making components on a trial basis and advanc-
ing the research and development prior to the formal inauguration of the
Defense Agency's deve~cpment plan. They expect to complete development in
FY-86.
The air-to-air missile (AAM for a~rial dogfights) that Mitsubishi Heavy
Industries plans to develop is intended to succeed the AIM-9L Sidewinder,
which is to be manufactured under license from a U.S. company. The hand-
carried SAM that Toshiba has been developing is also intended to be a future
replacement for one currently imported by the Defense Agency. Toshiba is
planning to apply a CCD (chatge-coupled device) uaed for home VTR cameras
in the homing device which locks onto enemy fighters. The plan has attracted
a great deal of attention from the technological viewpoint.
For the development of defense equipment such as missiles, the Defense Agency
ordinarily appropriates a development budget and comm4issions companies to do
the work. However, the Defense Agency will conduct its own research on the
development of the Nike Phoenix, a possible replacement for Nike and Hawk
surface-to-air missiles. The Defense Agency is also positively studying the
components necessary to improve the performance of missiles. The Defense
Agency has commissioned Fujitsu to develop an IR (infrared) CCD that will
possess the capability to detect infrared rays.
Japanese missile production has mainly been production under license from U.S.
companies, as in the case of the Nike and Hawk. However, with the successful
development of Mitsubishi Heavy Industries' ASM 1 and Toshiba's short-range
SAM (short-range surface-to-air missile) and the beginning of their installa-
tion, domestic missile development has gained momenttmm.
COP1'RIGHT: Nihon Keizai Shimbunsha 1982
Development of F-1's Successor
Tokyo NIKKAN KOGYO SHIMBUN in Japanese 2 Mar 82 p 9
[Text] The idea of developing a successor to the
F-1 support fighter (FSX) has been quickly boiled
down to the essentials, and the Defense Agency has
decided to launch the development plan for the post
F-1 aircraft as "research and development for future
fighters" in the FY-81 Mid-Term Operations Estimate
which the Befense Agency has been hastening to draft.
Mitsubishi Heavy Induatries, Japan's only fighter
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r~~c vrr~~.~wi, u~r. UIVLY
airplane manufacturer, is eager to develop the aircraft,
saying "we want to make an FSX that can engage in a
high-level air battle after firing anti-ship missiles
and dropping bombs" (Kenji Ikeda, managing director
~f Mitsub3.shi Heavy Industries). The Defense Agency
seems to be thinking of approximately 200 billion
yen for research and development expenses. waile
preparing three flying corps of supp~rt figh~~ss
(F-1), the Defense Agency is attempting to increase
support capability b~ prolonging the service life
and improving capability (trial remodeling) of the
F-4 (EJ) which soon will exhaust their f lying hours.
One hundred out of the 132 F-4 fighters the Air Seli
Defense Force now possesses will be remodeled. The
competition in terms of military uses between the
FSX and the remodeled F-4 as a successor to the F-1,
whose manufacture is supposedly to cease soon, has
begun to attract attention.
Support fighters are loaded with a large number of anti-ship air-to-surface
missiles and bombs. They assume the mission of aerial attack against enemy
ships which threaten the sea lanes and fleets which try to Iand troops and
preventing enemy invasion by a+_tacking at the water's edge. The FSX is
intended for development as a successor to the F-1. FSX fighters are supposed
to possess the capability not only for support at sea but also to attack
tanks and supply bases of enemies which have landed. On the ocean, an
ordinary pulse radar can pick up targets such as warships. Bu~ that is not
the case on land. The FSX is expected to add the ground support capability
that the F-1 lacks by using a pulse doppler radar to improve look-down capaLil-
ity and, furthermore, by installing a laser precision targeting system.
Research and development of the FSX will start in the latter half of the FY-al
Mid-Term Operations Estimate (FY 83-87). Development expenses are estims.ted
- to be approximatPly 200 billion yen. The 8.5 billion yen appropriated as
expenses for trail remodeling of the F-4 in the FY-82 budget is extremely
small in terms of cost compared with the case of developing an aircraft in
the United States. Since the remodeled F-4 will be equipped with apparatuses
from the world's most advanced ground attack airplanes and support fighters,
the remodeling of the F-4 may look like an experiment for the FSX. Because
the F-4 is an excellent fighter-inspector and can take off and land on an
aircraft carrier, the F-4 is expected to be remodeled into a support fighter
with extraordinary capabilities.
In remodeling the F-4, the Westinghouse APQ 120 will be replaced by the
digital APG 66 (Westinghouse) as an FCS radar. An APG 66 is the FCS radar
installed in the F-l.6 and has a history of being a target for worldwide
condemnat~on because it was used in the Israeli attack on the Iraqi nuclear
power reactor. As for a radar display, the 29200-01 by Kaiser of the United
States, which is also the F-16's radar display, will be installed. As for
a central computer, IBM's CP 1075/AYK, which has already been released for
- the F-15, will be used. As for an inertial navigation system which flies
an aircraft to a destination without guidance, the LL 39 (made by Litton)
which is used in the A-10, America's re~resentative tank attack airplane,
will be installed. Since the F-4 will be equipped with all these apparatuses,
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remodeling of each aircraft will cost 8.5 billion yen. As Mitsubishi Heavy
Industries will receive the contract for remodeling the F-4, it is expected
to accumulate knowr,ow concerning ground support capabilities and should be
able to apply a considerable portion of this knowledge to the FSX.
If all 100 nodifiable F-4's are converted to remodeled F-4's, the Defense
~ Agency may face a decislon as to whether the remodeled F-4's will be used
as fighter-interceptors or ground support fighters. According tu the national
defense plan outline, the number of fighter-interceptors has been set at
about 250. The plans for additional purchases of F-15's and remodeling of
the F-4's happen to coincide. But the F-15's cost over 10 billion yen apiece,
and under the present difficult financial conditions the additional purchase
of F-15's is difficult. For this reason, it is possible to cancel Rome of
the items in the mass production stage of F-4 remodeling and to make remodeled
F-4's fighter-interceptors. In this scenario, the necessity of the FSX is
increased.
COPYRIGHT: Nikkan Kogyo Shimbunsha 1982
Value of NEC Contracts
Tokyo NIKKEI SANGYO SHIMBUN in Japanese 9 Mar 82 p 7
[Text] It has becoffie certain that the value of Nippon Electric Company's
(NEC) FY-81 Defense Agency contracts for communications and control apparatuses
will appr.oach 30 billion yen. Since the beginning of March, the last month
of this fiscal year, NEC has entered the final spurt period for obtaining
- orders for defense-related apparatuses. According to NEC's government sales
group, the total amount of contracts in FY-81, including direct orders by the
Defense Agency's ~entral Procurement Office, shows a steady increase and is
expected to be 29 billion yen, a 3.6-percent incr?ase over last year.
The actual value of NEC's contracts in FY-80 was 22,313,000,000 yen. This
was only the portion directly received from the Central Procurement Office.
If the orders received from the Ground, Maritime, and Air Staff Offices are
added, the total reaches approximately 28 billion yen. This has been further
increased to almost 30 billion yen in FY-81. NEi.'s defense division supplies
mainly communications equipment such as radars and microcircuits and control
apparatuses such as missile guidance systems. These apparatuses are indispen-
~ sable for almost all defense equipment, such as airplanes, escort warships,
and tanks. In addition to an increase in the defense budget, because current
equipment--particularly aircraft--are in the process of being replaced now,
for example the F-15 is now in t?le process of deployment, NEC's contract total
has been steadily increasing. T/ith further budget increases in the next fiscal
year and construction of not only single items but also a"central cammand
system" for the purpose of mobilizing and commanding each Self Defense Force
unity promptly and properly in case of emergency, a large increase in orders
for communications and control apparatuses is expecCed. For this reason, it
appears certain that NEC's contract total in FY-82 will exceed 30 billion yen.
COPYRIGHT: Nihon Keizai Shimbunsha 1982
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Remodeling Phantoms
Tokyo NIKKAN KOGYO SHIMBUN in Japanese 4, 5 Mar 82
[Articlr by reporter Kunihiko Tanabe]
[4 Mar 82 p 11]
(Text] Is the Phantom, a great airplane which has
changed the concept of fighter aircraft and has
been playing the main role in Japan's air defense,
a rogue that likes to fight too much? Its debut
in Japan was really sensational. Because of its
extraordinary high performance, it caused a big
debate on defense. In the end, former Defense
Agency Director General Masuda ma.de it clear in
the Diet in 1968 that "The Phantom is not to be
equipped with bombing capability," and therefore,
the Phantoms came in force without striking power.
However, because the bombing capability will be
restored in the Phantom trial remodeling pro~ect
that is intended to extend its service life and
improve its capability, the aircraft has upset the
Diet again and has even caused suspension of the
execution of the budget. Compared with the case
of the F-15 Eagle, a new air defense ace that will
replace the Phantom and which was approved by the
Diet without any c~bstacle, the Phantom is in
striking contr~.st and is destined to be a rogue.
The Defense Agency is planning to prolong the life
and improve the capabilities of the "aged" Phantom,
whose flying hours will soon be exhausted, and open .
the road to "reemployment" of the Phamtom. Mean-
while, the defense industry is also eagerly awaiting
the project, which will cost over 100 billion yen.
Therefore, I have explored the situation surrounding
the Phantom remodeling project.
The F-4 Phantom EJ, which has been the star of Japan's air defense sinosition
latter half of the Showa 40's (1970-74), has surrendered the leading p
as a fighter-interceptor to the F-15J. The life of a Phantom is 3,000 flying
hours. The Phantoms were gradually to retire starting in FY-86 and to dis-
appear completely by about 1990, if the Defense Ag,ency did not do anything
about it. At present 132 Phantoms are assigned to scramble in Chitose (Hokkaido),
Hyakuri (Ibaragi Prefecture), Komatsu (Ishikawa Prefecture), and Tsuiki
(Fukuoka Prefecture).
The Defense Agency intends to prolong the life and improve the capability of
the Phantom to strengthen the air defense network, which is expected to consist
of only F-15 fighters from the mid-Showa 60's (1990-). According to the
FY-78 Mid-Term Operations Estimate, 100 F-15 fighters are to be eventually
assigned for duty, however, the F-104 Starfighters and Phantoms are to disappear
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from duty. As a result, the total fighter airplanes will number approxi-
inately 170, including about 7U F-1 support fighters. That will be far
from the "approximately 250" fighter-interceptors specified in the national
defense plan outline. On the other hand, it is not easy to ask for additional
purchases of F-15's, which cost over 10 billion yen apiece. That is especially
true for a government with a shortage of revenue sources. Consequently, the
Defense Agency decided to adopt a plan to extend the life ef the Phantom from
3,000 to 5,000 flying hours and to prolong the use of the Phantom by about
10 years.
Although old, the Phantom is the world's best selling fighter aircraft, with
, over S,OOb produced. In Japan, Mitsubishi Heavy Industries as the main
contractor has manufactured 143 Phantoms. The Phantom is a large fighter
whose body is approximately the same size as the B-29's which struck Japan
with terror as flying fortresses during World War II. The Phantom is mounted
with two J79-GE-17 ~et engines and can fly at a maximum speed of Mach 2.4
with the strong power of the engines. The original Phantom model could carry
four Sparrows (AIM) and four Sidewinders (AIM) in addition to over 6 tons of
bombs. Its cruising range is an extremely long 4,200 km. Because of all
these characteristics, the original type of Phantom appeared to be a very
aggressive fighter-interceptor that could threaten neighboring countries.
For this reason, the bombing system, nuclear control system, and air-to-
surface missiles were removed from the original configuration, to make the
F-4EJ.
Based on the result of an investigation, the Defense Agency guarantees that
the Phantom is still capable of fighting on the front line if electronic
apparatuses are replaced with the newest types, and the aircraft is remodeled
so that the latest air-to-air missiles and anti-ship air-to-surface missiles
can be carried. The Defense Agency has requested, so to speak, that "aged"
Phantoms approaching retirement be reemployed. In order to convert the
Phantoms into remodele~ F-4's which can rival new generation fighters, the
Defense Agency has decided to draw up two plans to prolong their service
life and to improve their capabilities.
According to the plan to prolong their service life, the Defense Agency will
purchase 25 VGH recorders with a budget of 700 million yen during FY-82. A
VGH cecorder will be installed in one out of every six Phantoms to obtain
data. on velocity, gravity, and height. In addition, C-A data, the actual
record of use of each aircraft, will be obtained from a load frequency meter
which was installed in every aircraft at the time of manufacture. This type
of ineasure to prolong service life is called ASIP in the United States. Japan's
Defense Agency is supposed to prepare software for the ASIP by FY-83 and start
operation as of FY-84.
According to the plan, instead of using the present method of determining
the service life of an aircraft when a representative aireraft of the type is
wrecked, the Defense Agency will determine the service life of each aircraft
separately by examining the detailed data of each aircraft. In predicting the
future degree of wear af each aircraft, the Defense Agency will employ necessary
checks and repairs for each aircraft. In addition, the limit of wear of each
structural part will be checked in detail. The Defense Agency cannot tell
for sure if the prolongation will be 2,000 hours or only about 500 hours until
it examines the result of its surveys.
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There is no particular problem in prolonging service life. The movement to ,
develop software in Japan has been rising in the defense industry. As for the
improvement of the capabilities tha~ is the other side of the remodeling pro-
ject, however, the current session of the Diet has suspended the execution of
the FY-81 budget. The restoration of the bombing system in the Phantom has
greatly stirred up the opposition parties.
[5 Mar 82 p 9]
[Text] Phantoms close to retirement will be converted into extraordinary
aircraft--since the Japanese are skillful, there is the possibility that it
may happen. In response to a remodeling project which requires 8.5 billion
yen in FY-82, speculation about an extraordinary aircraft ran thousands of
miles at a full gallop and the Diet has been giving red signals one after
another to measures to improve the capabilities of the "aged" Phantom.
Certainly, a big experiment on the Phantom is about to be made. Although
the Phantom belongs to the previous generation of fighters, the remodeling
project is aimed at modernizing the electronic apparatuses carried in the
Phantom and at strengtheming its missile power while making the best of the
Phantom's flying speed of Mach 2.4. Although the exterior will remain the
Phantom itself, the interior will be designed by picking up apparatuses from
the most advanced airplanee. It is no wonder that the project is considered
in some respects an experiment to absorb hungrily every merit of the F-15
fighter-interceptor, the F-16 light combat attack aircraft, the A-10 anti-
tank attack aircraft, and the Alfajet support fighter.
The capability improvement measures are: (1) improvetnent of the fire control
system, (2) strengthening and expansion of missile-carrying capability and (3)
~ improvement of bombing capability. The most outstanding feature of the design
is the installation of a central computer, which the present Phantom does not
have, and the collective processing of all information. If the same IBM
central computer as the one in the F-15 is used, the remodeled F-4 can be
armed with air-to-air missiles--AIM-7F (the latest Sparrow) and AIM-9L (the
latest Sidewinder). If this computer is installed, the remodeled F-4 will
incidentlally also possess bombing calculation capability. However, if it is
the computer used in the F-15, the bombing capability of the remodeled F-4
will not exceed that of the F-15. It is unnecesary to cite examples of Zero
fighters and Hayabusa fighters which were loaded with bombs and torpedoes and
sallied forth. Fighters are all equipped with some bombing capability. In
the case of the Phantom, however, because of its extraordinary high performance
and separate installation of a bombing computer, the removal of the bombing
capability was possible.
As for an FCS which locks onto a target, the Westinghouse APQ 120 will be
replaced by the Westinghouse APG 66 that is installed in the F-16. Although
both the APQ 120 and the APG 66 are made by Westinghouse, the former is an
analog pulse radar while the latter is a digital pulse doppler radar. This
change will greatly increase the look-down capability, which is presently non-
existent when flying at low attitudes. The doppler effect does not work in
the case of tanks and buidlings on the ground. Therefore, targets must be
identified visually by the pilot. Nevertheless, the APG 66 will be extremely
threatening to warships on the ocean.
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A pilot sees a shadow of an airplane in the headup display and takes action
to enga~e it. As a headup display system, the Defense Agency plans to use
~:he one which was jointly developed by West Germany and France for the Alfajet
support fighter. As for the inertial navigation system (INS) which flies the
airplane to its destination without guidance, the LL 39 (Litton of the United
States) from the A-10 anti-tank attack airplane will be used. Although the
Defense Agency explains that the LL 39 is cheaper than the INS of the F-16,
the combination of the INS from the A-10 and the FCS from the F-16 will give
new characteristics to the remodeled Phar?tom, and that concerns me.
The Defense Agency persistently defines the plan to prolcng the service life
and improve the capabilities of the Phantom as an effort to retain the fighter-
interceptors. The Defense Agency plans to protect Japanese airspace with Phan-
toms together with the F-15's until the Showa 70's (1995-2005), when self-
developed future fighters 4~i11 begin flying. For this reason, it is necessary
to replace the AIM-7E, who:~e firing speed is Mach 3.5 and whose range is 25 km,
with the AIM-7F, whose rang, is 44 km even though the firing speed remains the
same in the remodeled Phantom. Also, because the remodeled F-4 can separately
fire 7 km and 10 km range Sidewinders, its capability to handle dogfights
within these ranges will greatly be improved. With these reasons in the back-
ground, the Defense Agency even says that the pri.mary mission of the Phantom
is that of a fighter-intercepter, and it will not object to cancellation of
some of the items when mass production of the remodeled F-4's begins in 1986.
Nevertheless, it is true that the remodeled Phantom will collect the functions
of the world's most advanced support fighters and attack airplanes. Review-
ing the history of fighter airplanes, the unrivaled Zero fighters were shot
down as if they were red dragonflies during the final stage of World War II.
The uniformed officers' idea that "the more exclusively defei?sive Japan's
defense is, the more necessary excellent aircraft are to prevent enemy intru-
sions in advance," coincides with each item of the Phantom remodeling proj~ct.
Recently the idea that the distinction between fighter-iriterceptors and support
fighters is unnecessary has been spreading through the Air Self Defense Force.
It holds that in case of an emergency there is no time to choose battlefields
and all aircraft will have to be mobilized. For this reason, the Defense
Agency seems to want to say that fighters must be allround attack aircraft,
and the restoration of the Phantom's bombing capability is not incidential.
The Phantom happens to be close to the end of its normal flying life and just
short of the time when it will be worthless as a fighter. In their dreams
uniformed officers have seen that the world's best attack aircraft can be
produced at a cost of about 1 billion yen in the case of mass production if
measures are taken to prolong the service life and improve the capabilities of
the Phantom, which would otherwise soon be almost without value. The idea is
that it is better to depend on "the second life" of the Phantom to fight support
battles where the probability of damage to aircraft is high instead of using
the expensive F-16. The Defense Agency is planning to remodel 100 Phantoms.
Mitsubishi Heavy Industries, the main contractor, and various electronic
apparatus manufacturers are casting covetous looks at the remodeling project,
since it means that unexpected extra technological and pecuniary gains will
fall into their hands.
COPYRIGHT: Nikkan Kogyo Shimbunsha 1982
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SCIENCE AND TECHNOLOGY
INDUSTRIAL ROBOT PRODUCTION TECHNOLOGY DISCUSSED
1981 Industrial Robot Fair
Tokyo DENSHI GIJUTSU in Japanese Vol 24, No l, Jan 82 pp 49-52
[Article by Ryosuke Masuda and Takashi Mizutani, both of the Control Engineer-
ing Department, Tokyo Institute of Technology: "Sensors, Control Functions, an3
Mechanisms Which Drew Attention (From the 1951 Industrial Robot Fair--Photo-
gravure Commentary)"]
[Text] The Era of Robots With Intelligent Functions
We are having a robot boom today. Robots of all kinds, from industrial robots
to recreational robots, have caught the public eye. The industrial robot fair
held recently proved this point very G~ell. Never before have so many people
attended an exhibition of industrial machinery. One had to wait in line a
long time before entering the hall, and even after entering the hall, one had
to push through the crowd in order to be able to see.
Having been widely publicized by newspaper.s and TV, the ~uice serving robot
(Photogravure 14) above all was especially crowded with people. ~his robot
is capable of recognizing a number of words such as "orange" and "grape" from
a voice input, and according to the program's choice, the robot will pick up
a bottle of juice, remove the cap, and after checking it with a sensor, pour
the ;juice into a cup to serve. The existence of such a robot with intelligent
functions, which comes just a little bit closer to the image of a"robot" held
in people's r:iinds, must have stirred people's interest.
Instead of the term "intelligent robot," which has become quite popular in
recent years, "robot with intelligent functions" is used here for the follow-
ing reasons: Although the control technology employed in the industrial
robot today may be quite advanced, the robot does not possess true intelli-
gence or the ability to take action automatically according to the circum-
stances. Rather, the capabilities of the robot today remains at the level of
intelligent functions* including judging, thinking, learning, and adapting
through detection and memory.
*The term "intelligent functions is defined as the f unctions a robot should
possess in the draft definition of robot termin~logy (Research Report No 2
concerning standardization of robot; Japanese Industrial Robot Society, 1976).
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Control functions have been significantly improved in recent years, thanks to
the advancement of microelectronics. The statement "microprocessor is being
used" always appeared in the catalog or panel just a few years ago, but not
today. This is probably because microprocessors, whether 8-bit cr 16-bit,
are being utilized so couunonly that limitations on the scale capacity and
computation functions due to hardware have been relaxed to some extent.
Therefore, the problems encountered today in the construction of robots are
related to the sensors and the software used in the control system. A number
of new attempts in these areas could be seen in the recent robot fair, includ-
ing an attempt to raise the level of intelligent functions to that suitable
for industrial application. In the field of industrial robots, the era of
robots with intelligent functions consisting of sensors and associated proces-
sors together with control software may continue for some time to come.
In ttiis article, the sensor functions and the control functions of the intelli-
gent robot, together with the mechanisms which are indispensable for producing
the concrete action function of the robot, will be discussed centered around
the machines displayed at the industrial robot fair.
Activity of Sensors Has Only Begun
Sensor-controlled robots were tlie type of robots most widely expected at this
robot fair. However, there were only a few examples with unique sensor appli-
cation; it appeared that the time was not yet ripe for extensive and effective
application of sensor technology to robots.
On the other hand, in spite of the fact that an excellent vision system as a
single entity was successfully developed by Fu~i Electric and Tokyo Electron
(the U.S. Automatrix Co), the link between this vision system and the robot
movement has not been well developed. This delay is probably due to the great
difficulty encountered in robot control software when movement control is to
be accomplished by vision input.
The sensor control which is in greatest demand and is also used most widely
today is that used for searching the welding line used on the welding robot.
There were a few different formats of this type of control on displ.ay. One
of them was the vision system used on KawasaWhenethe machine is in
the~weld-
(Photogravures 1 and 4). In the beginning,
ing line discrimination mode, this system shines a slit of light onto the
work to be welded. The light reflected from the work is receiyed by a photo-
diode array camera via an optic fiber and the signal is processed. By this
process, the location of the welding path along an L joint or a butt joint can
be determined. This method uses a two-pass format consisting of the discrimi-
nation mode and the welding mode in order to achieve a highly reliable opera-
tion.
The proximity sensing format, which was used on Hitachi Limited's "Mr Aros"
robot (Photogravure 8), is a method in which the location of the welding line
is continuously checked and determined during the welding process. This
method has been in use for some time now.
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~`v~~ v~'t'~~�~t~a.. v.aa: w~i.�
The contact format was used in the welding robot of Shinmeiwa Industry. In
this method, the welding wire itself is used as the contact point, and the
welding line along an L joint is determined by fc,ur points which are searched
prior to the welding operation. This format is convenient for practical
applications because no speci~ . sensor elements are required.
Another method of on-line control of the welding line without the use of a
sensor element, which was used on Yasukawa Electric's welding robot, also
caught people's attention. This method utilize~ the welding current itself
as the feedback signal. This method is quite effective where the nature of
the welding line is known to some extent.
The accuracy of arc-welding can be improved through use of these on-line or
off-line sense functions. However, the most desirable method is one which is
capable of solving r.roblems related to strain in the work being welded and to
optical and electri.cal noises.
"Pana Robo," a product of Mata.ushita Industrial Machinery (Photogravure 3),
was one in which the vision system was utilized for the general operation.
Although it was a demonstration operation, a certain figure pattern was
picked up by a camera and the data was fed into a processor, which extracted
the center location (X,Y) and the angle of inclination (8) of the figure. The
operation table was then positioned by translating and rotating it according
to X-Y-A. The figure pattern was discriminated, a program was chosen, and the
motion of the arm was actuated according to this program.
Another Pana Robo had a photo sensor in its hand, and it was able to sort ob-
jects by detecting the color of the object (see Photograph A). This robot
was able to discriminate five or more different colors. It appeared to have
a highly practical applicational value.
Nippon Electric's ke~board assembly robot (Photogravure 2), together with the
arc-welding robot, is usually considered one of the goals of using a robot.
This robot was capable of detecting pressure on its arm through measurement
of the deformation of a spring in its arm's driving mechanism, and the assem-
bly operation was carried out with a force feedback control. Besides these,
robots with sense of touch control have also been developed by Hi~Cac.hi, but
no outstanding assembly robots with sensors were on display this time. The
force control technology should be pursued further in relation to the compli-
ance characteristics of tYee SCARA type robot, which will be discussed later.
Balance Between Control Functions and Operability
The robot's control fun~~tions on the servo level and the robot~s operability
characterized by the ea::e with which it can be taught or progr~ed will be
investigated next.
In regard to the servo control level, the continuous path control is greatly
in demand for the control of such operations as painting and welding. For
examp:le, the welding robots developed by Hitachi (Photograph B) and by
Shinmeiwa (Photogravure 5) are capable of smoothing the path by performing
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three-dimensional linear or arc interpolation through a nimmber of given teach
points. This capability enables the robot to connect any two given points in
space with an arbitrary curve. This function, together with the function fo~
smoothing the stop poin~s an3 nonstop points, enables the robot to execute a
smooth movement which could not be realized in conventional robots.
Another control function concerns eff ective coordination with the mechanism--
that is, as more and more robots with ~ointed construction appear, these
robots are equipped with an appropriate coordinates transformation function
so that they can operate along a path in any coordinate system. As a result,
horizontal and vertical mov~ment of the arm, and movement to maintain a fixed
wrist orientation are greatly facilitated. Moreover, the programming infor-
mation may be dealt with in a specific coordinate system such as the rectan-
gular coordinate system. This feature is indispensable for a robot with
imultiple degr.ees of freedom. The interpolation function and the coordinates
transformation function require a considerable amount of computation. There-
fore, the key factors should be simplification of the computation format and
improvement of computation speed.
The operating system is becoming more and more advanced and, as far as teach-
ing and programming are concerned, program selection and modification can be
easily carried out not only during the teaching period but also during the
operating period using an external signal.
Now then, since the control of robots by microprocessors became commonly in
use, its operability has become a focus of attention. Al1 controllers consist,
in general, of a keyboard and a CRT display for monitoring, and these con-
trollers have been simptified to make them easier to operate for on-site
application.
A control device con.Gisting of a flat touch keyboard and a 9-inch CRT used on
the arc-welding robot of Mitsubishi Electric (Photograph C) is a typical exam-
ple. The robot program data, welding conditions, and its relationship to the
external ~ig control can be displayed on the CRT screen. This system is very
effective not only for teaching but also for monitoring.
The robot languages employed to increase the effectiveness of teaching and
programming the robot include Sankyo Seiki's SERF and Kawasaki's PUMA language,
VAL. Using SERF, designation of the XYZ coordinates and designation of speed,
together with the sequence co~nand and the loop command connecting these
points can be programmed and entered into the system through the keyboard.
To utilize this function it is necessary to learn the language, but it is
worthwhile because the language facilitates the description of a complicated
operation and allows expansion into sensor control. Robot language is con-
sidered to become even more indispensable as the robot functions become more
advanced. At present, it is highly desirable to have more robot languages
introduced so that the use of robot language can become more popular.
Morphological Evolution of Robot
We will continue to review the details of the robot fair from the viewpoint
of the mechanisms.
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Nl1K VI'P~l.lA1. ~/JG VI~ILI
An overall trend, characterized by the transition from conventional robot ope-
rations consisting of transporting and painting to more advanced operations
such as welding and assembly, was apparent. A variety of innovations and
changes have been introduced into the shape of the robot itself and the r�aays
in which robots are utilized~.
One of the changes cancerns the type of robot. Traditionally, a typical
ir.dustrial robot belonged to either the rectangular coordinate type, the
cylindrical coordinate type, or the polar coordinate type. Robots of these
types have largely disappeared, and the ninnber of ~ointed robots resembling
human beings has increased significantly this year. This is because a robot
performing welding or assembly must be able to move f reely in all directions
within the operating space, and the ~ointed type has the advantage over the
conventional type for this type of application. Kawasaki's PUMA is a typical
example. This model was designed mainly for precision operation, and it comes
in several different sizes. It appears that this robot is well prepared to
deal with various applications that may come up in the future (Photogravure 4).
A similar type of robot was also used in the welding operation by Dainippon
Machinery, demonstrating the superior movability of a robot of this type.
On the other hand, a number of jointed robots with a new shap'e, called SCARA,
were also on display. As shown in Figure 1, the rotational axis of each joint
of this type of robot is vertical. This feature is the ma~n difference
between the SCARA type and the PUMA type. The functions of the SCARA type
robot emphasize operations in a horizontal direction. The SCA~.A type robots
possess one unique design concept: that is softness (compliance) in the
robot's horizontal action. Inst~ad of highly precise and rigid action, the
robot's movement is in part influenced by external pressure so as to carry
out the operation smoothly. Ta~,e the case of inserting a rod into a filleted
hole, for example. If this operation is carried out by the conventional
high-precision control, the rod and ~he hole may fight one another due to
unavoidable positioning error. On the other hand, even if the two are
slightly misaligned, a robot with compliance can align them without undue
strain, because of the softness in its horizontal movement. Examples of this
type of robot were displayed by Nitto Precision Industr} (Photogravure 9) and
Sankyo Seiki (Photogravure 10). In Pelten's PUHA (Photogravure 11), the
weight of the arm was reduced significantly by an innovative design in which
all the driving units weY�e concentrated in its base. Unfortunately, there
were no firms which designed their demonstration to highlight the compliance.
The utility value of compliance has not yet been f ully evaluated, according
to an explainer. It will be a great pleasure to watch its future development,
as the topic of compliance was discussed at the 11th International Industrial
Robot Symposium held 7-9 October in the Japan Federation of Economic Organ~.-
zations Hall. The f uture trend will be to strive not only for a more highly
accurate action function but also for smoother operation through adaptability
in movement.
As for the robots for welding, no significant changes either in the mechanisms
or in the types came to attention. However, the goals have been shifted from
conventional spot welding to arc-welding, which is more dif~icult to perform
and in which the deformation of the work musC be taken into consideration. As
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- (1~ ~:y~Tr:~
-~-c-
(2~ I
~l -
ri ~
(SCARA ~13) (PUMA )f's)/
Figure 1. Diagram of Robot's Degree of Freedom
Key: (1) Compliance (2) Acting force
~ more problems inherent to the arc-welding operat~on are uncovered, more new
mechanisms will be invented. In addition, there is a trend to replace human
operators by robots for all welding operationa, where the enviroYnnent is
harmful to hwnan operators. For this reason, too, the robots used in welding
operations must not only possess advanced functions but must also be easier
to operate.
Another way of utilizing the robot was demonstrated by the robot displayed
by Yasukawa Electric (Photogravure 12). An ordinary type of robot is placed
horizontally, and instead of using the robot to carry the welder, the welder
is approached by a robot carryir~g the work. To be sure, not only will many
new types of robots be developed in the future, but many ideas concerning
utilization of robots will also be invented.
As to other individual ideas, the wrist of Hitachi's robot (Photo~ravure 6)
provided an increasing example. This is a mechanism capable of working in a
limited space such as painting the inside of a box. Other innovations to ex-
pand the robot's capabilities could be seen in various forms, including in-
troduction of a linear motor into an actuator by Nippon Electric (Photogravure
13). Furthermore, many more ideas must have been put to good use in many
parts of the robot which could not be seen from outside.
The robot fair this year was reviewed briefly mainly f rom the viewpoint of
mechanisms. In spite of the great potential the xobot possesses, its pro-
gress does not appear to be as rapid as that of electronics technology. We
hope that robots in newly evolved forms will soon appear through innovative
technological development.
Conclusion
Robots, including those appearing in cartoons and science fiction, are dis-
cussed widely on television and in magazines today. Probably because of
this, a great many people of all age groupa came to see the robot fair this
year. The elementary school pupils, who were found in large number among the
spectators, may have been puzzled by the industrial robots which look so differ-
ent from the image of robots held in their minds and, at the same time, gained
new understanding about robots.
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. . .
But there are still many possibilities for the robot. The range of work
assigned to the robot can only grow wider and more advanced in nature. The
robot, without a doubt, will make progress steadily by overcoming many trials.
Many new phases of robots will certainly be revealed at the next robot fair.
My confidence in its futui�e progress was sufficiently assured by the youthful
future technologists I saw at the robot fair.
PHOTOGRAVURE CAPTIONS
1. "Treat me like an operator" was the catch phrase of Kawasaki's PUMA, a
computer-controlled robot.
2. Nippon Electric's keyboard assembly robot.
3. Matsushita's Pana Robo, an arc-welding robot, caught attention as a robot
capable of applying its vision syste~ to an ordinary operation.
4. Kawasaki's PUMA performing welding operation; aiming at greater relia-
bility in operation through application of sensor technology.
5. Shinmeiwa's Robel, a plasma shearing robot; carrying on board a 16-bit
microcomputer. ~
6. Hitachi's spray painting robot "PARKER" with a microcomputer.
7. The wrist of Hitachi's spray painting robot.
8. Hitachi's "Mr Aros," a welding robot, with noncontact type sensor,
carries out welding operation as it measures.
9. A progra~nable robot, "Picmat SCARA," for automatic assembly (Nitto
Precision Industry).
10. "SKILAM series" multiple-jointed robot controlled by microcomputer
(Sankyo Seiki).
11. Precision assembly robot "PUHA" (Pentel) concentrates all driving units
in its base to reduce the weight of its arm.
12. Yasukawa Electric's welding robot "Motoman." A robot carrying work
approaches a stationary welder--an interesting idea.
13. Nippon Electric's precision assembly robot "Model A," with actuator
driven by linear motor. New possibilities are uncovered.
14. Nippon Electric's juice serving robot can recognize spoken words such
as "grape" and "orange." It opens the bottle and serves ~uice in a cup
after checking it with a sensor.
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.~F.,~ r~.
,3
z~; ~
. . .~i
Photograph A. Robot capable of diacriminating colors (Matsushita Industrial
Machinery)
~~r-,
i~ ~ ~ �
d .
'i
-
-'Y v
~ . a
i~ i
t�
~r ti,t ~f~ .
n;~:,~ .
P , L.. . . .
i.
Y *
.~'.X .
~ ~Fclt� ___L` . .
Photograph B. Robot capable of arc interpolation (Hitachi Ltd)
J_
Y~~ 1^l ~ . . i ' ',Y,
tY,.
_ ! w'F'~ :.:i:r.
y
y.
. ;',w:7.
-r '
Photograph C. Robot control panel (Mitsubishi Electric)
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rvn vrr~~.u+a. v.,.: .i:~a..
We can cite the qualitative improvement of the robot itself as one of the
factors supporting the robot boom in recent years. The capabilities of indus-
trial robots are being upgraded by leaps and bounds, as indicated by words such
as diversified and multifunctional used to describe them. In support of all
this is the newest electronics technology such as LSI, microcomputer, and sen-
sor.
"The 1981 International Industrial Robot Fair" (sponsored by the Japanese
Industrial Robot Society and NIKKAN KOGYO SHIMBUNSHA) was held at the Tokyo
Industrial Sample Market Assembiy Hall in Tokyo-Haruumi for 5 days starting
8 October last year amidst this background. This robot fair, which was the
fourth of its kind, was represented by 36 rob~t makers (the largest so farj,
each displaying its own unique machine, and the fairground was crowded with
the spectators day after day.
In connection with this special issue, some exsmples of "robots with intelli-
gent mechanisms which caught most attention at the f air are introduced herein
together with a report written by Messrs Masuda and Mizuta of the Tokyo
Industrial University.
COPYRIGHT: Electronic Engineering 1982
Kawasaki Heavy Industries' PUMA
Tokyo DENSHI GIJUTSU in Japanese Vol 24, No 1, Jan 82 pp 53-56
[Article by Yasuhiro Kubota, director of Hydraulic Machinery Business Depart- i
ment, Kawasaki Heavy Industries: "PUMA Robot System"] i
(Text] The PUMA (Progra~nable Uni~ersal ~Ianipulator ~or Assembly) robot ~
system, consisting of a multiple-jointed, electrically operated robot with
artif icial intelligence was realized as a result of an R&D effort on the
computer-controlled robot system which lasted more than a decade. The PUMA
was developed not merely to replace hiunan muscular labor but also to simulate
human de:cterity.
The mediiun-scale robots of the 500 series in earlier days were each developed
for the purpose of replacing a human operator and to do assembly work along
with the hi.unan worker, so theii- shape and size were patterned after the
human figure and their range of action was also comparable with that o� a
human being.
The minirobots of the 200 series developed later were about half the size of
the 500 series. These minirobots were characterized by their compactness
(shoulder height 33 cm, arm length 40 cm), light weight (robot body weight
approximately 7 kg), high speed (1.5 m/s), and high accuracy (�0.05 mm). They
were used mainly for the assembly of electronic parts such as inserting
resistors, condensors, and transistors into the printed circuit board.
In response to a demand for power in addition to all the other attributes of
the PUMA robot--including dexterity, high speed, and high accuracy--robots of
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the 700 series which are 1.5 times bigger in size and four times latger in
load-carrying capacity (10 kg) than the 500 series were developed last summer.
These three types of PUMA robot system were developed on the basis of the same
design concepts (such as structure and control format) except for the differ-
ence in size. Therefore, they are all compact, light weight, and made with
~tructural precision. They can move faster (1-1.5 m/s) and more accurately
(�0.1-0.05 m�n) tha.n the human being can. Moreover, the robot's arm can be
freely switched from left to right, and vice versa. These robots can even
reach the back side of the work ob~ect, and since the robot's shoulder can
rotate both forward and backward, they can perform operations behind them, so
to speak, as easily as in front of the~n.
The robot's movements are all calcu;ated and processed by the microcomputer
contained inside the robot in real-time, so any arbitrary spatial linear or
curvilinear motion can be carried out with a high degree of accuracy. More-
over, the software system in support of this robot system has a versatile
robot language, "VAL," at its disposal, so the user is able to teach his robot
any movement he desires very easily using this program language.
Theref ore, PUMA robots, which can work along with human workers, are being
used widely in diversified fields for various handling operations including
arc-welding, inspection and measurement, in addition to performing assembly of
~ electronic parts and machine parts.
The System Components
The PUMA robot system consists of the following basic components: the robot,
the control device, and the teach box. To make the robot do actual work,
a program must be composed first and the robot must be taught to behave.
The following additional components are necessary to accomplish this task:
a CRT terminal (or a typewriter) to instruct the robot to move, a pneumatic-
ally operated hand, and an external signal interface (I/0 module). In any
case, these can be simply equipped as an option. In addition, an external
auxiliay memory device consisting of a minifloppy disc may also be used
to temporarily store the program prepared by the user. Figure 1 provides a
block diagram of this system.
The software system VAL, which controls the entire system, is stored in a
PROM inside the control device. VAL is an advanced program language used
for robot control and is equipped with the following Puncti.ons: 1) maintains
surveillance of the system state, 2) compiles the user program and executes
it, and 3) controls the movement of thr, robot. The user may also use this
language to give commands and make the robot perform various operations.
1. Robot Body
The external appearance of the robot body (Model 500), its main dimE~nsions,
and its range of movement are shown in Photograph 1, Figure 2, and Figure 3,
respectively.
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cvn va�a�aa.an.. v.~a: w~a.a
I ~�~:�f b ~~R~/z~ ~'/1R~el~
~B
rr~~ (3)
~ ~ ~ s ~ ~~r~~i (4)
3 (4) I
3~-:t,~ . i-o~~~-w i (5~
(CRT) �
~5 tr_it ~
~.~t~+n (6~
~-:t,~ E ~o~e~rTx~
(TTY) $ ~.q~! Sm~ll 200 ~i'"'~ Medium 500 k"? Large T00
9~T -;.y: ��r 7~ 7 _ p 33pr 670s~ 1030u
(MANUAL 8 YU3n_ 172n _ 650u
CONTNOL) C Y03u 13Yo B~r
~igure 1. PUMA Robot System $lock Figure 2. Main Dimensions of PUMA
Diagram Robot
Key: ~5) ~r Key:
(1) Robot (6) Termiral TTY (1) Waist rotation
(2) Control device (7) Floppy disc (2) S.houlder rotation
(3) Terminal CRT (8) Teach box (3) Elbow rotation
(4) I/0 module (Manual (4) Wrist bending
control) (5) Wrist rotation
(6) Wrist twisting
A Ir yl
I
~`',T_- ~D
0
~
A B C D E
~I�"" Smdl 200 315 720' 1~+
~P"," Medium 500 7Y0' YSO' 88/~ l6/r 13'!~
k1+Lun ~700 ~40' YSO' 1Y50~ 1250r 600r
Figure 3. Robot's Action Range
~hoto~;raph 1. External View of
PUMA Robot
(500 series)
~ 2~+
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~1~ t~fi~ve=-A
I MEMORV ~
IOKW ~KW I
~ EPROM RAM i
, CPU
C2, I LSI�II I 7~~~~'~_~
9-,t,~ ' 4 7-`~
~ ~r ~ 0 1:9,~ 'toy
""mK SRi~EIIF~ I 7roF ��r+t ~l _,y; 7~~ 7Y7'
S7~-~l
EXT. t~U
7orL~- m 7~pa7/~ OX/WIf
~ ~ ~ ~ io ~ fi 1
( ~ EX~'~�i-~Y
~ ZZ~
Figure 5. Control Device Block Diagram
Key:
(1) Main computer A~
(2) Terminal (8) Power amplification
(3) Brake control (9) Encoder
(4) Microprocessor I/F (10) (External memory) Floppy disc
(5) Digital servo (11) Manual control
(6) Analog servo (12) External machine
This control system is comprised of a microcomputer system consisting of a
CPU (LSI 11/2), a PROPi containing the system software VAL, a RAM for the user
program, a serial I/F controlling terminal-external memory-teach box couununi-
cations, a parallel I/F in parallel with the control circuit of the robot body
itself, together with the electric circuits for the control of each motion
axis and a DC power source. All circuits necessary for the control of the
PUMA robot system are contained in it. The external shape of the control
- device is such that it can be rack-mounted and its weight is 45 kg, so it
can be easily moved around.
3. Peripheral Devices
1) Terminal: The terminal may consist of a keyboard (standard typewriter
format) and a video display unit (CRT), or a printer (TTY). The user may use
this terminal to edit the user program in VAL and also to execute it. This
terminal may also be used to display the robot status. The terminal may be
disconnected from the control device while the robot is moving according to
the user program.
2) Floppy disc: The floppy disc drive is capable of storing the user pro-
gram and position data, and if necessary, it can read out data to the RAM of
the control device. The power to this device is supplied by the control de-
vice, so the device becomes operational as soon as the special cable is con-
nected (applicable disc: 4.5-inch minifloppy disc).
3) I/0 module: The PUMA robot system must work in concert with other equip-
ment such as a conveyer in an actual operation situation. Therefore, the
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The robot's degree of freedom consists of three basic axes: waist rotation
(JTI), shoulder rotation (JT2), and elbow rotativn (JT3); plus three wrist
movements: twisting (JT4), bending (JTS), and rotating (JT6)--a total of
6 axes. Depending on the type of work, the robot may also be operated with
five-axis movement by deleting the wrist twist.
Each axis is driven by a DC servomotor through a speed-reducing gear train.
The driving unit consists of a DC servomotor, an incremental encoder, and a
potentiometer. The basic axes are equipped with electromagnetic brakes, so
in case of power failure, the robot's attitude can be frozen in order to pre-
vent any damage that may result from contact between the robot and the inciden-
tal equipment. In order to realize high-speed action, the dynamic balance of
the structure was carefully considered through extensive measures, including
hioh-strength member construction with cover, use of light alloy material and
die-c~sting technique to achieve lightweight design, plus miniaturization of
mechanism design.
Moreover, to insure reproducibility with a high degree of precision, in addi-
tion to the lightweight high-rigidity design described above, a special back-
lash adjustment mechanism was introduced to the speed-reducing gear train.
Thus, the desired degree of precision was attained.
2. The Control Device
The external appearance of the control device and its block d~agram are shown
in Figure 4 and Figure 5, respectively.
~1~~-:t,~ ~ a~ ~ 2 r~~~en 3
. ,
=~i. ~ 44M~.~~!...
t � ~ ~
-rr ,
� "~�yy. ~ i
, M y~; ~
~ - X ~
d ' �
_ y7__, i
~ , ~ 3;r4)~:r.�, 9~ ~
~
~,,,c;i~I.i: 7 a�, t'-~' T~ 4
( 5)
Figure 4. External View of the Control Device
Key :
(1) Input terminal (3) Peripheral equipment
(2) Control unit (4) Teach box
(5) Floppy disc
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PUMA robot system ~st be equipped with a line through which it can receive
signais from other equipment in order to know the~r status and also to trans-
- mit signals to the outside equipment. The T/0 module is equipped with these
functions, and it 3s connected with the control device by a flat cable. It is
constructed in such a way that it can be rack
mounted.
4) Teach box: The teach box consists of various switches for operating the
robot and a display unit to display the message concerning the system status
issued by tiie control device. In the teach mode, the speed of manual opera-
tion and the position and orientation of the robot's wrist can be set by the
teach box. Or, the user program can be stopped during its execution, or the
speed of the robot can be changed during its operation by the teach box. By
switching to "free mode," the robot can be operated manually. Furthermore,
the pne~atically operated hand can be opened or closed, or the coordinate
system used (to be described later) can also be changed by the teach box.
Specifications and Characteristics of the Robot
The specif ications of the robot body and the control device of the PUMA S00
series are su~aarized in Table 1, and their characteristics are as follows.
1) Superior Operability
(1) Lightweight and compact construction with multiple degrees of
freedam: it occupies only a small space, so it can be installed easily
anywhere and becomes operable as soon as it is connected to a commercial
power source.
(2) Easy to Teach (Program)
The roboti can be taught in robot control language VAL.
The robot can be taughttry the teach box in various action ~odes with
respect to: a) each motion axis, b) absolute coordinar.e system (X,Y,Z,),
and c) wrist coordinate system.
(3) Program changes can be implemented even during the repeat action
period.
2) Diversified Control and Advanced Functions
(1) Applicable to all control modes including PTP (point to point) and
CP (continuous path) control of the work orientation.
(2) High accuracy (�0.05-0.1 mm), high speed (1-1.5 m/s).
(3) Compatible with vision senaor, touch sensor, or force sensor
control.
3) High Reliability
High reliability is insured by a combination of a maintenance-~ree robot body
and a controller containing LSI-11.
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rvK vrr~~.~A~ ~oa .,~v~~
Table 1. Specification List
500 series (medium type)
Model 550 560
Number of axes 5 6
. Waist rotation (JT1) 320~
0
~ Shoulder rotation (JT2) 250
0
~ Elbow rotation (JT3) 270
0 o Wrist twisting (JT4) - 300�
~ ~ Wrist bending (JT5) 200~
d Wrist rotation (JT6) 520~
w
~ Load capacity 2.5 kg
Static load 6.0 kg (wrist tip)
�0 .1 mm
o Repeat positioning accuracy
~ 1,000 mm/s
Maximum speed
Machine wei~ht approximately 55 kg
Control format Computer-controlled electric servo
Free Each axis can be moved manually
freely
~ Each axis control Each axis can be moved independently
o Absolute coordinate control Wrist tip moves in the XYZ coordi-
nate system
~
Wrist system control Action in the wrist tip (work)
coordinate
~ a
~ Program control Action according to user program
~
u Program language VAL (ntunber of commands= approx 100
~ Program number No limit. Conditional and uncondi-
~ tional branching may be introduced
~a freely
o Interlock Transmission (OX) and reception (WX),
~ 8 circuits each (expandable to
0 32 circuits)
U
Power source 100/200/220 VAC, 50/60 Hz, 1,500 W
Dimensions 320 (H) x 490 (W) x 610 (D) mm
Weight Approximately 45 kg
TTY terminal 300 baud, RS-232 C
~
o CRT terminal 9,600 baud, RS-232 C
o Auxiliary memory unit Minifloppy disc
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Control Format
The control format belongs to the computer-controlled electric servo format.
The control signal for each axis obtained by the main computer (LSI-11) in
real-time computation is distributed to each axis control circuit, consisting
of a microcomputer, a PROM, and a RAM through a microprocessor I/F. The
action of each axis is then controlled by an analog servo driven by the control
signal via a D/A converter. The following five control modes are a.vailable:
1) Free control: each axis can be moved manually.
2) Independent control of each axis: each axis can be moved independently.
3) Absolute coordinate control: the tip of the wrist moves in the XYZ
coordinate system.
4) Wrist system control: the tip of the wrist moves in the wrist (work) co-
ordinate system.
5) Program control: movement is controlled by the user program.
In the PUMA robot system, the position information that is, the position of
the hand flange, is stored in the memory in the form of either converted
- value or displacement value with respect to each axis. To prov ide the robot
with a large amount of position information, a relative designation format
can be used (when a reference position exists, the name of the new position
to be designated can be separated from the name of the reference position by
a colon If the reference position is changed, all other position infor-
r~ation designated relative to it changes automatically. Therefore, it is
relatively easy to deal with a situation involving a change in arrangement of
the work object. Moreover, if the wrist coordinate system is employed, a new
hand's dimensional data need not be designated even after the hand is replaced
by a new hand with a different shape. A new wrist vector matching the new
shape will be designated b} ~~-?L.
External Signal Connection
The control device of this system is connected with the external equipment by
the following input/output signal lines.
1) Input signal usable by VAL (8 circuits).
2) Output signal usable by VAL (8 circuits).
3) Input signal with special function.
Moreover, since the inpuc/output circuit signals are on TTL level (Figure 6),
it is necessary to amplify the signals in order to be able to drive the relay
and to insulate or isolate the system in order to eliminate nuise and to pro-
tect the circuit. Therefore a photocoupler is used to isolate the system from
the external circuit, and the signals to drive relays and the relay output
signal are transmitted via this coupler.
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~ 1 ~ i
~o~>3-ne~t
L5765 (JAE JDSOS)
WX 1
it 2
~~-v ~
v-n-v ~
~ 5
-tl~l'cl
~ ,
Tf~1At a. ~ 14~ 3Mn~1~89r_}~?~~t! a.
Figure 3. Action Modes
Key:
(1) XY system operation (during (8) System operation
teaching and playback modes) (during teaching mode)
(2) Up/down (Z axis) (9) Upper arm a3
(3) Torch rotation axis (10) Bending a4
(4) Torch tilting (11) Lower artn a2
(5) Back/f orth (Y axis) (12) ~aisting as
(6) Left/right (X axis) (13) Rotation al
(7) Action in the XYZ system with (14) Each axis may be operated
coordinated movement of the independently
five axes: al - a5
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5/19p4f~Iq1M9~0 ~1~ 5/M9E$I67q11d1i~ ~2~
F-~11R~~ho-n,4it2 ~ItMIM h-i~F1?~~lo-n.
.
~ ' ~
~
l.~ 'f' '
i
) 1 ~-tt~ret�
~34t!ltbt_IfYSMb`9E41:1l1101L. ~ 4/ .1Mtu~r~
F-~Aq41FFo~ikl3t~1#9?iA'yli7~.~` I~SOlMt4IlT~
~RtiMrKMta, ~ ~ ,M�uer,,.
(a) , (b)
Figure 4. Completely Harmonized Five-Axis Control
Key:
(1) Completely harmonized five-axis control: three-dimensional linear
interpolation including torch angle control
(2) Completely harmonized f ive-axis control: torch ~~itude control
(3) After the locations of only two points are taught, the robot is capable
of moving the torch at a designated speed along a straight line while
holding the torch at a designated angle with all f ive axes perfectly
synchronized.
(4) The welding point does not move even when the torch is rotated.
(5) The welding point does not move even when the torch is tilted.
(i!1 TMt~n~-iM~mMtsfil0')M9 �
IIR~Nt7J~-6~~~1~-RKi!!1 , 8.
~nr
. ~~~>r C~~
i ,
� r T ~ r .
?
, - + - ~ t ~
~ , � ,r~ . ~
/ ~ ~ '
/ itC'~ _ ~ ~ M A
~ i I _ ~
i
� ~ i
K3~ : ,
l ~ ,
' i
~,~i~,
~
~ [ i . o~MM�'ve~~�?~~~~~t.
~ t. f-t~t~~ttaY~lufro~M~fuhni-tntltis,
Figure 5. Action Range Diagram
Key: le from the state
(1) (Note) The range in the direction of increasing ang
in which the lower and upper arms form a line (180�)
(2) The B-B view
(3) A plane
(4) Rotation center
(5) 1. The range of action of a point "a" on the ai axis is shown.
2. The range of action of torch tip will vary somewhat according to the
bending and twisting of the wrist.
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~~~i~~~~~
~
~ �i
, ~ t i
L
S\.tl .~1~ ~
` i
t~~ JS '
~ ~
1 I
C1' 300MX1lOOLx1000H~0.51~'
600Yi%IWOLXIOOON~0.60^'
(2\ t.f:L.:v~iP.~l~=1S~Yo1rl1.U~
~ 1 nn~mhar.nf~ltfa_ta~~,a,
Figure 6. Action Range Comparison Diagram
Key:
(1) Action range cumparison diagram
(2) This range will vary somewhat according to the bending and twisting of
the wrist.
~1~,-(3~) 70��~ v.t-~T��rfi 7a�r i~~fi!!
(B~) ~ ~ (s~)
� g1/ f(4)(5)(6) `
~ iOOOOOO �
7~~f1 1~~ O O
7
T~ 4444444 ~9~ ~
~ " 101J
~ ~ A! I~ ~7-l-
rz 11
T3 ~ ~ ~
0 0 0
i~. rFY-9~~-'1 ~1 17~
~iw~ i~-yTi:~F10 16 ~9-F~4��rfi
'/-~/74 htl1~7tT~�rf~
Figure 7. Auxiliary Panel
Key :
(1) Timer(3) (9) Eject
(2) Block number switch (8) (10) Cassette recorder
(3) Block number indicator (8) (11) Read
(4) Edit (12) Write
(5) R~set (13) Start
(6) Erase (14) Cassette data recorder
(7) Timer (15) Tape eject button
(8) Block (16) Read/write changeover switch
(17) Start switch
61
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Electronics of RJ 65
Figure 7 provides a detailed diagram of the control device. The main and the
auxiliary panels of the control device are used for control of the power
source for the entire system and in particular for control of the operation
during the automatic operation period.
As soon as the power source is connected, the cassette data recorder on the
auxiliary panel begins to read in the system software data. This lasts
approximately 1 minute and 30 seconds. The origin setting switch on the main
panel is pressed down next. The five axes of the robot are each equipped with
an optic encoder, which feeds back the angle of rotation of each axis. Origin
setting means an operation to move the robot to a predetermined position desig-
nated as the reference point for action.
Only after the origin is set is the robot able to move freely. The top start
switch is used to set the automatic control in motion. The pause switch causes
the operation to stop temporarily. The operation resumes when the top start
switch is pressed again. An error lamp lights up when an error in operation
is detected, and an error code will be displayed on the remote-control box
simultaneously. The details of the error can be understood from the error
code number. When the emergency stop switch is pressed, the operation stops
instantly no matter what state the robot may be in.
Eight different types of operation can be performed by selecting any one of
them using the block number switch on the auxiliary panel. The editing
switch enables editing of a sequence of operations according to the block
number. When the editing switch is pressed twice, the operation becomes
endless, and a sequence of operations will be repeated again and again.
The timer is used to set the pause time bet~aeen steps.
Key:
,,,,,t,,_ � (1) Control device
PROM p~y RAM 5 A1 ~.~.U... ~pv4 M~t00 ~ Common memory
eus~n~ ewsk - I i, (3) Remote control I/0
I, (4) Welding remote-control I/0
B~S'��'�"" ~ (5) panel SW LAMP
(6) Cassette MT
(6 ) (7) Remote control box
I � (8) Welding remote-control
L t"' ~ (9) Robot body
~M M M M M " x"s' N _ (10) Welding electric power source
'oi '02 ~aa ~Qa ~QS ~i~~ (11) Torch
(12 a+~~~ (12) Robot body
Figure 8. Control System Diagram
62
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Figure 8 illustrates the control system diagram. A 16-bit computer and a
DRAM 32 kW memory are used. This computer is a high-performance microcom-
puter with a microprogram control format using a high-speed bipolar micro-
processor. Its characteristics include: add command 0.84 microseconds, mul-
tiply command 4.9 microseconds, and high-speed data channel 1.85 MHz. Vari-
ous I/0 interface connections are connected to the BUS, which is connected
to the CPU via a GP I/0 interface. The robot body and all its comp~nents are
connected to the computer via these I/0 interfaces. The main and the auxili-
ary panels, the remote-control box, as well as the switches and lamps described
above are also connected to the BUS through their own I/0 interfaces.
In addition, there are also limit switches for various robot axes which are
activated when the action reaches a preset limit, the welding control box,
and the I/0 interface for sensor unit; the drive system employs the software
servo format. There are five independent drive systems for the five axes; each
system consisting of a servo amplifier and a servomotor. Each servomotor has
its own tachogenerator and encoder which generate the feedback signals used
for the speed and position control. The CPU used for the softservo applica-
tion is connected with the main CPU through the common memory and receives
timely position coutmand value from it. The action angle of each axis is
determined as follows: the pulses generated by the encoder are counted by
the UP/DOWN counter and the output value is determined by comparing this value
with the command value. Moreover, a single D/A converter is shared by the
five axes by switching from one to another sequentially. This does not pose
any problem, because the time interval is sufficiently short compared with
the servo system action.
Software
Coordinate transformation: Teaching is accomplished either in the a system
or in the XY system, and playback action is carried out in the X-Y system.
Inside the CPU, coordinate transformation from the a system to the X-Y sys-
tem is calculated first, and the results thus ob~tsined are stored in the
memory as the teaching point data together with all data in the remote-
control box.
During the playback action period, the data are retrieved f rom the memory and
computation is carried out in the X-Y system. Take the case of linear inter-
polation, for example. The distance between the two teaching points will be
divided by the velocity to find the time, then the new position to which the
robot must move during each time interval will be calculated. The distance
of travel from the present position to the new position will then be converted
to the a system through coordinate transformation, and outputs to al - as axes
will be generated. The robot will trace a straight line connecting the two
points at a designated speed with a position reproduction accuracy of �0.2 mm.
Arc interpol.ation: As shown in Figure 9, if three points in space are given,
the robot will trace a circular arc passing through these three points at a
designated speed. A complete circle can be traced if four points are given,
as shown in Figure 9. If an additional point is given in addition to a set of
63
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~ i ) ~~nn~e~
3,~t1l,tatt~~dti~aF9ilti
t ~i~I~STfin~irt,aT~ YMo~-~S?kF9lltl~+rl,Tfl~!
~2~ sr-s.'ANiF-I Y~
I ~ 1 ~
I
i.~ ~ ' ~10~ 1tMni~-ym
(4) r~-t>~~ m ` y~~~i_~r~e.
a~t~~
1 r~
m ~ ~ ~
~ (i~ I ~r~, ~
~
( S e~IZ4P9 ~wMn~ar
Figure 9. Arc Interpolation Function Diagram
Key:
(1) Arc interpolation function: An arc passing through three given points
can be traced; the three points may be on a horizontal plane or on a
slanted plane.
(2) Path during teaching mode (arbitrary)
(3) Path during playback mode
(4) Teaching point
(5) A full circle from four points
(6) Arc of points 1, 2, and 3
(7) Arc of points 2, 3, and 4
(8) Connected ares
(9) Arbitrary curve interpolation: Application of arc interpolation; small
section of a curve treated as an arc
(10) Useful in tracing complicated curve of press work; applicable to 3-D
also
(11) An arbitrary curve
(12) An ellipse
three points which define an arc, the first point will be omitted and the
robot will trace an arc passing through the remaining two points and the addi-
tional point. An arbitrary curve can be traced by a series of operations of
this type.
Weaving functian: This function is achieved by a software format as shown
in Fig~re 10. The pattern is arbitrary. Once the robot is taught a single
pattern is entered into the system as a menu, that pattern can be called and
used elsewhere.
Torch offset correction function (Fi~ure 11): The standard torch has offset,
so it can be used with ease even in a narrow space.
Sensing sys tem [Figures 12-14): This is a unique sensorless sensor. No
special sensor other than the torch itself is used. The welding wire itself
is used as the sensor. Its principle of operation is as shown in the drawing.
6k
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~n~x~~ ~9) ~-r-r.7~t~~(~-y:3.~ - -
(z~ v ~ ~ ~=p~~ (10)
~ r ~ r v 9'i~ I C~e 1~1 * r
t~~~t:~t~~, 12 nn~~� .7...,;tv
C ~ ~ o~ n h ~�t~s~a~ ~~~r
6, ~ �o~~~. o )~~-e'.y,:y.t~;~ i ~7~~ ~3~
/3 ,~~7a'l~a '
=i'~(~ in `ys~.
r ~m ~~~1_ b ~T � ~ ~
.r ~h19n .:9>4
o Tod ~ ~1-ti~ 1~
~~r~ a 14107)I:l1
i44�
r sa~
r r m
0 0 0 ~ O �~T-r.y~ ing system (S.L.S.) (Patent) using
' welding wire as detector
~t ~"-~'~=P~ ~
~ 6~ (3) Principle of detection
~~,f '
(7)F-~ ~ (4) Hardware
51NL (5) Detection unit
(9~ ~mQ~ ~ (6) Welding wire
a ~ ~
~ (7) Torch
. (8) Changeover switch
(9) Robot control device
' 13 ~1 r,~ 16~ (10) Detection circuit
t14 ~~~~'~=p~ .~'f~~' ~ F_~. (11) Welding power source
. io ~ io ~
"'~--y soov (12) High-voltage power source
i ~ 600Hz (13) Principle of detection
" 10 (14) (Software)
io......,;.:w.._ 7-~~~ `17 (15) Wel~~ing wire
,
(16) Torch
Figure 12. Sensing System (17) Work error
66
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~1 ~ _ ~T.:3. ~ Key:
J' ~ (1) Automatic extension adjustment function
i2 ~Y / / (2) Correct dimension
:.rm ~i�-P
~ a~~a~~ ~~m~ ~ (3) Reference surface
(4) Wire retracted
~6 ~x~~r~ ~,?~~.:.y n~~, ~~tm (5) Wire extended
(6) Horizontal fillet: one-point sensing
wy `~~y (detection of parallel travel error)
~ Y (7) Sensing menu No O1
. ~ _.:r
~ ~ (8) Horizontal fillet: two-point sensing
(detection of parallel travel error
'7 t:;.,,=~-roo~ and rotational error
~a Z~t ~,.,.,y ~ ~ (9) Sensing menu No 02
~}�~~~.~'~'i~
T r
' ~ 4:~::7i-s-xcot
Figure 13. Sensing System (automatic extension function)
1 ~6~ Key:
(1) Application of individual~
3~Cittiii9'NA~( ~IA213i7 h)
$ sensing (menu Nos 03-07)
~AM~
~ ,.~,NS~I ~7~ y�"'�"~~ (2) Detection of small step
~ r.�~s~ error
- _ - e~~.~t;rrre~~r,~.i ~3~ Option menu ~III2IIIOY'y capacity
~9~ ~rtKr,~~.t,.
~
Figure 3. Block Diagram of SVU Unit Figure 4. Detection of Abnormality
Such as Potentiometer
Key: Breakage
(1) System bus
(2) Interface Key:
(3) Command (1) Trouble
(4) Microprocessor (2) Broken wire
(5) D/A conversion
(6) A/D conversion
(7) Servo valve of each axis of robot
(8) Position of feedback of each axis
of robot
'fl~e unit is equipped with an abnormality detection circuit (see Figure 4)
wt~ich can prevent the robot or the positioner from running away even if a
breakdown in the potentiometer or a breakage in the circuit should take
place.
1, 2'I}ie data length is not f ixed. It is variable according to the effec-
tive s*_roke of the robot and the accuracy requirement.
' 73
; FGR OFFICIAL USE ONLY
~
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2. Input/Output Interface
Figure S shows the block diagram of the IOP unit. Almost all input/output
information required for the operation of the system are grouped together
and the information is transferred to the master CPU via the 256-byte dual
port RAM. The UART transfers data concerning the button, digital display,
and light-emitting diode via the series-parallel conversion board contained
inside the operation console and the teaching box. Moreover, various input/
output registers are constructed of an 8-bit parallel bus belon~ing to an
independent T/0, and the input/output information of the peripheral equipment
are transferred via the relay input/output unit or the welder interface unit.
Key:
(1) System bus
(2) Dual port RAM
~ ~ (3) Microprocessor
1~ (2~ HAti,
~ 1 (6 7~ (4) Timer
~ R~ ~:.3t (S) UART series/parallel conversion
T p /L ~ , .~rs=~.~
L ~M* (6) Various input/output register
x F gates
~ uAR' (7) Positioner hydraulic unit/
~ ~tt
~ 5 welder
_ x (8~~,~,,-n (8) Operation console/teaching box
~ lrr-~~9i~~9z
~
Figure 5. Block Diagram of IOP ~
i
I
~
3. Sensor Interface i
If the robot orbit is to be modified according to the work object, a sensor '
which can detect the distance between the work and the torch becomes neces-
sary. A contact-type sensor used in the automatic follow device has a number
of disadvantages, including the fact that it is affected by sputter, scale,
temporary welding, and defects.
The sensor used in "Mr Aros" is a noncontact type magnetic ser?sor which will
not be affected by ttie arc heat, sputter, surface condition of the work,
fumes, or external noise unique to arc-welding.
Its principle of operation utilizes the change in magnetic flux, and as shown
in Figure 6, it consists of excitation coil Cp, and detection coils C1 and
C7. By connecting the two detection coils C1 and C2 of the same winding in
the differential action format, the change in magnetic flux due to the eddy
current generated between the work ar.d the coil can be detected. The thermal
performance of this sensor is characterized by an error of the order of
4 percent when used at a temperature of 200�C or less and a distance in the
range of 0-8 ~n from the work. Figure 7 shows a block diagram o~ the sensor
interface. When excitation coil Cp is excited with a 20 kHz AC wave form,
output voltage will be induced in detection coils C1 and C2. If this output
voltage is amplified and waveform shaped, a curve like those show^ in Figure 8
7~+
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m~
' (i) ~5) tt~; 6)
tizo~HZ~ N~ ~~r,~ (1 (Z) ~3) (4) ~
~E1w~Y3 ~ 1~{ Q:~d LO(i AAix A p i7ltf.
~ 2~ 0~t ~:acN: ~av ~ p 93 3CN! T ~ x
2%X~~f~~ C~ ee
PI: e: i l J
C: "
m-= ~u~ra (9)
Nt ii ez: ~ LQ
i+ i
+ ~+~(3) ~~-~(ii)
Figure 6. Principle Diagram of Figure 7. Block Diagram of Sensor
Noncontact Type Interface
Sensor Key:
Key: (1) Oscillation circuit
(1) Primary coil (2) Amplifier circuit
(2) Secondary coil (3) Rectification
(3) Material (4) LOG conversion
(5) Position setting
(6) Comparison circuit
(7) Function conversion
(8) System bus
(9) Protection circuit
(10) Sensor
(11) Work
z.o 7~
t
i.o .
7n?_,-e ~
1~ o.s y~
~ 0.3 - 1~
~ 4 ~ /
= o. I~tHiY@~~ ~i"")
0.1
0.05
0.03
~t,~~(5)
( ~
0 2 4 6 e io
Figure 8. Sensor Output Characteristics
Key:
(1) Output voltage (5) Stainless steel
(2) Aluminum (6) Steel
(3) Copper (7) Sensor
(4) Detection distance (8) Material
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can be obtained. To use this signal in the various functions described
above, the signal is subjected to an A/D conversion at the last stage.
Like the abnormality detection circuit described previously, this circuit
also contains a protection circuit which can prevent robot runaway if a
primary or secondary breakage of sensor cable should take place or if the
sensor should come too close to the work object, exceeding a designated
distance.
Software
The majority of the functions of this robot are realized through software.
The basic construction of the software is illustrated in Figure 9. The pro-
cess monitor system (PMS) carries out multiple processing of various tasks.
It executes a task according to the priority order when an interruption
occurs (such as an input/output press-button). A high-level starting pri-
ority is assigned to tasks related to emergency and abnormality treatment,
and all individual tasks are carefully ordered by takinb into consideration
the detail of treatment so as to shorten the treatment time. At the end of
a task, the control is returned to the PMS. During the execution of a task,
if the starting conditions for a task having higher priority order should be
established, the PMS would withdraw all registers of the present task and
execute the task that liad been inserted. Table 3 summarizes the tasks that
are actually used and Table 4 shows a summary of the subroutines.
i
7at~
~=9it'F6
~7
~
C~Vii~1i x5'r7 1#~Mi.F �i1X~ 1~7R~1~
Nlt& ~i1iMt.f M1~F. 9.Z9 MCic Mf.f
9~~ 9~9 q~9 9~4 ~~4
8 01: i h1~q0077~~-i~v(fi11M1t1[.~mIL~)
~ ~ s~~~,~-~. cr-~~~~.~o~+~~
9 ~~~~~~-~.e~
Figure 9. Basic Construction of Software
Key :
(1) Process monitoring system
(2) Tasks related to automatic operation
(3) Tasks related to step operation
(4) Tasks related to manual operation and teaching
(5) Tasks related to stopping
(6) Tasks related to initialization
(7) Tasks related to emergency treatment
(8) Robot control subroutine (interpolation and other); basic subroutine
(data transfer and other)
(9) Common subroutine group
76
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FOR OFFICIAL USE ONLY
Table 3. A List af Tasks (classification and assignment of tasks)
Important Abbreviated
factor symbol I/0 Remarks
02 ESTOP I Emergency stop
03 STOP I Instant stop
04 ABNMI I Abnormality I(same as intant stop)
OS BSTOP I Block stop
07 CSTOP I Cycle stop
10 RCVRY I Recovery from emergency stop
11 LOAD I Hydraulic pressure loading
12 ULOD I Hydraulic pressure unloading
13 CTAUT I Switch automatic mode
14 CTSTP I Switch step mode
15 CTMAN I Switch teach mode
20 STUPO I Step and group center operation
42 EMGG 0 Emergency stop on
53 MANDV 0 Manual operation
55 TEACH 0 TEACH TA~K
60 STOPG 0 Instant stop on
63 STEP 0 Step opeiation
67 AUTCR 0 Automatic operation
72 AMODG 0 Automatic mode on
77 CPUIT 0 CPU INITIALIZE
Important factor I : interrupt
for starting 0 : OUEUE
Table 4. A List of Subroutines (standardized subroutines for Aros series)
No. Name Abbreviated symbol
1 Transfer MOVE
2 RAM CLEAR CLEAR
3 ENCODE DATA ENCOD
4 DECODE DATA DECOD
S Multiplication MULT
6 Division, one of them DIVI
~ ~ SORT
8 CORE MEMORY Read core memory RCORE
9 CORE MEMORY Write core memory WCORE
lU Quadruple length addition AD 4
11 SINE SIN
12 Corner computation CCRNR
13 COSINE COS
14 Index matching MEXP
15 Normalization NORM
16 Multiply floating M~
17 Absolute ~S
18 BCD to binary BCDTB
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A delicate abnormality treatment function and interlocking function which
could not be achieved in the conventional robot, were realized through the
use of software. The rationality checks--more thar. 30 in number-- which
maintain surveillance over the operator teach error and the operation error,
hgve a significant effect on prevention of 3ccident and increasing the teach-
ing work ntmnber, by teaching the operator in advance, unlike the conventional
robot, with which the teaching errors can be revealed only after it is
played back. Table 5 sim~marizes the causes of abnormalities which are
checked and the details of their treatment.
Table 5. Cause of Abnormality and Its Treatment (abnormalities being
checked and details of the treatment)
Signal name Cause of abnormality Details of treatment
Emergency Emergency stop button Deviation signal to servo valve OFF
stop pressed Stop arc
Emergency stop lamp ON
Stop positioner
Hydraulic power source OFF
(un~oad simultaneously)
Abnormal oil Oil temperature > 50�C Block stop
temperature A
Abnormal oil Oil temperature > 60�C Same as emergency stop
temperature B Abnormality display (main console)
Motor Thermal trip on hydraulic Same as emergency stop
overload unit Abnormality display (main console)
Encoder lamp Lamp inside encoder Same as emergency stop
broken broken Abnormality displ~y (main console)
Torch contact Torch touches work Same as emergency stop
Abnormality display (main console)
CPU CPU fails to operate Same as emergency stop
abnormality Abnormality display (main console)
Teaching box Abnormalityin teaching Same as emergency stop
abnormality box circuit or missed
transmission from Abnormality display (main console)
teaching box
Broken arc Overall abnormality of Instantaneous stop of automatic
welding power source operation
Abnormality display (main console)
Sensor Broken sensor or Same as emergency stop
abnormality abnormal approach to work Abnormality display (main console)
The industrial robots are about to change from lonesome stable robots to
ranch robots with social status thanks to the development of the microproces-
sor. It is the task of the maker to realize the dream robot of the user.
COPYRIGHT: Electronic Engineering 1982
9113
CSO: 4106/46 78
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SCIENCE AND TECHNOLOGY
CREATIVE SCIENCE, TECHNOLOGY PROMOTION PROGRAM BEING SET UP
Outline of Program
Tokyo NIHON KOGYO SHIMBUN in Japanese 6 Jan 82 p 2
[Text] A Greater Degree of Freedom: The Path to Success for the Creative Science
and Technology Promotion Program
The Science and Technology Agency announced the "Creative Science and Technology
Promotion Program as one of its new policies for the 1980's. It began in 1981
with an initial budget of approximately 600 million yen. At the end of October
last year, the general directors of four research pro~ects were named, and now a
total of 80 researchers {about 10 percent from overseas) are being selected. By
the end of March all personnel will be selected and the research is scheduled to
get under way in earnest.
This program abolishes the concepts of previous science and technology policies
and aims at promoting science and technology with an "individual-centered organi-
zation." An increase to 1.98 billion yen was approved in the 1982 budget. How-
ever, in order to achieve the final goals, the people involved from industry,
government, and acadeinia must all recognize that this is a"difficult pro~ect"
which requires a great turnaround in thinking.
The Creative Science and Techno~ogy Promotion Program, along with the "Next-
Generation Basic Industrial Technology R and D Program," is a major part of the
government's proposed policy for building the country on the basis of science and
technology in the 1980's. The thinking behind it is quite unusual.
The creative science program is a plan for selecting people of exceptional ability
to be general directors, gathering superior researchers under their leadership by
cnntract from industry, government, and academia, and using existing research
facilities to carry out highly original research. The purpose of the progra~ is
to discover the "seeds" of science and technology which can become the source of
innovative technology. The aim throughout is to carry out research in an "indi-
vidual-centered" way which will make the most of the ability of creative and
ambitious researchers.
In accordance with the conclusions of the Council for Science and Technology, the
New Technology Development Corporation, which is the parent body for promoting
79
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�'Vi~ Vl'l'~L.~HL VJa: VI\LI
the new program, selected the four following subjects on which to begin research
in 1981: super-fine particles, specially structured substances, fine polymers, and
perfect crystals. A researcher-president of a privaLe company and three univer-
sity professors have been chosen as general directors. Some of the research has
already begun, but it will start in earnest in April. In addition, "holonic func-
tion" and "bioinformation" have been selected as new research subjects for 1982.
- In view of these conditions, it would seem likely that the Creative Science and
Technology Promotion Program would go ahead smoothly, but in reality, this is not
necessarily true.
The reason is that it is an "individual-centered" research and development project,
which differs in concept from the previous government-led projects. Even if it is
suited to creative activity, it is doubtful whether it can be easily accepted by
; Japan's industrial society.
For example, there is the problem of retaining researchers. At present, there is
great interest in the various industrial sectors and it is necessary to refuse
some applications for participation. However, in the long term, there is a prob-
lem of whether Japanese industry, with its principle of "company loyalty comes
first because of lifetime employment," can accept a research organization that
gives priority to the individual.
In any case, we hope that the related institutions wil.~ respond with greater free-
dom in order to at least reward the efforts of the general directors, among whom
are included representatives of industry who believe that this is a public service
and that the piofit of private corporations comes second.
C~PYRIGHT: Nihon Kogyo Shimbunsha Tokyo Honsha 1982
Research Setup
Tokyo NIKKEI SANGYO SHIMBUN in Japsnese 12 Feb 82 p 15
[Text] Sixty-Eight Researchers Including Foreigners; New Technology Corporation's
Creative Science Program; 15 Locations Selected for Research Facilities
The New Technology Development Corporation is hurrying to organize the "Creative
SciencP and Technology Promotion Program" which began last fall. The places where
the research is to be carried out and the persons who will perform the research,
including the group leaders, have beer. mostly determined. The equipment and in-
_ struments necessary for each research theme are being ordered, and the main re-
search activity wi].1 begin early in F'Y-82. Research will be carried out at 15
locations, and there will be 68 researchers including the group leaders (30 of
these are scheduled to sign contracts by March). Eight of the researchers are
foreigners. ~
The Cre~.iti~.e Science and Technology Promotion Program will work on four projects
expected to be the seeds of next-generation technology innovation: 1) super-fine
particles, 2) specially structured substances, 3) fine polymers, and 4) perfect
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crystals. These pro~ects will be undertaken in a 5-year plan under a new system~~~
kncwn as a f~exible research system. Superior researchers will be gathered for
the projects from industry, academia, and government and placed under project
leaders who are excellent researchers with managerial ability. This program will
work under a person-centered research system. The research locations and the num-
l~er of researchers for each project are as follows.
Super-fine particles (project leader: Shuzei Hayashi, president of Nippon Vacuum
Technology)--1) basic material properties: Meijo University Science and Engineer-
ing Department (Nagoya), five researchers; 2) physical application: uakei Elec-
tric (Tsukuba Research and Education Garden City), four researchers; 3) biochem-
ical application: Maruzen Oil Company (Satte-machi, Saitama Prefec~ure), four
researchers; 4) method of refining: Nippon Vacuum Technology Ultimate Materials
Laboratory (Sanbu-gun, Chiba Prefecture), four researchers.
Specially structured substances (project leader: Takeshi Masumoto, Tohoku Univer-
sity professor)--1) basic physical properties: Electromagnetic Materials Labora-
tory (Sendai), six researchers; 2) amorphous compounds: Otsuka Chemical and
Pharmaceutical Company (Tokushima), four researchers; 3) amorphous metal thin
films: Gakushuin University (Tokyo), three researehers; 4) special ceramic mate-
rials: Furukawa Electric Central Research Laboratory (Tokyo), four researchers;
5) intrastratal compounds: (will be researched in basic material properties group
during 1981), one researcher.
Fine polymers (group leader: Naoya Ogata, Jochi University professor)--1) molecule
design: Jochi University Science and Engineering Department (Tokyo), four re-
searchers; 2) selective function materials: Mitsubishi Chemical Industries Gen-
eral I,aboratory (Yokohama), five researchers; 3) organic electron materials:
Matsushita Technical Laboratory (Kawasaki), five researchers.
Perfect crystals (group leader: Junichi Nishizawa, Tohoku University professor)--
1) basic structure: Semiconductor Laboratory (Sendai), seven researchers; 2)
super-high-speed elements: Mitsubishi Electric (Itami, Hyogo Prefecture), four
researchers; 3) perfect crystal manufacturing process: Mitsubishi Metals (Omiya,
Saitama Prefecture), four researchers; 4) optical application: Hamamatsu Televi-
sion (Hamamatsu), four researchers.
COPYRIGHT: Nihon Keizai Shimbunsha 1982
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CSO: 4106/65 END
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