The Pioneering Evolution of the World's First Truly Collaborative Dual Arm Industrial Robot

Back in 1978, within the confines of IBM’s Poughkeepsie factory, a groundbreaking step in industrial automation was achieved. By programming four 2-arm robots, a remarkable milestone was set, marking the beginnings of truly collaborative dual arm industrial robots. This endeavor aimed to test wiring on the complex backplanes of 3033 computers, a process that has since undergone significant advancements.

The Initial Context and Setup

The backplane layout differed significantly from today's standards. Each backplane measured approximately 6 feet by 6 feet, accommodating numerous smaller boards with complex wiring setups. The wires, referred to as 'tri-leads', contained a signal conductor and two grounds, with lengths and end connectors vastly differing.

Given the intricacy of the task, over 2,000 wires needed to be installed on each backplane, with each computer potentially having more than one backplane. The process was entirely manual, leaving room for human error, which often manifested as one or a few wires being connected incorrectly.

The Human Touch and its Limitations

The installation process relied heavily on human installers who would invariably make a few mistakes. After the installation, it was essential to detect and rectify these errors before the computers could be shipped to customers. The efforts involved were extensive, with engineers running software diagnostics on fully assembled computers, which often took nearly a week to complete accurately.

The Introduction of Robotic Testing

The introduction of the test robots revolutionized the process, drastically improving efficiency and accuracy. These robots were designed to read the computer files detailing where each wire should be placed, ensuring they navigated non-colliding paths for both sets of arms to connect the wires. They then tested for electrical connectivity and ground short circuits, guaranteeing that each connection was correct.

The dual-armed robots could complete the testing of a complete backplane in under two hours, a significant improvement over the manual process and human predisposition to error. IBM's innovative solution not only streamlined the installation process but also provided a robust quality check mechanism.

Impact and Legacy

Interestingly, shortly after the robots were installed, the human installers ceased making errors, rendering the robots seemingly 'useless'. However, IBM’s shrewd plant manager recognized the long-term benefits of retaining these robots. Their continued operation served as a deterrent for installers to return to less meticulous practices, maintaining the high standards of quality.

This period of industrial history illustrates the delicate balance between human expertise and automation, as well as the importance of the human element in the design and refinement of technology. It marks a pivotal point in the evolution of industrial robotics and collaborative dual arm systems, pioneering a new era in automation.

Conclusion

While the specific details of industrial automation techniques have expanded tremendously since 1978, the foundational work done at IBM's Poughkeepsie factory laid the groundwork for modern collaborative dual arm industrial robots. Recognizing the historical significance of this development highlights the continuous innovation and adaptation necessary in the field of industrial automation and robotics.