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KNP3063 Robotics and Automation

Introduction Part I

Robotics and automation course covers discussion on sub-system of robotics, robot

design, industrial robot fundamental, robot programming and control, vision system
and development in robotics and automation.

AUTOMATION

TERM What is automation?

The use of various control systems
Term automation was inspired by the word
for operating equipment which
automatic (from automaton), was not
minimalize or reduce the
widely used before 1947, when ford
intervention of human.
established an automation department.
.
.

How Meant by Automation

Automation has been achieved by the
combination of various means including Automation is a technology that is
mechanical, hydraulic, pneumatic, electrical, concerned with the use of electronic
electronic devices and computers. mechanical and computer based system
Automation is vital in complicated systems in the operation control and production.
application.
.

Product Variety and Production Quantity Relationship

Product variety refers to the different type of product designs

produced in a plant

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Production Quantity and Layout

AUTOMATION TYPES
PROGRAMMABLE
FLEXIBLE AUTOMATION FIXED AUTOMATION
AUTOMATION
System is capable of Capability to change the Sequence of processing (or
changing over from one job to sequence of operations assembly) operations is
Definition the next with little lost time through reprogramming to fixed by the equipment
between the job accommodate different configuration
product configurations
 High investment for  High investment in  High initial investment
custom-engineered programmable for custom-engineered
system equipment equipment
 Flexibility to deal with  Flexibility to deal with  Relatively inflexible in
soft product variety variations and accommodating
Typical Features changes in product product variety
configuration
 Physical setup and
part program must be
changed between jobs
(batches)

Production Rates Medium Lower than Fixed High

 Continuous production  Most suitable for batch  Less product variety

of variable mixes of production
Type of Products products

 

Fixed Position Process
 
Process
Layout Process Cellular
 Product

Labor Product

 Increase labor  Improve product

productivity quality
 Reduce labor cost  Reduce
manufacturing
THE PURPOSE  Mitigate the effects of
lead time
labor shortages
OF  Reduce unit cost
 Reduce or eliminate
AUTOMATING routine manual and
clerical tasks
 Improve worker safety
 Accomplish processes
that cannot be done
manually

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Reasons for Not AUTOMATING

Task is too
Customized
technologically Short product
product – one-
difficult to life cycle
of-a-kind
automate

Flexibility in coping Supply more than

with changing demand
demand

PRINCIPLES

Understand the existing Process

• Input/output analysis
• Value chain analysis
• Charting techniques and Mathematical
Modelling

Automation
Simplify the Process
• Reduce unnecessary steps and moves Principle

Automate the process

• strategies of automation and production
systems
• Automated migration strategy

• Specialization of Operations
• Combined Operations
• Simultaneous Operations
• Integration of Operations
• Increased Flexibility
You can simply impress your audience and add a unique zing
• Improved Material Handling and
Storage
• On-Line Inspection
• Process Control and
Optimization
• Plant Operations Control
• Computer Integrated
Manufacturing

Automation Strategies

Automation Migration Strategy

Automate
the
process

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Benefit of automation

 Save labor
 Save energy and materials
 Improve quality, accuracy and precision

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INDUSTRIAL ROBOTS

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CONTENTS

[1] DEFINITION
[2] HISTORY
[3] ROBOT TYPES
[4] MANUFACTURER
[5] BASIC CONFIGURATION
[6] TERMINOLOGY & PROGRAMMING
[7] ADVANTAGE
[8] APPLICATION IN THE INDUSTRIES
[9] LATEST TECHNOLOGY
[10] FUTURE TECHNOLOGY
[11] CAREER – ROBOTICS/SYSTEM ENGINEER

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“A reprogrammable,
multifunctional manipulator
designed to move material,
parts, tools, or specialized
devices through various
programmed motions for the
performance of a variety of
DEFINITIONS tasks."
I
• Robot Institute of America, 1979

An Industrial robot is an
automatically controlled,
programmable & reprogrammable,
multipurpose manipulators in
three or more axes.

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“a machine capable of carrying out a

complex series of actions
automatically, especially one
programmable by a computer”
• Definition by the Concise Oxford English
DEFINITIONS
II  An example of technology for automation.
 Robot is something controlled by a computer
that runs a program. The computer then
direct its movement.
 Reprogrammable multifunctional manipulator
that can move material, parts or tools through
variable programmed motions.

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Classification of INDUSTRIAL
Robots
• Japanese Industrial Robot
Association (JIRA) has 6 classes
of robot
• The Robotics Institute of America
(RIA) only considered 3 to 6 of
JIRA classification as robots
• The Association Francaise de
Robotique (AFR) has 4 types of
robots

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ROBOT CLASSIFICATIONS
JAPANESE INDUSTRIAL ROBOT ASSOCIATION
THE ROBOTICS INSTITUTE OF AMERICA (RIA) FIXED AUTOMATION
(JIRA)
Class 1: Manual-Handling Device: Type A :
A device with multiple degrees of Handling device with manual
freedom that is actuated by an x control and telerobotics
operator.
Class 2: Fixed-Sequence Robot: Type B :
A device that performs the successive x Automatic handling devices with
stages of a task according to a predetermined cycles
predetermined, unchanging method
and is hard to modify. Similar to fixed
automation.
Class 3: Variable-Sequence Robot: Type C:
Same as class 2, but easy to modify. Similar to programmable Programmable, servo controlled
automation. robots with continuous or point-
to-point trajectories
Class 4: Playback Robot: Type D:
A human operator performs the task manually by leading the robot, Same as type C, but with capability
which records the motions for later playback. The robot repeats the to acquire information from its
same motions according to the recorded information. environment
Class 5: Numerical Control Robot:
The operator provides the robot with a movement program rather
than teaching it the task manually.
Class 6: Intelligent Robot:
A robot with the means to understand its environment and the
ability to successfully complete a task despite changes in the
surrounding conditions under which it is to be performed.

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BRIEF HISTORY

1954:
• The first programmable robot is designed by George Devol.
• He coins the term Universal Automation.

1962:
• The first industrial robot was online in a General Motors automobile factory in New Jersey.
• It was Devol and Engelberger's UNIMATE.
• It performed spot welding and extracted die castings.

1970s-1980s:
• The industrial robot industry starts its rapid growth, with a new robot or company entering
the market every month due to rapid growth in automotive and electronics industries.
•

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BRIEF HISTORY

 Robotic applications
originated in the
automotive industry.

 Cost effectiveness, job

efficiency and safety are
the three main reasons
that robots have
become a big part of the
automotive industry.

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Installations Statistics by Industry

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Robot’s Installation Trend :

Positive medium-Term Growth Expectations

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Largest Market

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BRIEF HISTORY – IN MALAYSIA

 The Malaysia robotics market is marked by growing

competition among manufacturers in each of the product
segments.

 An increasing end-user awareness for robotic technology

and a demand for higher levels of production by end-users
are drawing greater installation of flexible automation
system in companies across Malaysia.

 The total robotics in Malaysia had a market base of

RM58.6mil in 2004 and it is estimated that the market share
for robots used in automotive industry is about 60% of the
total robotics.
Source : Frost & Sullivans

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BRIEF HISTORY – IN MALAYSIA

The automotive industry continues to be the dominant end-user for robots especially in
welding segments (arc welding and spot welding).

Assembly Material Handling Welding

Light Assembly Parts Transfer Arc Welding

Heavy Assembly Machine Loading and Spot Welding

Unloading
Electronic Assembly Packaging
Clean room Assembly Palletizing

Material Application Processing Others

Coating Cutting and Drilling Inspection

Dispensing Grinding, Polishing, and Laboratory

Deburring
Service

Source: Frost & Sullivan

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A robot may not injure a

human being or, through
inaction, allow a human
being to come harm.

Asimov’s laws
of robotics A robot must obey any
Introduced in orders given to it by human
beings, except where such
1942 by Isaac orders would conflict with

Asimov.
the first law.

A robot must protect its own

existence as long as such
protection does not conflict
with the first and second.

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ROBOT
TYPES

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Generally, there are at least five different

configurations of robots In the global market today
such as:-

(a) Articulated arms robots

 These robots have at least 4 axis and is

not gantry in its movement.
 It enable to move in an almost infinite
possibilities as opposed to just X & Y
.

movement.
 These robots are used extensively in
heavy assembly operations and
Automotive Industry utilize 75% .

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(b) Selective Compliance Assembly Robotic Arm robots (SCARA)

 SCARA robot is held by a single

to three axis for turning.

 The smaller robots or more

commonly known as the
“simple manipulator arm” does
not use any axis, as it utilizes
.

servos.

 SCARA are mostly used for

general purpose assembly,
especially in electronics &
semiconductor factories.

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(c) Cartesian coordinates robots

 It follows the X, Y and Z axis and tend to smaller in size

and lighter in weight than the SCARA robots.

 Due to their limited movement, these robots are often

used in a restricted manufacturing environment.

 Cartesian robots are generally used for more higher

.

accuracy assembly.

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(d) Gantry robots

Gantry robots frequently incorporate an articulated arm
within their overhead frame

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(e) Mobile robots

Found in the inspection, services and other applications.

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[4] MANUFACTURERS

Japan USA

Sweden

Italy

Germany

France

Korea

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Market Shares

Robot installed up to 2016

Fanuc – 400,000
Yaskawa – 300,000
ABB – 250,000
Kawasaki – 110,000
Nachi – 100,000
Kuka – 80,000
Denso – 80,000
Epson – 45,000
Adept – 25,000

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