Industrial Robotics

1
 Introduction

The Evolution of Robots:

• George Moore built a walking robot in 1893 !
• It had a .5 Horsepower Steam Engine using a Gas
Fired Boiler….
• It was a mechanical device without any intelligence.
• It could walk at 9 Miles Per Hour.

2
 Introduction

The Evolution of Robots:

• George Moore built a walking robot in 1893 !
• It had a .5 Horsepower Steam Engine using a Gas
Fired Boiler….
• It was a mechanical device without any intelligence.
• It could walk at 9 Miles Per Hour.

2
 Robot Definition

• Robot term from Webster’s dictionary 

An automatic device that performs function ordinarily
ascribed to human being

• Robot Institute of America

“A robot is a programmable, multifunction manipulator
designed to move material, parts, tools, or special
devices through variable programmed motions for the
performance of a variety of  tasks”

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 Definition of Robotics

ISO defines Industrial Robotics as

An automatically controlled, reprogrammable,
multipurpose, manipulative machine with several
reprogrammable axes, which may be either fixed in
place or mobile for use in industrial automation
applications.

4
 Robot Application Characteristics

1. Hazardous work environment for humans

2. Repetitive work cycle
3. Difficult handling task for humans
4. Multi-shift operations
5. Infrequent changeovers
6. Part position and orientation are established in the
work cell

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 Industrial Robot Applications

1. Material handling applications

 – Material transfer – pick-and-place
 – Machine loading and/or unloading
2. Processing operations
 – Spot welding and continuous arc welding
 – Spray coating
 – Other – water jet cutting, laser cutting, grinding
3. Assembly and inspection

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 General Classification Of Robots

• Low technology
• Medium technology
• High technology

Low technology

• Material handling, using simple assembly

• 2 to 4 axes of movement

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 Medium technology

• Pick-and-place
• Material handling
• 4 to 6 axes

High technology

• Material handling
• Pick-and-place
• Loading and unloading
• Painting and welding
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Robot Anatomy

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 Robot Anatomy

Robot manipulator - a series of joint-link combinations

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 Robot Anatomy

• Manipulator consists of joints and links

 – Joints provide relative motion
 – Links are rigid members between joints
 – Each joint provides a “degree-of-freedom”
 – Most robots have five or six degrees-of-freedom

• Robot manipulator consists of two sections:

 – Body-and-arm  – for positioning of objects in the
robot's work volume
 – Wrist assembly – for orientation of objects 11
 What is a joint?
• A joint of robot is
similar to a joint in the
human body
• Each joint gives the
robot a degree-of-
freedom of motion
• In nearly all cases, only Joint
1 degree-of-freedom is
allowed to a joint

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 What is a robot link?
• Links are rigid
components that form a
chain connected
together by joints
Link
• Each joint has two links,
known as an input link
and an output link

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 Types of Manipulator Joints

• Translational motion
 – Linear joint (type L)
 – Orthogonal joint (type O)
• Rotary motion
 – Rotational joint (type R)
 – Twisting joint (type T)
 – Revolving joint (type V)

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 Linear joint (type L)

The relative movement between the input link and the

output link is a linear sliding motion, with the axes of 
the two links being parallel

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 Orthogonal joint (type O)

This is also linear sliding motion, but the input and

output links are perpendicular to each other during the
move

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 Rotational joint (type R)

This type provides a rotational relative motion of the

 joints, with the axis of rotation perpendicular to the
axes of the input and output links

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 Twisting joint (type T)

This joint also involves a rotary motion, but the axis of 
rotation is parallel to the axes of the two links

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 Revolving joint (type V)

In this type, the axis of the input link is parallel to the

axis of rotation of the joint, and the axis of the output
link is perpendicular to the axis of rotation

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Joint Drive Systems

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 Joint Drive Systems

• Electric 
 – Uses electric motors to actuate individual joints
 – Preferred drive system in today's robots
• Hydraulic 
 – Uses hydraulic pistons and rotary actuators
 – Noted for their high power and lift capacity
• Pneumatic 
 – Typically limited to smaller robots and simple
material transfer applications
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End Effectors

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 End Effectors

The special tooling for a robot that enables it to

perform a specific task.
• End effectors two main categories:
 – Grippers – to grasp and manipulate objects during
work cycle.
 – Tools  – to perform a process, e.g., spot welding,
spray painting.

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24
 End Effectors

Grippers
1. Mechanical Grippers
2. Suction cups or vacuum cups
3. Magnetized grippers
4. Ladles
5. Spray gun

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 Robot Mechanical Gripper

A two-finger mechanical gripper for grasping rotational

parts

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 Cam-operated hand

• It can easily handle heavy weights or bulky objects.

• It is designed to hold the object so that its center of 
gravity (CG) is kept very closed to the wrist of hand.
• The short distance between the wrist and the CG
minimizes the twisting tendency of a heavy object.

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 Simple Vacuum Cup Hand

This simple vacuum cup

hand is suitable for
handling fragile parts such
as cathode ray tube face
plates.

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Magnetic Pick up

• Magnetic handling is
most suitable for parts
of ferrous contents.
• Magnets can be
scientifically designed
and made in numerous
shapes and sizes to
perform various tasks.

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 Ladle

• Ladling hot materials such as molten metal is a hot

and hazardous job for which industrial robots are
well suited.

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 Spray gun

• Ability of the industrial robot to do

multi-pass spraying with controlled
velocity fits it for automated
application of primers, paints, and
ceramic or glass frits, as well as
application of masking agents used
before plating.

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 Wrist Configurations

• Wrist assembly is attached to end-of-arm

• End effector is attached to wrist assembly
• Function of wrist assembly is to orient end effector
 – Body-and-arm determines global position of end
effector
• Two or three degrees of freedom:
 – Roll
 – Pitch
 – Yaw
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 Wrist Configuration

• Notation :RRT 

• Typical wrist assembly has two or three degrees-of-

freedom (shown is a three degree-of freedom wrist)
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Robot Sensors

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 Sensors in Robotics

Two basic categories of sensors used in industrial 

robots:

1. Internal - used to control position and velocity of the

manipulator joints

2. External - used to coordinate the operation of the

robot with other equipment in the work cell

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 Type Of Sensors Being Used In Robotics
1. Position • Monitors the location of joints
Sensors • Coordinate information is feedback to controller
• This communication gives the system the capability
of locating the end-effectors
2. Range • Measures the distance between a point in the robot
sensors and interest point that surrounds the robots
• The task is usually performed by cameras
3. Velocity • Estimates the speed using a moving manipulator
sensors • Due the effects caused by, mechanical force, gravity,
weight of load etc, desired speed and required force
to reach the speed should be computed
continuously
4. Proximity • Sense and indication of presence of another object
sensors within specified distances
Prevents accidents and locate the existence of w.p.
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 Sensors in robotics

Required features of sensors:

1. Accuracy
2. Operation range
3. Speed of response
4. Calibration
5. Reliability
6. Cost and ease of operation

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 Robot Geometry Type

1. Cartesian or x-y-z axis

2. Cylindrical
3. Polar arm (Spherical)
4. Jointed-Arm (Articulated)
5. SCARA

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 Cartesian Coordinate
Body-and-Arm Assembly
Notation LOO:
• Consists of three sliding joints,
two of which are orthogonal
• Other names include rectilinear
robot and x-y-z robot

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 Cartesian Type Configuration
Cartesian manipulator are useful for table-top assembly
applications and, as robots for transfer of material and
cargo

 Advantages:
1. 3 linear axes.
2. Easy to visualize.
3. Rigid structure.
4. Easy to program off-line.

Disadvantage:
1. Can only reach in front of itself 
2. Requires large floor space for size of work envelop
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 Cylindrical
Cylindrical Body-and-Arm Assembly

Notation TLO:
• Consists of a vertical
column, relative to
which an arm assembly
is moved up or down.
• The arm can be moved
in or out relative to the
column.

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 Cylindrical Type Configuration
 Advantages:
1. 2 lin
linea
earr ax
axes,
es, 1 rotat
otatin
ingg axi
axiss
2. Can
Can rea
reach
ch all
all ar
around
ound itse
itself 
lf 

Disadvantages:
1. Cann
Cannotot reach
each abov
bove itse
itself 
lf 
2. Base
Base rot
rotat
ation
ion axis
axis is
is less
less rigi
rigid
d than
than a lin
linea
earr axis
axis
3. Hori
Horizzont
ontal moti
motion
on is cir
circula
cularr

42
 Polar Coordinat
Coordinate
e
Body-and-Arm Assembly

• Notation TRL:

• Consists of a sliding arm (L joint) actuated relative to

the body, which can rotate about both a vertical axis
(T joint) and horizontal
horizontal axis (R joint) 43
Spherical

44
 Spherical Type Configuration
 Advantages:
1. 1 linear axis, 2 rotating axes
2. Long horizontal reach

Disadvantages:
1. Generally has short vertical reach

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 Jointed-Arm Robot

Notation TRR:
• General configuration of 
a human arm

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 SCARA Robot

Notation VRO:
• SCARA stands for Selectively
Compliant Assembly Robot
Arm
• Similar to jointed-arm robot
except that vertical axes are
used for shoulder and
elbow joints to be compliant
in horizontal direction for
vertical insertion tasks
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 SCARA Type Configuration
There are two type of SCARA robot configuration:
either the first two joints are revolute with the third
 joint as prismatic (linear), or the first joint is revolute
with the second and third Joints as prismatic.

 Advantages:
1. 1 linear axis, 2 rotating axes
2. Height axis is rigid
3. Large work area floor space
4. Two ways to reach a point

Disadvantages:
1. Difficult to program off-line
2 Highly complex arm 48
Robot Performance

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 Resolution

Smallest increment of motion at the wrist end that 

can be controlled by the robot. Depends on the
position control system, feedback measurement, and
mechanical accuracy

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 Accuracy

Capability to position the wrist at a target point in the

work volume.
• One half of the distance between two adjacent
resolution points.
• Affected by mechanical Inaccuracies.
• Manufacturers don’t provide the accuracy (hard to
control) .

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 Repeatability

 Ability to position back to a point that was previously 

taught.
• Repeatability errors form a random variable.
• Mechanical inaccuracies in arm, wrist components.
• Larger robots have less precise repeatability values.

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 Weight Carrying Capacity

The lifting capability provided by manufacturer 

doesn’t  include the weight of the end effector.

• Usual Range 2.5lb-2000lb

• Condition to be satisfied:
Load Capability > Total Wt. of workpiece +Wt. of end
effector + Safety range

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 Speed of Movement

Speed with which the robot can manipulate the end 

effector.

•Acceleration/deceleration times are critical for cycle

time.

Determined by:
1. Weight of the object
2. Distance moved
3. Precision with which object must be positioned
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 Motion Control

Path control - how accurately a robot traces a given

path (critical for gluing, painting, welding applications);
Velocity control - how well the velocity is controlled
(critical for gluing, painting applications)

Types of path control:

1. point to point control (used in assembly,
palletizing, machine loading);
2. continuous path control/walkthrough (paint
spraying, welding). 55
Robot Drives

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 Robot Actuators and Drive Systems
What is meant by actuator? 

The commonly used actuators are:

1. Stepper motors
2. DC servomotors
3. AC servomotors
4. Hydraulic pistons
5. Pneumatic pistons

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 Electric Drive
Small and medium size robots are usually powered by
electric drives with gear trains using servomotors and
stepper motors.

 Advantages
1. Better accuracy & repeatability
2. Require less floor space
3. More towards precise work such as assembly applications

Disadvantages
1. Generally not as speedy and powerful as hydraulic
robots
2. Expensive for large and powerful robots, can become fire
hazard
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 Hydraulic Drive
Larger robots make use of hydraulic drives.

 Advantages:
1. more strength-to-weight ratio
2. can also actuate at a higher speed

Disadvantages:
1. Requires more floor space
2. Tendency to oil leakage

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 Pneumatic Drive

1. For smaller robots that possess fewer degrees of 

freedom (two- to four joint motions).

2. They are limited to pick-and-place tasks with fast

cycles.

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 Direct Drive Robots
In 1981 a "direct- drive robot" was developed at
Carnegle-Mellon University, USA. Is used electric
motors located at the manipulator joints without the
usual mechanical transmission linkages used on most
robots.
The drive motor is located on the joint 

Benefits:
1. Eliminate backlash and mechanical defficiencies
2. Eliminate the need of a power transmission
3. Joint back-drivable (allowing for joint-space force
sensing)
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 Practical Application

Automotive Component Paint Technology

Robotic Painting Justification:

1. Quality
2. Material Cost
3. Warranty cost
4. Labor Cost
5. Compliance

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 Quality

Automated robotic application of material brings

consistency to the spray out process.

•Improve appearance consistency

•Improve product film build
consistency
•Provide consistent gun target
distance
•Reduce part defects

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 Material Savings

Repeatable robot paths and gun triggering means the

material application will save material.

-Gun triggers are precise

-Consistent gun target distance
-Consistent material delivery
-Higher transfer efficiency
-Overspray reduced

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 Warranty

- Proper application per the specification

- Eliminates product defects caused by build variation
- Reduction of application related variables
- Reduced part rework
- Reduced scrap rate

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 Labor

- Reduce repetitive motion injuries

- Reduced worker’s compensation claims
- Reduce turnover of skilled operators
- Productivity increase
 – Multi shift operation savings
 – Greater painting speed endurance
 Compliance

1. Removes employee from a hazardous

environment
2. Eliminate cost of operator protection
3. Booth air can be recirculated
4. Lower booth air velocity

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Fanuc Robotics Off Line Programming Software
Paint Pro

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Robot Programming

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 Robot Programming
• Robots execute a stored program of instructions that
define the sequence of motions and positions in the
work cycle
 –Much like a part program in NC

• In addition to motion instructions, the program may 

include commands for other functions:
 – Interacting with external equipment
 – Responding to sensors
 – Processing data

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Two Basic Robot Programming Methods

1. Leadthrough programming
Teaching-by-showing - manipulator is moved
through sequence of positions in the work cycle and
the controller records each position in memory for
subsequent playback

2. Computer programming languages

Robot program is prepared at least partially off-line
for subsequent downloading to robot controller

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 Robot Programming

• Leadthrough programming - work cycle is taught to

robot by moving the manipulator through the required
motion cycle and simultaneously entering the program
into controller memory for later playback
• Robot programming languages  – uses programming
language to enter commands into robot controller
• Simulation and off-line programming  – program is
prepared at a remote computer terminal and
downloaded to robot controller for execution without
need for leadthrough methods

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Leadthrough Programming Advantages
•  Advantages:
 –Can readily be learned by shop personnel
 –A logical way to teach a robot
 –Does not required knowledge of computer
programming

• Disadvantages:
 –Downtime - Regular production must be interrupted
to program the robot
 –Limited programming logic capability
 –Not readily compatible with modern computer-based
technologies
73
Simulation and Off-Line Programming

• In conventional usage, robot programming languages

still require some production time to be lost in order
to define points in the workspace that are referenced
in the program
 – They therefore involve on-line/off-line programming
• Advantage of true off-line programming is that the
program can be prepared beforehand and
downloaded to the controller with no lost production
time
 – Graphical simulation is used to construct a 3-D model
of the robot cell in which locations of the equipment
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Example

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 Example

A robot performs a loading and unloading operation for a

machine tool as follows:
 – Robot pick up part from conveyor and loads into machine
(Time=5.5 sec)
 – Machining cycle (automatic). (Time=33.0 sec)
 – Robot retrieves part from machine and deposits to
outgoing conveyor. (Time=4.8 sec)
 – Robot moves back to pickup position. (Time=1.7 sec)
Every 30 work parts, the cutting tools in the machine are
changed which takes 3.0 minutes. The uptime efficiency of 
the robot is 97%; and the uptime efficiency of the machine
tool is 98%.
Determine the hourly production rate. 76