ECEG 5332- INDUSTRIAL AUTOMATION AND INTRODUCTION TO ROBOTICS

LECTURE NOTES BY V.RAJAGOPAL / AP/ SECE

INTRODUCTION TO ROBOTICS

‘Robotics’- the term coined from the CZECH word ‘ ROBATA’ which means the
Labour or Forced Worker or Slave which serves for its master.

Definition:

According to the Robotics Industries Association ( RIA), An Industrial Robot is a

PROGRAMMABLE, MULTIFUCTIONAL MANIPULATOR designed to move materials,
parts, tools or specialized devices through various programmed motions for the performance of a
variety of tasks.

Laws of Robot:

Isac Ashimov framed 3 laws of robot.

Law 1 : Robot must not harm human being or through inaction, human to be harmed.

Law 2 : Robot should obey the orders given by human being except when they conflicts with law
1.

Law 3: A robot must prtect its own existence unless that conflicts with law1 and 2.

[Need for using robotics in industries:-

Industrial robot plays a significant role in automated manufacturing to perform different kinds of
applications.

1. Robots can be built a performance capability superior to those of human beings. In terms of
strength, size, speed, accuracy…etc.

2. Robots are better than humans to perform simple and repetitive tasks with better quality and
consistences..

3. Robots do not have the limitations and negative attributes of human works .such as fatigue,
need for rest, and diversion of attention…..etc.

4. Robots are used in industries to save the time compared to human beings.

5. Robots are in value poor working conditions 6. Improved working conditions and reduced
risks.
Overview of Robotics:-

"Robotics" is defined as the science of designing and building Robots which are suitable for real
life application in automated manufacturing and other non-manufacturing environments.

It has the following objectives,

1.To increase productivity

2.Reduce production life

3.Minimize labour requirement

4. Enhanced quality of the products

5.Minimize loss of man hours, on account of accidents.

6.Make reliable and high speed production.

The robots are classified as, Programmable/Reprogrammable purpose robots *Tele-operated,

Man controlled robots *Intelligent robots. Robots are used in manufacturing and assembly units
such as,

1. Spot or arc welding

2. Parts assembly

3. Paint spraying

4. Material, handling

5. Loading and unloading

The feature and capabilities of the robots are as follows,

1. Intelligence

2. Sensor capabilities

3. Telepresence

4. Mechanical design

5. Mobility and navigation

6. Universal gripper

7. System integration and networking.] – For your reference only.

Basic functions of robot:

1. ‘Sensing’ the environment by external sensors.

Eg; vision, voice, touch , proximity etc.
2. ‘Decision making’ based on the information received fron sensors
3. ‘Performing’ the task assigned.

Types of Industrial robots:

1. General Purpose Robots:

 Ready made robot
 These robots carry standard designs and parts
 Easily adopted to the user’s requirements by attaching suitable end effectors to
perform the work such as Part picking and placing in the pallets, welding , spray
painting etc. * Such robots are mass produced and cheaper.
2. Special purpose robots:
 Tailor made robot for specific job requirements.
 Their designing and manufacturing consumes lots of time.
 They cannot be readily available. *Not in mass production.

ELEMENTS OF ROBOTIC SYSTEM:

1. BASE – Fixed or Movable

2. MANIPULATOR (Combination of ARM, BODY & WRIST) with several D.O.F.
3. END EFFECTOR or GRIPPER to hold object.
4. ACTUATORS for Transmission
5. CONTROLLER with hardware and software support for giving commands to the drives.
6. SENSORS to feedback the information for subsequent actions of the arm or gripper as
well as to interact with environment in which robot is working.
7. INTERFACES- Communication between subsystems to the external world.

DESIGN CONSIDERATIONS:

 Strength and Stiffness of the link.

 The materials used for fabrication
 The weight and inertia.
 The location of the bearings
 The selection of the type of bearings
 The fits and tolerances in the joints.
 The external shape and aesthetics.
 The friction and lubrication.
Types of drive systems / Actuators :-

1.Hydraulic drive

2.Electric drive

3.Pneumatic drive

1. Hydraulic drive:-

Hydraulic drive and electric drive arc the two main types of drives used on more sophisticated
robots.

Hydraulic drive is generally associated with larger robots, such as the Unimate 2000 series.

The usual advantages of the hydraulic drive system are that it provides the robot with greater
speed and strength.

The disadvantages of the hydraulic drive system are that it typically adds to the floor space
required by the robot, and that a hydraulic system is inclined to leak on which is a nuisance. This
type of system can also be called as non-air powered cylinders. In this system, oil is used as a
working fluid instead of compressed air.

Hydraulic system need pump to generate the required pressure and flow rate.

These systems are quite complex, costly and require maintenance.

2.Electric drive:-

Electric drive systems do not generally provide as much speed or power as hydraulic systems.
However, the accuracy and repeatability of electric drive robots are usually better. Consequently,
electric robots tend to be smaller.

Require less floor space, and their applications tend toward more precise work such as assembly.

In this System, power is developed by an electric current. It required little maintenance and the
operation is noise less.

3.Pneumatic drive:-

Pneumatic drive is generally reserved for smaller robots that possess fewer degrees of
freedom (two- to four-joint motions).

In this system, air is used as a working fluid, hence it is also called air-powered cylinders.

Air is compressed in the cylinder with the aid of pump the compressed air is used to generate
the power with required amount of pressure and flow rates.
Applications of robots:-

Present Applications of Robots:-

(i) Material transfer applications

(ii) Machine loading and unloading
(iii) Processing operations like,
(a) Spot welding
(b) Continuous arc welding
(c) Spray coating
(d) Drilling, routing, machining operations
(e) Grinding, polishing debarring wire brushing
(f)Laser drilling and cutting etc.

(iv) Assembly tasks, assembly cell designs, parts mating.

(iv) Inspection, automation.

Future Applications of Robots:-

The profile of the future robot based on the research activities will include the following,

(i) Intelligence
(ii) Sensor capabilities
(iii) Telepresence
(iv) Mechanical design
(v) Mobility and navigation (walking machines)
(vi) Universal gripper
(vii) Systems and integration and networking
(viii) FMS (Flexible Manufacturing Systems)
(ix) Hazardous and inaccessible non-manufacturing environments
(x) Underground coal mining
(xi) Fire fighting operations (xii) Robots in space
(xii) Security guards (xiv) Garbage collection and waste disposal operations
(xiii) Household robots
(xiv) Medical care and hospital duties etc.

ROBOT JOINTS:

The robot’s motions (either LINEAR or ROTATIONAL) are accomplished by means of

powered joints.

The common 4 types of joints are

 LINEAR or PRISMATIC ( L or P )
  ROTATIONAL (R)
 TWISTING (T)
 REVOLVING (V)

1. LINEAR JOINT:
It involves a sliding or translator motion of the connecting link
 One sliding motion * Degrees of Freedom(D.O.F) = 1
2. ROTATIONAL JOINT:
 The axis of rotation is Perpendicular to the axes of two connecting links.
 It has one sliding and one rotating motions.
 D.O.F = 2
3. TWISTING JOINT:
 Second type of rotating joint
 The axis of rotation of the twisting joint is Parallel to the axis of rotation of the shaft.
 It has one rotary or twisting motion
 D.O.F = 1
4. REVOLVING JOINT:
 Third type of rotating joint.
 Output link revolves about input link.
 The input link is Parallel to the axis of rotation of the shaft and the output link is
Perpendicular to the axis of shaft.
 D.O.F= 1.

SPECIAL TYPES:

 PLANAR JOINT
 SCREW JOINT
 SHERICAL JOINT
PLANAR JOINT: * Two sliding motions and One Rotary motion * D.O.F = 3

SCREW JOINT: *One sliding motion and one Rotary motion *D.O.F = 2

SHERICAL JOINT: *Three rotary motions *D.O.F = 3

ROBOT GRIPPERS or END EFFECTORS: Grippers are used to hold work parts ( in pick and place
operations , machine loading, Assembly operations) or tools.
Classified as

1. Mechanical Grippers

 Here friction or physical configuration of the gripper retains the objects.

2. Suction or Vacuum Cups

 Made up of Rubber ( silicone, Neoprene)

 Suitable for work piece temperature upto 200 c.
 Efficiency depends on the air-pressure source.
 Used for picking up metal plates, parts of glass, light weight boxes.
3. Electro magnetic grippers: ( For simple diagram, refer class lectures)

 Can handle metal parts with holes.

 Fast pick up time.
  Variations in part size can be tolerated.
 Require source of electric power.
 Can sustain enormous holding power.
4. Hookes: Used to lift parts off conveyors.
5. Scoopes or Laddles: Used for fluids, powders, pallets etc.
6. Adhesive or electro static grippers-

Specifications of robotics:-

1.Axil of motion 2.Work stations 3.Speed 4. Acceleration 5. Pay load capacity

6. Accuracy & Precision 7. Repeatability 8. Reach 9. Work volume 10. Degrees of Freedom

IMPORTANT DEFINITIONS:

1.Payload: The rated load carrying capacity of an industrial robot is defined by its weight of the
object.

2. Repeatability: The accuracy with which the particular defined position can be repeatedly
achieved by a robot.

3.Precision: The reach of a position of a robot is defined by the resolution of actuators and
control feedback systems.

4.Reach: The maximum and minimum extents of the robot positions

5.Work volume: It is defined as the 3 dimensional space around the arm where it can reach
again and again with a desired accuracy and precision.

6. Degrees of Freedom: Translatory and Rotary motions of a robot arm.

ROBOT CONFIGURATIONS

1. CARTESIAN ( PPP / LLL)

2. CYLINDRICAL (PPR / LLR)
3. SHERICAL ( RRP / RRL)
4. JOINTED ARM (RRR)
5. SCARA ( Selective Compliance Assembly of Robot Arm)
EXPLANATION WITH DIAGRAMS:
1. CARTESIAN ROBOT( LLL / PPP)

 Also called as RECTILINEAR or GANTRY Robot.

 Simplest configuration
 Manipulator is considered to move in LINEAR manner.
 It has 3 dimensional co ordinates (X,Y,Z)
 Positioning is done in the work space with 3 PRISMATIC or LINEAR Joints.
 Hence it is a PPP or LLL Configuration and is used for PICK and PLACE work, Assembly
operations, Handling machine tools and ARC welding.

Advantages:

 Simple kinematic model

 Rigid Structure
 Easy to visualize,
 Compatible with Pneumatics
 Good Repeatability.

Disadvantages:

 Requires large work volume.

 2. CYLINRICAL ROBOT ( PPR / LLR}

 The robot has revolute motion about base, a prismatic joint for radius.
 It is PPR or LLR configuration and is used for Assembly operations, handling machine
tools, Spot welding and handling at die casting machines.
 A full 360 degree rotation is not permitted due to restrictions imposed by electrical,
hydraulic and pneumatic actuators connections.
 Hence work volume is the portion of the Cylinder. ( disadvantage)

Advantages:

 Simple kinematic model

 Easy to Visualize
 Very powerful with hydraulic drives.
3. SHERICAL ROBOT

 Resembles like TELESCOPIC ARM.

 Two revolute joints and one Prismatic joint allow the robot to point in many
directions and then reach out some radial distance.
  It is a RRP / RRL Configuration and is used for handling machine tools, spot welding,
Die casting, Fettling machines, Gas welding and Arc welding.
 Owing to mechanical actuators connections, the work volume is portion of the
sphere.

Advantages:

 Can bend down to pick up the fallen objects

 Covers large volume from a central support.

Disadvantages:

 Complex kinematic model.

4. JOINTED ARM ROBOT

 The robot uses 3 revolute joints to position the arm.

 Resembles like human arm having wrist, elbow and joints
 It is RRR configuration and is useful for pick and place operations.
 Sub class of this type is SCARA (Selective Compliance Assembly of Robot Arm)
 SCARA has RRP Configuration and is used for pick and place , Assembly operations
and handling machine tools.

Advantages:

 Maximum Flexibility
 Suits electric drives

Disadvantages:

 Complex kinematic model

 Difficult to visualize