THE OVERVIEW OF INDUSTRIAL ROBOTICS

1.1 The Various Industrial Revolutions

1.2 Overview of Industrial Robots
1.3 Programming & Simulation With IO Device Configurations
1.4 Digitalization and the Network Systems
1.5 Cyber Physical System – Robotics Automation and Cobots
1.6 Robot Selection and Health Parameter Identification
1.7 Mastering With EMD - Techniques
1.6 Comparison of Industry 4.0 Factory and Today's Factory
1.7 Summary
The Various Industrial Revolutions
 The Various Industrial Revolutions

I -The first industrial revolution, which began in the UK in the 18th century, was
characterized by the widespread adoption of steam power and the
mechanization of production.
II -There was a second industrial revolution in the early 20th century when
‘mass production’ became dominant, pioneered by US automotive
manufacturers such as Henry Ford.
III
- A ‘third industrial revolution’ began later in the 20th century when
programmable electronic systems and computer technologies helped to further
automate production lines.
IV - Now we are experiencing the fourth industrial revolution. It is based on
hugely increased sharing of data across multiple systems and between
participants in the manufacturing process – and the benefits that arise from this.
World “Growth” Initiatives
Produktion
2030
Made
Smart Difference Industrial
Industry Internet Business
Revolution
High Value
Manufacturing
Industry 4.0

Industry of Digital
the Future Manufacturing
Manufacturing Innovation 25’
for SME
Renaissance Program
Fabricacion Produktionder
Avanzada Zukunft
Made In China
Operational 2025
Fabbrica Programme
Intelligente Make in India

Precision
Manufacturing
Digitalization and the Network Systems
In essence, industry 4.0 is the trend towards automation and data exchange in
manufacturing technologies and processes which include cyber-physical systems
(CPS), the internet of things (IoT), industrial internet of things (IIOT), cloud
computing, cognitive computing and artificial intelligence.
DID NOT EXIST IN 2006 - Activity

Smart Phones ► Android

Smart Devices ► Smart Devices
Kindle ► Instagram
4G ► Snapchat
Uber, Ola ► Whatsapp
Airbnb, OYO

TIME TO REACH 100 MILLION CUSTOMERS

Telephone - 75 Years
Web - 7 Years
Facebook - 4 Years
Instagram - 2 Years
Whatsapp - 6 Months
Today’s Factory
Tomorrow’s Factory
 INDUSTRY NEX
Six Design Principles
• Interoperability: the ability of cyber-physical systems (i.e. work piece carriers,
assembly stations and products), humans and Smart Factories to connect and
communicate with each other via the Internet of Things and the Internet of
Services
• Virtualization: a virtual copy of the Smart Factory which is created by linking
sensor data (from monitoring physical processes) with virtual plant models
and simulation models
• Decentralization: the ability of cyber-physical systems within Smart Factories
to make decisions on their own
• Real-Time Capability: the capability to collect and analyze data and provide
the insights immediately
• Service Orientation: offering of services (of cyber-physical systems, humans
and Smart Factories) via the Internet of Services
• Modularity: flexible adaptation of Smart Factories for changing requirements
of individual modules
 Robots working in Amazon WH

45000
40000
35000
30000
25000
20000
15000
10000
5000
0
2013 2014 2015 2016
 CHANGYING PRECISION TECHNOLOGY COMPANY
(SMART PHONE MANUFACTURER)
Before After

Number of employees 650 60

Number of robots 0 65

Defects (%) 25% Below 5%

(80% reduction)

Production per person 8000 21000

(more than 2.6 times)

https://www.assemblymag.com/keywords/5566-changying-precision-technology-co
 Stronger Customer More Efficient
Centricity Production
Processes

Agility
Efficiency
INDUSTRY
4.0

+75
%

87

2019
Innovation
Value Chain
Transformation
through
New Marketing & Networked
Business Models Processing &
Objects
 HISTORY OF ROBOTICS

Robota (Czech) = A worker of forced labor

From Czech playwright Karel Capek's 1921 play “R.U.R” (“Rossum's Universal Robots”)

Motor driven Robots

– 1928: First motor driven automata

– 1961: Unimate - First industrial robot

– 1967: Shakey - Autonomous mobile research robot

– 1969: Stanford Arm - Dextrous, electric motor driven robot arm

 ROBOTS

Industrial Robots

Autonomous Robots
Mobile Robots

Humanoid Robots
Pre-Programmed Robots

Teleoperated Robots

Augmenting Robots
 INDUSTRIAL ROBOT DEFINED

A general-purpose, programmable machine possessing certain

anthropomorphic characteristics

• Hazardous work environments

• Repetitive work cycle
• Consistency and accuracy
• Difficult handling task for humans
• Multi-shift operations
• Reprogrammable, flexible
• Interfaced to other computer systems
 Joint Arm Articulated Robots

• Manipulator consists of joints and links Link3

Joint3
Joints provide relative motion
Links are rigid members between joints
End of Arm
Various joint types: linear and rotary
Each joint provides a “degree-of-freedom” Link2
Most robots possess five or six degrees-of- Link1
freedom
Joint2
• Robot manipulator consists of two sections:
Body-and-arm – for positioning of objects in the Joint1
robot's work volume Link0
Wrist assembly – for orientation of objects Base
Industrial Robotics

 A simple definition is: a programmable, mechanical device used in place of a person

to perform dangerous or repetitive tasks with a high degree of accuracy.

Types of Industrial Robots

While industrial robots can be custom programmed to handle a variety of tasks and
applications for many industries, there are really 5 main categories of industrial
robotics. The tasks needing completion determines which type of robot is
necessary.

Industrial robot categories include:

•    Cartesian robots

•    Gantry robots
•    SCARA robots
•    Articulated arm robots
•    Human-assist robots
Robot Programming

Robot Programming is the defining of desired motions so that the robot may
perform a task or application as command or order received.

Identifying and specifying the robot configurations

•Base Coordinate
•World Coordinate
•Joint Coordinate
•Tool Coordinate

Programming Methods
•Manual Method
•Walkthrough Method
•Lead through Method
• OLP
Industrial Robotics

ROBOT PROGRAMMING

Method of programming based on the application and Coordinates

On Line Programming
- Teach pendant (Smart Pad)
- lead through programming

OFF Line Programming

write a program using a text-based robot programming language – does not need
access to the robot until its final testing and implementation

- Robot programming languages

- Task level programming
Programming Methods

On-Line/Teach Box
Advantage: – Easy – No special programming skills or training – Can specify other
conditions on robot movements (type of trajectory to use – line, Circular, PTP, arc)
Disadvantages: – Potential dangerous (motors are on)

Off-line Programming
• Programs can be developed without needing to use the robot
• The sequence of operations and robot movements can be optimized or easily improved
•Previously developed and tested procedures and subroutines can be used
•External sensor data can be incorporated, though this typically makes the programs
more complicated, and so more difficult to modify and maintain
•Existing CAD data can be incorporated-the dimensions of parts and the geometric
relationships between them, for example.
• Programs can be tested and evaluated using simulation techniques, though this can
never remove the need to do final testing of the program using the real robot Programs
can more easily be maintained and modified
•Programs can more be easily properly documented and commented.
KUKA smart PAD teach pendant
Overview

CIT-KUKA
KUKA smart PAD, front view

CIT-KUKA
CIT-KUKA
On line Programming
OFF line Programming

zshfdg
MITSUBISHI ELECTRIC – MELFA RV 4FLD
Motion Commands

SERVO ON
OVRD 50
MOVE P1
HERE P1 - used during lead through of manipulator
MOVES P1
DMOVE(4, 125)
APPROACH P1, 40 MM
DEPART 40 MM
DEFINE PATH123 = PATH(P1, P2, P3)
MOVE PATH123
OVRD 75
SERVO OFF
END
INTERLOCK AND SENSOR COMMANDS

Interlock Commands
WAIT 20, ON
SIGNAL 10, ON
SIGNAL 10, 6.0
REACT 25, SAFESTOP
Gripper Commands
OPEN
CLOSE
CLOSE 25 MM
CLOSE 2.0 N
OFF line Programming

SIMPRO 3.1 – KuKA

Robo DX
Robot Studio
OCTOPUZ
AUTOMAPPS
DELFOI
And Etc.,
CIT – KUKA Robotics Training Centre

Technical data Maximum reach - 1612 mm

Maximum payload - 20 kg
Rated payload - 16 kg
Pose repeatability (ISO 9283) ± 0.04 mm
Number of axes 6 Mounting position
Weight approx. - 245 kg
Peripherals

EOAT’S
Robot Controller
Programmable Logic Controller
IO Devices
Communication Protocols
Software's
 EOAT’s

The special tooling for a robot that enables it to perform a specific task

Two types:
Grippers – to grasp and manipulate objects (e.g., parts) during work cycle
Tools – to perform a process, e.g., spot welding, spray painting

Types of Actuation
Pneumatics
Hydraulics
Electrical
Electronic Assisted
 ROBOT CONTROL SYSTEMS

• Limited sequence control – pick-and-place operations

using mechanical stops to set positions
• Playback with point-to-point control – records work
cycle as a sequence of points, then plays back the
sequence during program execution
• Playback with continuous path control – greater
memory capacity and/or interpolation capability to
execute paths (in addition to points)
• Intelligent control – exhibits behavior that makes it
seem intelligent, e.g., responds to sensor inputs, makes
decisions, communicates with humans
 Robot Control System

Cell
Cell Level 2
Supervisor
Supervisor

Controller
Controller Level 1
&
& Program
Program

Joint
Joint 11 Joint
Joint 22 Joint
Joint 33 Joint
Joint 44 Joint
Joint 55 Joint
Joint 66 Sensors
Sensors Level 0
Communication Devices

EtherNet/IP, ControlNet and DeviceNet to Modbus, Profibus, EtherCAT and CC-Link

https://s3.amazonaws.com/RobotiqContent/Documents/Industrial-robot-communication-protocols.pdf
PLC – PROGRAMMABLE LOGIC CONTROLLER
PLC

• First Programmable Logic Controllers were designed and

developed by Modicon as a relay replacer for GM and
Landis.
• These controllers eliminated the need for rewiring and
adding additional hardware for each new configuration of
logic.
• The new system drastically increased the functionality of the
controls while reducing the cabinet space that housed the
logic.
• The first PLC, model 084, was invented by Dick Morley in
1969.
• The first commercial successful PLC, the 184, was introduced
in 1973 which was designed by Michael Greenberg.
PLC – PROGRAMMABLE LOGIC CONTROLLER

A PROGRAMMABLE LOGIC CONTROLLER is a solid state control

system that continuously monitors the status of devices connected as inputs.
Based upon a user written program, stored in memory, it controls the status
of devices connected as outputs.
Inside a PLC
Languages used to Program PLC

• Ladder Diagram (LD),

• Sequential Function Charts (SFC),
• Function Block Diagram (FBD),
• Structured Text (ST),
• Instruction List (IL)
Ladder Logic

Inputs Outputs

Read / Conditional Write / Control

Instructions Instructions
Start (Rung #1) || ()

| | | | |/| ()

|| |/| ()

End (Rung #4) || |/| ()

||
Functional Block Diagram - FBD
Structured Text - ST
Instruction List - IL
Ladder Diagram - LD
Sequential Function Chart - SFC
Communication Protocol

•communication protocol is • Ethernet

a system of rules that allow • Profibus
two or more entities of •RS-232
a communications system to •RS-485
transmit information via any •Multi-Point Interface
kind of variation of a physical (MPI)
quantity. •Point to Point (PPI)
•Data Highway
•USB Adapter
•PC Adapter
Sequential Function Chart - SFC
PLC Manufacturer

• ABB
• Allen Bradly
• Siemens
• Mitsubishi
• Honeywell
Criteria for Selecting PLC

• Number of logical inputs and outputs

• Memory - Selected based on the size of the program
• Number of special I/O modules: Depends on the application.
For exotic applications, a large number of additional cards may
be required.
• Scan Time: Depending on the size of the program, a larger
program needs shorter scan times. And, the shorter the scan
time, the higher the cost.
• Communications: serial and network connections allow the PLC
to be programmed and to communicate with other PLCs. The
needs are determined by the application.
• Software: the availability of programming software and other
tools determines the ease of programming and debugging.
Applications of PLC

• Whenever automation is desired

PLCs are best suited to meet the task
• Monitor and control production
processes,
• Conveyor system,
• Material Handling,
• Railway Track control systems,
• Autonomous Car Parking
 ROBOTIC ARC-WELDING CELL

Robot performs flux-cored

arc welding (FCAW)
operation at one
workstation while fitter
changes parts at the other
workstation
 Press Releases

High demand for “Robotics skills” in post-Corona recovery

Education and training urgently needed for the automated economy of
the future
Aug 06, 2020 Frankfurt By 2022, an operational stock of almost 4
million industrial robots are expected to work in factories
worldwide. These robots will play a vital role in automating
production to speed up the post-Corona economy. At the same
time, robots are driving demand for skilled workers. Educational
systems must effectively adjust to this demand.

REF : IFR
 Summary

Technology exists today that can make I4.0 a current reality. The speed and
scale of future technology development ensures that I4.0 will become a
common feature of manufacturing industry within a few years.

The benefits of adopting an I4.0 strategy to deliver smart manufacturing is

clear; increased efficiency, increased productivity, increased flexibility,
reduced downtime, reduced time to market, greater competitiveness and
increased profitability.

The road to digitalization to achieve these goals may be challenging but by

approaching the task in a structured manner and ensuring that return on
investment can be seen for each phase of the project, delivering smart
manufacturing is very possible to achieve today and with further
technological advances guaranteed, what will be possible will clearly change
the way we operate in the future.