ME6703 – Computer Integrated

Manufacturing System

Unit V
Industrial Robotics
Prepared by:
K. Chellamuthu, M.E.,
Asst. Prof./ Department of Mechanical
Engineering,
 Syllabus
Robot Anatomy and Related
Attributes – Classification of Robots -
Robot Control systems – End
Effectors – Sensors in Robotics –
Robot Accuracy and Repeatability -
Industrial Robot Applications – Robot
Part Programming – Robot Accuracy
and Repeatability – Simple
 The History
The Czech word “robota” means
“forced worker” which became the
root word for Robot.
This word was first introduced by
a Czechoslovakian play writer Karel
Capek, in his science fiction titled
“Rossum’s Universal Robots”.
Cyril W. Kenward, a British,
invented a “x-y-z” axes moving
robotic arm which was patented and
released in 1957.
 Robot - Defined
An industrial robot is a general-
purpose, programmable machine
possessing certain anthropomorphic
characteristics to perform various
industrial tasks.
It may be also defined as re-
programmable, multi-tasking device
designed to perform tasks at high
speeds with greater ease & accuracy
than human.
Robot Anatomy
Joint

Link

End Effector

Base
 Robot Elements
The basic elements of a general robot are:
 Manipulator Components – To provide
the necessary movements of the joints and
the links.
• Manipulator (Base / Arm assembly)
• End Effector (Gripper, Tooling, etc.)
• Actuators (Motors / Drives)
• Transmission Elements (Belts, pulleys,
gears, etc.)
 Robot Elements
The basic elements of a general robot are:
 Control System Components – Used to
generate signals to co-ordinate the
movements of the robot.
• Mechanical, Hydraulic, Pneumatic,
Electrical, Electronics, etc. (open or
Closed loop control)
• Sensors
• Equipment Interfaces
 Robot Elements
The basic elements of a general robot are:
 Computer System Components – Data
processing capabilities to interpolate the
positions and control of the movements.
• PLCs, Computers, Microprocessors
• User Interfaces (keyboard, Displays,
Teach Pendant)
• Software & Programs
 Robot Anatomy
The Manipulator of an industrial
robot consists of series of joints and
links.
Robot anatomy is concerned with
the types and sizes of these links and
joints and other aspects of the
manipulator’s physical construction.
 Joints & Links
A joint in a robot provides relative
motion between two bodies.
A joint or axes provides the degree
of freedom (dof) of motion to the
robot according which it ma be
classified.
Links are rigid components of the
robot manipulator. The relative
movement of the input and the output
links is through them connected by
the joint.
Classification of Joints
The types of joints, basically 5, are:
1. Linear Joint (Type L Joint) – The
relative motion between the input
and output link is a translational
sliding motion with axes of the
Input Link Output
links parallel. Link

Joint motion
Classification of Joints
2. Orthogonal Joint (Type O Joint)
– The relative motion between the
input and output link is also
translational sliding motion but the
axes of the linksJoint
are motion
perpendicular.
Input Link

Output
Classification of Joints
3. Rotational Joint (Type R Joint)
– This type provides rotational
relative motion, with the axis of
rotation perpendicular to the axes
of the input and output links.
Joint motion
Input Link

Output
Link
 Classification of Joints
4. Twisting Joint (Type T Joint) –
This joint also provides rotational
relative motion, but the axis of
rotation is parallel to the axes of
the two links
Joint motion
Input Link

Output
Link
 Classification of Joints
5. Revolving Joint (Type V Joint) –
In this type, the axis of the input
link is parallel to the axis of
rotation of the joint an is
perpendicular to the axis of the
output joint. Output
Link
Input Link
Joint motion
 Range of Joints
Normally the range of a
traditional robot will be less than a
meter or rotation about few degrees,
but in the case of gantry types, the
range may extend up to several
meters and several complete turns.
 Robot Classification
Industrial robots can be classified on
the following basic characteristics.
• The Physical Geometry of the Joints
& links
• dof (Degrees of Freedom) – (2, 3, 6,
etc.)
• Complexity of the robot movement
path (Point-to-Point or Continuous
Path)
• Power source or drive for the
manipulator (Electrical, Hydraulic,
Pneumatic, etc.)
 Physical Geometry
Configuration
Body–and-Arm configuration is basically
classified into the following 5 types.
The various configurations are:
1. Cartesian Co-ordinate (Rectangular)
2. Cylindrical Co-ordinate (Rectilinear)
3. Polar Co-ordinate (Spherical)
4. Jointed Arm (Revolute or
Anthromorphic)
5. SCARA ( Selective Compliance
Robot Configuration

Gantry
Robot Configuration
Yaw

Roll
Pitch
 Robot Configuration
Roll – Rotational / Swivel movement
in a plane perpendicular to the end of the
arm
Pitch – Rotational / Bending
movement in a plane vertical to the arm
Yaw – Rotational / Twisting
movement in a plane horizontal to the
arm.
Robot Configuration
 Robot Control Systems
The motion of a robot is controlled
by a combo of h/w and s/w as
programmed by the user.
There are basically 2 types:
1. Servo Controlled Robot &
2. Non-servo Controlled Robot
Servo Vs. Non-servo Control Systems
S.No
Feature Servo Non-servo
.

01. Design Complex Simple

02. Control Path control Point-to-point

Velocity,
Controllable End point
03. Acceleration and Path
Parameters Control
of motion
04. Flexibility High Low

05. Operation Smooth Rugged

Servo Vs. Non-servo Control Systems
S.No
Feature Servo Non-servo
.

06. Robot Path Complex Simple

Sensors, Computers,
Mechanical
Control Electronic
07. systems, Limit
Mechanism controllers (PLCs),
switches, etc.
etc.
Programmin
08. Mutli-programmable Limited
g Versatility

09. Cost High Relatively low

Functions - Robot Control
Systems
The major functions involves:
(i) Generating the path of motion for
the manipulator
(ii) Feedback devices
(iii) Co-ordinate transformation
(iv)Safety controls
(v) Interfaces
Functions - Robot Control
Systems
Grippers
Sensors Vision
Joint Sensor
Encoders

Printer
Workstation
Interface
Electronics Monitor

Safety Teach
Devices Pendant
Performance Capabilities
Specifications:
• Axes of Motion – No. of degrees of
freedom.
• Work Envelope – The 3D space
range.
• Speed – Depends on the payload,
position in the space envelope and
axis of movement.
• Acceleration – Rate of travel to
reach the destination.
• Payload Capacity – The max. load
carried at normal or reduced speeds.
Performance Capabilities
Specifications:
• Accuracy – The closeness of the end
of the end-effector can be moved to
the destination.
• Resolution – Precision or the
smallest incremental motion, the robot
can be controlled.
• Repeatability – The ability of the
manipulator to return to the same
position every time.
• Reliability – The mean time between
failures (MTBF) is desired to be
Performance Capabilities
Key Feature Capabilities
In addition to the typical
specifications, the other desirable
features are:
• Quality
• Serviceability - Reduction in
failures and the time taken to repair
• Safety – Prevention of damage /
injury
• Modularity – Modular design for
easy failure analysis / repair /
replacement
End Effectors
 End Effectors
The end effector is the final
component and is attached to the
wrist of the robotic arm.

The end effector is the

component which does the task for
which it is built.

It is generally known as
“Grippers”.
End Effectors - Types
Based on the application the
grippers are classified as follows.

• Mechanical Grippers
• Vacuum Grippers
• Magnetized Devices
• Adhesive Devices
End Effectors – New Designs

• Dual Grippers – Loading and

Unloading of r/m or WIP and FG
at the same time.
• Interchangeable fingers to adapt
to different materials handled
• Sensory feedback or pressure
pads
 Sensors

A device which measures a

parameter and converts it into a
readable signal is known as a Sensor.
 Sensors - Classification

Basical robotic application

classifies sensors into:
Internal & External Sensors
Internal Sensors are used to control
the positions and velocities of various
joints.
Eg.: Potentiometers, Optical
 Sensors - Classification

External Sensors are used to

co-ordinate the operation of
the robot with the other components
within the work cell.
Eg.: Tactile, Proximity, Optical, etc.
Industrial Robots - Applications
The general characteristics of
industrial work situations that tend to
promote the substitution of robots for
human labor are the following:
• Hazardous work environment
• Repetitive work cycle.
• Difficulty in handling parts / process
• Multi-shift operations
• Infrequent changeovers
• Part position and orientation are
established in the work cell.
Industrial Robots - Applications
Most of the current applications of
industrial robots are in the
manufacturing. The applications can
usually be classified into one of the
following categories:
• Material Handling,
• Processing Operations and
• Assembly and Inspection.
 Material Handling
Material handling applications are those
in which the robot moves materials or parts
from one place to another. To accomplish
the transfer, the robot is equipped with a
gripper type end effector. The gripper must
be designed to handle the specific part or
parts that are to
be moved in the application.
 Material Handling
The main applications in material
handling are:
a. Material Transfer &
b. Machine Loading / Unloading
 Material Handling
Material Transfer

These applications are ones in which

the primary purpose of the robot is to pick
up parts at one location and place them at
a new location.

In many cases, reorientation of the

part must be accomplished during the
relocation.
 Material Handling
Material Transfer
Simplest operation is “Pick & Place”
operation where a limited dof, low
technology, pneumatic powered robots are
used.

Complex operation might include:

Palletizing, Depalletizing, Stacking,

Insertion (inserting parts into the divided
compartments of the bin) operations etc.
Material Handling
Pick & Place
Material Handling
Palletizing & Depalletizing
Material Handling
Insertion
 Material Handling
Machine Loading and/or
Unloading.
The three applications are:

1. Machine Loading
2. Machine Unloading
3. Machine loading & Unloading
 Material Handling
Few applications related to
Machine Loading and/or Unloading
are:

1. Die Casting
2. Plastic Moulding
3. Metal Machining Operations
4. Forging
5. Press Working
6. Heat Treating, etc.
Applications - Processing
Operations
Processing applications are those in
which the robot performs a proccss.ing
operation on a work part.

A distinguishing feature of this

category is that the robot is equipped
with some type of tool as its end
effector .
Applications - Processing
Operations
To perform the process. the robot
must manipulate the tool relative to
the part during the work cycle.

In some processing applications,

more than one tool must be used
during the work cycle.

In these instances. a fast change

tool holder is used to exchange tools
during the cycle.
Applications - Processing
Operations
Operations listed below are some
processing operations that can be
performed with accuracy and ease with a
robot.
• Spot Welding
• Continuous Arc Welding
• Spray Coating
• Drilling,
• Routing,
• Grinding
• Wire Brushing
• Waterjet Cutting.
• Loser Culling..
Applications - Assembly
Operations
In some respects. assembly and
inspection are hybrids of the previous
two application categories,
i.e., material handling and
processing.
Assembly operations typically
involve the addition of components to
build a product.
Applications - Assembly
Operations
This requires the movement of
components from a supply location in
the workplace to the product being
assembled, which is material handling.
In some cases, the fastening of the
components requires a tool to be used
by the robot (c.g. Stacking, Welding.
Driving a screw)
Applications - Assembly
Operations
Assembly work typically involves
diverse and sometimes difficult tasks,
often requiring adjustments to be
made in parts that don't quite fit
together.
A sense of feel is often required to
achieve a close fitting of parts.

Inspection work requires high

precision, patience and human
judgment is often needed to determine
whether a product is within quality
Applications - Assembly
Operations
ASSEMBLY
Assembly involves the addition of
two or more parts to form a new
entity, called a subassembly (or
assembly).

The new subassembly is made

secure by fastening two or more part,
together using mechanical fastening
techniques (such as screws, nuts, and
rivets) or joining processes (e.g ..
welding. brazing, soldering, or
Applications - Assembly
Operations
Industrial robots used for the types
of assembly operations described here
are typically small. with light load
capacities.
The most common configs arc
Jointed arm, SCARA, and Cartesian
coordinate.
Accuracy requirements in assembly
work are often more demanding than
in other robot applications, and some
of the more, precise robots in this
category have repeatabilities as close
Applications - Assembly
Operations
INSPECTION
There is often a need in automated
production and assembly systems to
inspect the work that is supposed to be
done.
These inspections accomplish the
following functions:
1. To make sure that a given process
has been completed.
2. To ensure that parts have been
added in assembly as specified and
3. To identify flaws in R/M & FG.
 Robot Programming
A robot program can be defined as
a path in space to be followed by the
manipulator, combined with peripheral
actions that support the work cycle.
Examples of the peripheral actions
include opening and closing the
gripper, performing logical decision
making, and communicating with
other pieces of equipment in the robot
cell.
A robot is programmed by entering
the programming commands into its
 Robot Programming
In the case of limited sequence
robots, programming is accomplished
by setting limit switches and
mechanical stops to control the
endpoints of its motions.
The sequence in which the
manipulator moves is regulated by a
Sequencing device.
This device determines the order in
which each joint is actuated to form
the complete motion cycle.
 Robot Programming
In the case of limited sequence
robots, programming is accomplished
by setting limit switches and
mechanical stops to control the
endpoints of its motions.
The sequence in which the
manipulator moves is regulated by a
Sequencing device.
This device determines the order in
which each joint is actuated to form
the complete motion cycle.
 Syllabus
Robot Anatomy and Related
Attributes – Classification of Robots -
Robot Control systems – End
Effectors – Sensors in Robotics –
Robot Accuracy and Repeatability -
Industrial Robot Applications – Robot
Part Programming – Robot Accuracy
and Repeatability – Simple