Robotics

BMS INSTITUTE OF TECHNOLOGY AND MANAGEMENT
Introduction to Mechanical
Engineering
Module 5
ROBOTICS
Introduction
Robots are devices that are programmed to move parts, or to do work with
a tool.
Robotics is a multidisciplinary engineering field dedicated to the

development of autonomous devices, including manipulators and mobile
vehicles.
An industrial robot is a general purpose, programmable machine possessing

certain anthropomorphic characteristics.
09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 2
Introduction
 The most typical anthropomorphic or human like, characteristics of a robot
is its arm.
 This arm, together with the robots capacity to be programmed, make it
ideally suited to a variety of production tasks, including machine loading,
spot welding, spray painting and assembly.
 The robot can be programmed to perform sequence of mechanical motions,
and it can repeat that motion sequence, until programmed to perform some
other job.
Industrial Robot
An industrial robot is a general purpose programmable machine that possesses
certain anthropomorphic features
• The most apparent anthropomorphic feature of an industrial robot is its
mechanical arm, or manipulator
• Robots can perform a variety of tasks such as loading and unloading machine
tools, spot welding automobile bodies, and spray painting
• Robots are typically used as substitutes for human workers in these tasks

Components/Elements of Industrial Robot
The main components of an industrial robot are:
 Manipulators,
 End Effectors,
 Feedback devices,
 Controllers, and
 Locomotive devices.
1. Manipulators
To simply understand what a manipulator is, think of it as the arm of a
robot and like a human arm that has several joints. These joints or
mechanical linkages are capable of movement in various directions to
perform the work of the robot.
These mechanical linkages are driven by actuators which may be
pneumatic or hydraulic cylinders, hydraulic rotary actuators, electric
motors, drives, etc. The actuators may be coupled directly to the
mechanical links or joints or may drive indirectly through gears, chains, or
screws. When pneumatic or hydraulic drives are utilized, the flow of air or
oil to the actuators is often controlled by valves mounted on the
manipulator.
2. End Effectors
This is a device that is attached to the end of a robotic arm to carry out
its tasks. Think of it like the palm and fingers of a human hand. The
End Effector is the component that moves or orients the product or
process. It is used for specialized tasks such as welding, measuring,
marking, drilling, cutting, painting, cleaning, and so on.

3. Feedback Devices
These are a class of devices used to monitor an operation or process
and then verify the operation or process has occurred. Back to a
human body analogy, they are the organs that supply data to the brain
(controller).
In a robot, a feedback device could be installed to sense the positions
of the various links and joints and transmit this information to the
controller. They may be simple limit switches, actuated by the robot's
arm or position-measuring devices such as encoders, potentiometers,
resolvers, and/or tachometers. Depending on the devices used, the
feedback data is either digital or analog.
4. Controllers
The robot controller is a computer, composed of hardware and
software, linked to the robot and essentially functions as its "brain”.
Controllers have all of the characteristics associated with computers
and contain sophisticated decision-making and data storage
capabilities. They initiate and terminate the motion of the manipulator
through interfaces with the manipulator's control valves and feedback
devices, or perform complex arithmetic functions to control path, speed,
and position, or provide two-way communications between the
controller and ancillary devices.

5. Locomotive Devices
Muscles help in the movement of the arm, fingers, and palm in humans.
For the robot, the power of movement is provided by motors.
pneumatic, electric, and hydraulic motors are the three most popular
types of motors used in robot movement.

Types of Robot Joints
Robot joints
Robot joints refer to the movable components of the robot that result in
relative motions between adjacent links. In this context, links are used
to refer to the rigid members connecting the joints for clear and
adequate functioning. The robotic joints are also at times referred to as
axes.


1. Linear Joints
In the linear joints, the relative motion featured by the adjacent links is
meant to be parallel. This means that the input and output links are
sliding in a linear motion. This kind of movement results in a
translational motion. This kind of linear motion can be achieved in
several ways including the use of the telescoping mechanism and
piston. This type of joint is also referred to as the L- joint.

2. Orthogonal Joints
The orthogonal joints are also popularly referred to as the type O-joints.
They feature a relative movement taken by the input link and output
link. This kind of motion involved in the Orthogonal joints is a
translational sliding motion. However unlike the linear joints
arrangement, with the Orthogonal joint, the output link is perpendicular
to the input link.

3. Rotational Joints
When it comes to the rotational joints, you’ll find the use of rotational
relative motions that come in handy for robot manipulators working
multiple workspaces. These movements are carried out with the axis of
rotation perpendicular to the axes of the input and output links. These
rotational joints are also referred to as Type R joints.

4. Twisting Joints
This type of joint features rotary motion that also results in some
degree of rotation when in use. The movement in these joints is relative
to the axis of rotation that is perpendicular o the axes of the input and
output links. The twisting joints are also referred to as type T joints.

5. Revolving Joints
In the revolving joints, things are a bit different compared to the others.
These joints also feature a rotational movement that comes in handy in
different applications. The movement of these joints features motion
between the two links. The axis of the input link is designed to be
parallel to the axis of rotation of the joint. On the other hand, the axis of
the output link is designed to be perpendicular to the axis of rotation of
the joint. This type of joint is also referred to as the Type V joint.
Robot Anatomy
 The robot has human like characterization to respond to sensory inputs,
communicate with other machines and perform a variety of useful tasks.
 The manipulator of a robot consists of series of joints and links. Robot

anatomy looks into these type of joints, its sizes and other physical
construction.

Joints and Links
 A joint in a robot is similar to joint in a human body. It provides relative
motion between two parts of the body which is also called as degree of
reedom of motion.
 Generally one degree of motion is associated with each joint.
 Links are the rigid component of the robot manipulator.
 Joints are connective between two links.
 The purpose of joints is to provide controlled relative movement between
the input link and output link.
Joints and Links

Robotic Configuration
Industrial robots come in a variety of shapes and sizes. They are capable of
various arm manipulations and they possess different motion systems.
Classification based on Physical configurations
1. Cartesian configuration
2. Cylindrical configuration
3. Polar/Spherical configuration
4. Jointed-arm/Revolve configuration

1. Cartesian configuration: A robot which is
constructed around this configuration consists of
three orthogonal slides, as shown in fig. the
three slides are parallel to the x, y, and z axes of
the Cartesian coordinate system. By appropriate
movements of these slides, the robot is capable
of moving its arm at any point within its three
dimensional rectangular spaced work space.
Advantages of Cartesian Configuration:
High resolution and accuracy.
No counterbalance problem.
3 linear axes
Disadvantages of Cartesian Configuration :
Large structural framework.
Complex mechanical design for linear sliding motions.
Confinement of the workspace (limited).
2. Cylindrical configuration: in this
configuration, the robot body is a vertical column
that swivels about a vertical axis. The arm
consists of several orthogonal slides which allow
the arm to be moved up or down and in and out
with respect to the body. This is illustrated
schematically in figure.
Advantages of Cylindrical Configuration :
Almost no counterbalance problem.
Mechanical design is less complex than Cartesian robots.
2 linear axes +1 rotating can reach all around itself.
Disadvantages Cylindrical Configuration :

Large structural framework.
Lower accuracy compared with the Cartesian robots.
Restriction of the workspace
3. Polar/Spherical configuration: this

configuration also goes by the name “spherical
coordinate” because the workspace within which
it can move its arm is a partial sphere as shown in
figure. The robot has a rotary base and a pivot
that can be used to raise and lower a telescoping
arm.
Advantages of Polar/Spherical Configuration :
Low weight and minimal structural complexity.
Short joint travel for many motions.
Good accuracy and resolution.
1 linear + 2 rotational axes
Disadvantages of Polar/Spherical configuration :
Large variable torque on second joint creating counterbalance problem.
Position error is large due to rotary joints.
4. Jointed-arm/Revolve configuration:
is combination of cylindrical and articulated
configurations. This is similar in appearance to the
human arm, as shown in fig. the arm consists of
several straight members connected by joints which
are analogous to the human shoulder, elbow, and
wrist. The robot arm is mounted to a base which can
be rotated to provide the robot with the capacity to
work within a quasi-spherical space.

Advantages of Jointed-arm/Revolve Configuration :
Flexibility to reach over or under an object.
Good workspace.
3 rotational axes can reach above or below obstacles.
Disadvantages of Jointed-arm/Revolve Configuration :
Counterbalance problem.
Poor resolution and accuracy due to rotary joints.
High moment of inertia and dynamic instability (i.e. vibrations).
Areas of Application of Robot
 Outer Space
 Military
 Industry
 Health Service
 Agriculture
 Underwater
 Security and Surveillance
Industrial Application of Robot
An industrial robot is a robot system used for manufacturing.
Industrial robots are automated, programmable and capable of
movement on three or more axis.
Typical applications of robots include welding, painting, assembly,
disassembly, pick and place for printed circuit boards, packaging and
labeling, palletizing, product inspection, and testing; all accomplished
with high endurance, speed, and precision. They can assist in
material handling.
Loading and Unloading: Robots are extensively being utilized for the
loading and unloading of machines and parts in industries, thus
substituting human labor and other mechanical methods. Robots possess
the benefit of duplicating the designed tasks, performing accurately,
and being compatible with the nearby equipment.
Arc Welding: The surroundings of arc welding are unsafe for the fitness
of human beings, and achievement of quality welds is difficult by
manual operations. Therefore, since smooth movements provide
superior welds, the use of robots for such operations is growing very
rapidly. Utilization of industrial robots for arc welding is economical,
and the welds are of an excellent quality.
Repetitive work cycle: A second characteristic that tends to promote
the use of robotics is a repetitive work cycle. If the sequence of
elements in the cycle is the same, and the elements consist of
relatively simple motions, a robot is usually capable of performing the
work cycle with greater consistency and repeatability than a human
worker. Greater consistency and repeatability are usually manifested as
higher product quality than can he achieved in a manual operation.
Spot Welding: Robots perform spot welding very accurately, with

recurring operations, and are extensively being used in automotive
industry. They can extend to places which normally would be difficult
to reach by manual welding.
Painting: It is a difficult and unhealthy operation, where hazardous
fumes are released that are extremely dangerous for human beings,
and in which a danger of explosion exists in the areas of operation.
Furthermore, manual painting results are not consistent due to
unpredictable speed of movement of the components involved in this
process.
Investment Casting: Investment casting requires duplication,

accuracy, and uniformity in production, all of which can be achieved
with employment of industrial robots.

Integration of Parts: The integration of parts in various sub systems of
production is an important application where robots can function
more efficiently and with extra speed, thus assisting in the increase of
production rate. Presently, robots are being used for tightening of
bolts and nuts, placing of components in circuit boards, and a variety
of other similar tasks. Logic devices are used for identification and
rectification of defects or inconsistencies.
Hazardous work environment for humans: When the work

environment is unsafe, unhealthful, hazardous, uncomfortable, or
otherwise unpleasant for humans, there is reason to consider an
industrial robot for the work.

Material Handling Application of Robot
Material handling robots can automate some of the most tedious, dull,
and unsafe tasks in a production line and is one of the easiest ways to
add automation. Material handling robots enhance the efficiency of your
production line and increase customer satisfaction by providing quality
products in a timely manner.
The term material handling encompasses a wide variety of product

movements. Part selection and transferring, palletizing, packing, and
machine loading are just a few of the applications that are considered
material handling.

Part transfer, a dull and tedious process, can also be injury-inducing
to human workers. By adding robots to this job, human workers are
kept free of the hazardous environment.
Packaging robots are extremely flexible and easy to integrate into a

workspace. Some of the advantages of packaging robots include
reduced part package time, ability to lift larger packages and labor
cost reduction . With the right end of arm tooling, a robot can
complete any packaging process. There is a large variety of robot
sizes, mounting options, payload and reach available to choose from.

Palletizing robots can be seen in many industries including food
processing, manufacturing, and shipping.
Machine loading robots not only increase production speeds, it also
protects workers from injury.
Die casting: The robot unloads parts from the die casting machine.
Peripheral operations sometimes performed by the robot include
dipping the parts into a water bath for cooling.
Plastic molding: Plastic molding is a robot application similar to die
casting. The robot is used to unload molded parts from the injection
molding machine.
Machining operations: The robot is used to load raw blanks into the
machine tool and unload finished parts from the machine. The
change in shape and size of the part before and after machining often
presents a problem in end effector design; and dual grippers are
often used to deal with this issue.
Heat treating: These are often relatively simple operations in which
the robot loads and/or unloads parts from a furnace.
Forging: The robot is typically used to load the raw hot billet into the
die, hold it during the forging blows, and remove it from the forge
hammer. The hammering action and the risk of damage to the die or
end effector are significant technical problems. Forging and related
processes are difficult as robot applications because of the severe
conditions under which the robot must operate
Part Selection and Transfer Robot

Palletizing Robot
Packing Robots Machine Loading Robot

Assembly Application of Robot
Assembly robots are used for lean industrial processes and have expanded
production capabilities in the manufacturing world. An assembly line robot
can dramatically increase production speed and consistency. They also save
workers from tedious and dull assembly line jobs.
End of arm tooling can be customized for each assembly robot to cater to the
manufacturing requirements. Additional options, like robotic vision, can also
be incorporated to improve efficiency and accuracy of part orientation or
sorting identifiers.

Assembly Application of Robot
Applications for robotic assembly include automotive components, like
pumps, motors and gearboxes. Computers and consumer electronics are
another excellent area, as are medical devices and household appliances.
Assembly robots are ideal for tasks demanding speed and precision like
applying sealants and adhesives. Not only can they put together parts that are
too small or intricate for a human, but they work quickly and accurately
without tiring or making mistakes. They are good in applications where
cleanliness is paramount, like pharmaceuticals and medical device assembly,
and they aren’t prone to debilitating injuries, like carpal tunnel syndrome, that
come with repetitive work.

Processing Operation - Application of Robot
In this application, the robot requires a tool to perform a process on the
work part. Things such as spot welding, spray painting and continuous
arc welding are carried out. An example would be that the robotic arm
positions a spot welder against a car panel and frames to complete the
assembly of the basic car body. Arc Welding is a continuous process in
which the robot moves the welding rod along the seam to be welded.
Then spray painting involves the manipulation of a spray painting gun
over the surface of the object to be coated. Some other applications in
this category include polishing, grinding and routing.

Assembly and Inspection - Application of Robot
There can be a high labor cost associated with manual labor in this type of
application. This is why there has been a sharp increase in the use of
robots for assembly and inspection. Robots can be programmed to
assemble in a specific style and reprogrammed to produce a different
product style in an alternative assembly cell. Saving time and money in the
long run. whilst upskilling staff to work alongside the robots and creating
more jobs too.
The design of a product is a key aspect when using robots for assembly.
Methods that work for humans do not necessarily work for robots. Using a
screw and nut as a fastening method is easily performed manually but
much more difficult for a one armed robot. The use of robots for inspection
is a growing area, a sensor is used to determine whether or not the parts
consistently
09/01/2024
meet quality specifications.
Department of Mechanical Engineering | Dr. Keerthi Kumar N 46
Advantages of Robot
 Increased efficiency: Industrial robots can complete certain tasks
faster and more efficiently than humans as they are designed and
built to perform them with higher accuracy. This combined with the
fact they are used to automate processes which previously might
have taken significantly more time and resource results in the use of
industrial robots to increase the efficiency of production lines.
 Improved quality: Given their higher levels of accuracy, industrial

robots can be used to produce higher quality products which result in
the reduction of time required for quality control and ensures that
standards of quality are adhered to.
Advantages of Robot
 Improved working environment: Some tasks are deemed as too
dangerous or laborious and repetitive for humans to carry out and so
instead robots can perform these tasks instead. Working conditions,
therefore, can be vastly improved as well as the safety within
factories and production plants by introducing industrial robots.
 Increased profitability: The results of introducing industrial robots

can only ensure higher profitability levels with lower cost per product
as by increasing the efficiency of your process reducing the
resource and time required achieving higher quality products,
introducing industrial robots save money in the long run.
Advantages of Robot
 Longer working hours: As human breaks in the working day are
required, distractions happen and attention spans slow. Whereas
robots can work 24/7 and keep working at 100% efficiency. On
average a 40% increase in the output of a production line occurs
when one key person is replaced by a robot who operates the same
working hours, simply because of stamina. Also, robots don’t take
holidays or have unexpected absences.

Disadvantages of Robot
Capital cost: Implementing industrial robots can incur a high capital cost
however, they do prove highly effective and bring a positive ROI.
Expertise: The initial set up of industrial robots requires a lot of
training and expertise as with any other type of technology, this is
because they are excellent for performing many tasks.

Thank You

Robotics

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BMS INSTITUTE OF TECHNOLOGY AND MANAGEMENT

Robotics is a multidisciplinary engineering field dedicated to the

An industrial robot is a general purpose, programmable machine possessing

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 4

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 7

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 9

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 10

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 11

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 12

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 13

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 14

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 15

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 16

 The manipulator of a robot consists of series of joints and links. Robot

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 18

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 20

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 21

Disadvantages Cylindrical Configuration :

3. Polar/Spherical configuration: this

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 28

Spot Welding: Robots perform spot welding very accurately, with

Investment Casting: Investment casting requires duplication,

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 34

Hazardous work environment for humans: When the work

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 36

The term material handling encompasses a wide variety of product

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 37

Packaging robots are extremely flexible and easy to integrate into a

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 38

Part Selection and Transfer Robot

Packing Robots Machine Loading Robot

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 43

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 44

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 45

 Improved quality: Given their higher levels of accuracy, industrial

 Increased profitability: The results of introducing industrial robots

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 49

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 50

09/01/2024 Department of Mechanical Engineering | Dr. Keerthi Kumar N 51

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