CHAPTER 2

LITERATURE REVIEW

This chapter will be provided the literature review of the “Pick and Place
Robot for Inserting Load with Position Control”. In literature review, robotic
automation, social impact, overview of robots that are used in industrial automation
and conveyor system are described. Also, illustration of the robot drive systems, and
the key components of robot are illustrated. There are many types of pick and place
robot arm. Therefore, this chapter also describes the review of the paper relevance
with the pick and place robot arm. All of these are explained in this chapter.
Hegde, G. S. [1] defined that “A robot is a mechanical device with links and
joints, guided by sensors, driven by actuators and controlled through programmed
software, to handle and manipulate parts, materials, tools and devices for performing
various tasks in variety of work environments”.

2.1. Social Impact

Replacement of the conventional machinery by industrial robots has a
transforming impact on the industrial society, especially direct labour, in the form of
displacement, conversion and change in the employment pattern, and also training and
education system is also to be modified. The management is inclined to opt for
introducing robots in the industry, biased by the derived benefits like higher
productivity and flexibility. Robotics has stretched its hands in various industrial
fields like assembly of parts, material handling, welding and spray painting,
irrespective of environs of operation hazardous or non-hazardous in nature. The
impact of robotics can be studied and analysed under the following sub headings.

2.1.1. Impact of Robotics on Direct Labour

A robot performing multiple tasks, can be a substitution for more than one
human worker leading to the displacement, shift of direct labour to indirect labour
activities and change in strategy in the appointment of new workers. The setup of the
work-space and operating the robots need the education and training the direct labour
in conversion to indirect labour, which involves diversion from direct manual
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participation in the production work performed. The change from direct to indirect
jobs is subjected removal of high degree of skill, monotony and organization of
activities in the conventional work area occupied by non-robotic machines. The new
workers appointed in a robot installed industries need to be knowledge in installing
programming, inspecting, trouble shooting and maintenance of the industrial robots.
The knowledge content, the technological skill and the education standard of the
operator has to be improvised as the expertise needed in a robotic cell has to match
consistently. The job opportunities open up in the robot manufacturing industries for
the upgraded technical human skills.
To counter the unrest among the workers the labour unions have to be taken
into confidence through sufficient prior notice, minimum-careful-displacement, new
technology adaption training and guidance, also convincing the security of job is a
serious task as well.

2.1.2. Professional Adjustment Impact

The professional and semi-professional forces in a conventional industry are
adjusted to age old techniques like process plans, try outs, personal management,
quality control, rigorous testing procedures and material movements. With the advent
in automation they have to be familiar with and expertized in computer programming,
alternating the software, robot maintenance, optimization of processes, system
analysis, product planning etc. The engineers from specialization in machine design,
machine tool technology, control system engineering, electronics and computer
science can fulfil the need of professionals in the robotic industries.

2.2. Overview of Robots

The general understanding about the robotics applicable in industries in
particular are discussed in detail in the following sub-headings.
 Degree of Freedom: The translator and rotary motions of the arms of the
robots.
 The Reference Frames: The Cartesian frames attributed to the base, joints and
the tip of the robot arms.
 Robot Joints: The type of arm connections between which different types of
motions are, like linear and rotational, possible.
 Configurations: The total set of movements of the robot manipulators of
different types generally available in the industry.
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 Robot Components: All possible types of components used in the industrial

robots, which constitute them in complete.
 Robot Specification: The characteristics that has to be incorporated while
designing and selection of the components, also to be considered while
purchasing it.
 Modes of Programming and Control: The modes of programs and languages
to produce a controlled action in robot for the robot to function effectively.

2.2.1. Degree of Freedom

Degrees of freedom, in a mechanics context, are specific, defined modes in
which a mechanical device or system can move. The number of degrees of freedom is
equal to the total number of independent displacements or aspects of motion. A
machine may operate in two or three dimensions but have more than three degrees of
freedom. The term is widely used to define the motion capabilities of robots.
Robot’s freedom of motion is in three-dimensional space-specifically, the
ability to move forward and backward, up and down, and to the left and to the right.
For each degree of freedom, a joint is required. A robot requires six degrees of
freedom to be completely versatile. Its movements are clumsier than those of a human
hand, which has 22 degrees of freedom.
In this research, the position control has been based on the 3 degrees of
freedom articulated robot in which one degree of freedom is for base rotation; the
second degree of freedom is shoulder rotation and the third for elbow rotation.

Figure 2.1. Degree of Freedom of the Robot [12]

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2.2.2. The Reference Frames

There are three types of reference frames attributed to the robot structure.
 Base Reference Frame: The basic x, y and z axes are the three axes of the
base. The base may be fixed or rotate about the z-axis according to the
need of the application. The base reference frame is the universal frame of
reference for a robot which is depicted as in figure 2.2.

Figure 2.2. Base Reference Frame [1]

 Joint Reference Frame: The reference axes defined at the joints of the
robot are called the joint reference frame. The joint can have both
translator and rotational movement about it defined axes. In this case the
frame is not fixed. The joint frame is shown in figure 2.3.

Figure 2.3. Joint Reference Frame [1]

 Tool Reference Frame: This is the local frame of reference defined by the
axes at the arm tip or the robot hand. The tip or the tool reference frame is
related to the base reference frame by the transformation of the
coordinates.
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Figure 2.4. Tool Reference Frame [1]

2.2.3. Robot Joints

The robot joints are made to produce motions which can be linear, rotary or
spherical in nature. The joints that give linear motion are known as ‘prismatic joints’,
and the joints producing rotary movements are named as ‘revolute joint’. The joints
that produce multiple rotations are ‘spherical joints’ which are uncommon in
industrial applications.
The motion to the joints can be given by hydraulic, pneumatic or electric
drives. The hydraulic or pneumatic drives can take higher payloads and for light
payloads the electric drives are sufficient. The most of the industrial application
robots have either prismatic joints or the revolute joints as the incorporation of the
drives in these kinds of joint is easy and the control of the drives is simple.

2.2.4. Robot Configurations

The possible types of movement that a robot can provide define the
configuration of a particular robot. The different configurations of different robots
help in positioning of the robot hand in the defined coordinate of the work envelope.
If ‘P’ represents the prismatic joint and ‘R’ represents the revolute joint then a robot
with three prismatic and 2 revolute joints is configured as 3P2R robot.

2.2.4.1. Cartesian (3P) robot

This type of robots has three degrees of rigid body freedom. They have three
prismatic joint which produces three linear motions in x, y and z directions. Cartesian
robots typically consist of three or more linear actuators assembled to fit a particular
application. Positioned above a workspace, Cartesian robots can be elevated to
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maximize floor space and accommodate a wide range of work-piece sizes. (When
placed on an elevated structure suspended over two parallel rails, Cartesian robots are
referred to as “gantry robots.”) Cartesian robots typically use standard linear actuators
and mounting brackets, minimizing the cost and complexity of any “custom”
Cartesian system. Higher capacity units can also be integrated with other robots (such
as articulated robots) as “end- effectors” to increase system capabilities. That said, the
custom nature of Cartesian robots can make design, specification, and programming
challenging or out of reach for smaller manufacturer intent on a “DIY” approach to
robotics implementation. Cartesian robots are unable to reach into or around obstacles
easily. And their exposed sliding mechanisms make them less suited for dusty/dirty
environments.

Figure 2.5. Cartesian Robot [13]

2.2.4.2. Cylindrical (2 PR) robot

This type of robots has two prismatic joints and one revolute joint. The two
prismatic joints given linear movements about any two axes and the third movement,
rotation is produced by the revolute joint. The robot can be placed in the middle of a
workspace and, because of its rotation element, it can work anywhere around it.
Simple applications where materials are picked up, rotated and then placed work best
for Cylindrical robots. Installation and use are not complex, and they come as fairly
complete solutions with minimal assembly.

Figure 2.6. Cylindrical Robot [14]

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2.2.4.3. Articulated/Anthropomorphic robot (3R)

The robots of this type have three revolute joints giving three rotary
movements resembling the human hand. The axes of the revolute joints can be
parallel or orthogonal to each other with some pairs of joints parallel and others
orthogonal to each other.
Articulated robots have a base called as waist which is vertical to the ground
and the upper body of the robot base is connected to the waist through a revolute joint
which rotates along the axis of the waist. Another link is also connected to the waist
through a revolute joint perpendicular to the waist joint. This joint between the waist
and the link is called as Shoulder of the articulated robot and the link may be called as
the Arm.
One more link is connected to the arm through a revolute joint parallel to the
shoulder joint. This joint with the arm forms the elbow of the articulated robot.
Finally, a wrist and a gripper are attached to the last link. The structure of the
articulated robot with three revolute joints is very much similar to the human arm.

Figure 2.7. Articulated Robot [15]

2.2.4.4. Spherical (2RP) robot

Two revolute joints and one prismatic joint characterize this type of robot in
which there is one linear and two rotary movements produced at the joints, connected
to a singular base with a twisting joint. This results in a spherical-shaped work
envelope and range of motions. Apart from gas and arc welding, polar robots are also
used in environmental monitoring, planetary and underwater exploration, and
rehabilitation and physical therapy machines.
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Figure 2.8. Spherical Robot [16]

2.2.4.5. Selective compliance assembly robot arm

This is a specially configured robot which has two horizontal and parallel
revolute joints with the axis vertical and one prismatic joint which can move the arm
vertically up and down. SCARA robots offer a more complete solution than the
Cartesian or Cylindrical.
They are all-in-one robots, meaning a SCARA robot is equipped with x, y, z
and rotary motion in one package that comes ready-to-go, apart from the end-of-arm
tooling. The work envelope is similar to cylindrical robots but it has more degrees of
motion in a radius or arch-shaped space. Applications are also similar to Cylindrical
and Cartesian robots, but SCARA robots can move quicker than the other two. Often
used in high-speed assembly operations, packaging, and pick and place machines.

Figure 2.9. SCARA Robot [17]

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2.2.5. Robot Specifications

Any standard product has to be designed and marketed under certain requisite
specifications or characteristics which aids in making decision to select and categorize
it. Definite specifications that an industrial robot should bear are the maximum load
carrying capacity the repeatability or accuracy, the precision and the maximum and
minimum reach defining the work space.
 Payload: The rated load carrying capacity of an industrial robot is defined by
its weight of the object or the tool held by the gripper, without affecting
other functional characteristics like allowed tip deflection, control of motion
along defined path etc. The overload may lead to the malfunctioning of the
robot systems.
 Repeatability: The accuracy with which the particular defined position can
be repeatedly achieved by a robot is the repeatability. To arrive at the
repeatability of a robot the statistical procedure of distribution of the
positions have to be recorded and analyzed and the estimated error has to be
adjusted through programming the repeatability is affected by the condition
of the robot components also. The error in robot positions can give a random
picture also, which has to be defined by the experimentations.
 Precision: The reach of a position of a robot is defined by the resolution of
the actuators and the control feed-back systems. The robot precision is given
in length units.
 Reach: The lengths of the links the configurations define the reach of an
industrial robot. The maximum and the minimum extents of the robot
positions given an idea about the reach of the robot, which is also useful in
the specification of the work-envelope of the robot.

2.3. Need for Robots

Accuracy aspect: The robots can perform tasks with highest accuracy,
repeatability and the finish is of high quality.
Environmental aspect:They can operate under the environments hazardous to
human being.
Human aspect: The human error is eliminated by using robot. Human
beings cannot work round the clock without fatigue.
Skill aspect: The robots controlled by computer program can execute
the tasks with better skill than human being.
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Performance aspect: Productivity is enhanced by induction of robots. They

can produce better the performance and the efficiency
than human being.
Automation aspect: The highest technology component of automation in the
robot can give a competitive edge in the international
level.

2.4. Robot Drive Systems

The links of the robots move about the prescribed axis by receiving the power
through, what are called the drive systems also known as actuators. The movements
produced may be translator in nature or rotary about a joint. At the joints the actuators
provide required force or torque for the movements of the links. The movement of all
the links, combined together from the arm end or wrist motion. The source of power
for the actuators can be through the compressed air, pressurised fluid or the
electricity, based on which they are classified as follows.

Actuator
Actuator

Hydraulic
Hydraulic (Uses
(Uses Pneumatic
Pneumatic (Uses
(Uses Electric
Electric (Uses
(Uses
pressurized
pressurized fluid)
fluid) compressed
compressed air)
air) electric
electric current)
current)

Reciprocating
Reciprocating Reciprocating
Reciprocating
Rotary
Rotary Type
Type Rotary
Rotary Type
Type
Type
Type Type
Type

Servo
Servo Stepper
Stepper Direct
Direct Drive
Drive
Motors
Motors Motors
Motors Motors
Motors

Produce
Produce Rotational
Rotational Movement
Movement

Translatory
Translatory movements
movements are
are produced
produced by
by
mechanical
mechanical transformation
transformation

Figure 2.10. Robot Drive System [1]

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2.5. Conveyor System

A conveyor system is a common piece of mechanical handling equipment that
moves materials from one location to another. Conveyors are especially useful in
applications involving the transportation of heavy or bulky materials. Conveyor
systems allow quick and efficient transportation for a wide variety of materials, which
make them very popular in the material handling and packaging industries. They also
have popular consumer applications, as they are often found in supermarkets and
airports, constituting the final leg of item/ bag delivery to customers. Many kinds of
conveying systems are available and are used according to the various needs of
different industries. Industrial conveyors have many different designs and uses.
The most common types of industrial conveyors are:
 Belt conveyor
 Gravity roller conveyor
 Chain conveyor
 Live Roller conveyor / CDLR
 Slat conveyors
 Beam trolley systems
 Overhead conveyor
 Power and Free conveyors
 Over Under conveyors
Manufacturing engineers include conveyors in their production facilities for a
variety of reasons:
 Moving products from point A to B (to avoid wasted time walking, or to
reduce movements of forklifts, etc.)
 To carry products that are too heavy to be lifted manually
 To simultaneously move a product while operators are working on it (or
adding to it). Like a final assembly conveyor at an auto plant
 To present products to a robot for processing, or to receive products from
a robot that have been processed
 To store products in between processes or at the final process step
 To avoid injury to workers from repetitive movement, and to prevent
damage to products caused by movement
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 To sequence or re-sequence products in between processes. Conveyor

types like power and free conveyors can provide this.
SAEED B. NIKU et al. [2], “Introduction to Robotics Analysis, Control,
Applications”.
 In this book, studied about the basic principle of control systems, how they
are analyzed, and how they may be designed.
 A variety of different actuating system.
 A variety of different sensors used in conjunction with robots and robotic
application.
Rudresh. H. G. et al. [3] showed that the colour-sensor based object sorting
robot. Their Project deals with an automatic material handling system. It coordinates
the movement of robotic arm pick the items moving on the conveyor belts. It aims in
organizing the coloured objects which are approaching on the conveyor by picking
and placing the objects in its separate located place. There by reducing the tedious
work done by human, accomplishing accuracy and rapidity in the work. Their project
includes colour-sensors that sense the items colour and lead the signal to the
controller. The microcontroller guides signal to the motor driving circuit which drives
the different motors of the robotic arm to grasp the object and place it in the correct
location. Depending up on the colour sensed the robotic arm go to the correct location
to releases the object and comes back to the normal potion.
Dharmannagari Vinay Kumar Reddy. et al. [4]. He studied on sorting of
objects based on colour by pick and place robotic arm and with conveyor belt
arrangement. This research aims at the problem he was attempting to solve was to
create an autonomous robot that could identify objects when placed on the conveyor
belt based on color sensing and then sort by relocating them to a specific location. It
would be using a picking arm which uses a controller motor to pick the particular
object from the conveyor belt and place it according to the color sensing. Micro
controller (AT89S52) allows dynamic and faster control. Liquid Crystal Display
(LCD) makes the system user-friendly. AT89S52 Micro controller is the heart of the
circuit as it controls all the functions.
S. V. Rautu et.al. [5]. He expounded on sorting of objects based on colour,
weight and type on a conveyor line using PLC. They have proposed an efficient
method which uses load cell, inductive sensor and TCS 230 colour sensor for
identifying and segregating on the basis of weight, colour and type (metal or non-
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metal) of object and Siemens 300 Series PLC to control the overall process of sorting
two types of objects. The system rejects and discards objects that are not of required
characteristics by pushing them out of conveyor line using a flipper mechanism. A
circular container, having three partitions is used to collect objects of three different
colours. Two conveyor belts were used, each controlled by separate DC motors. The
first belt is for placing the product to be analysed by the load cell and inductive
sensor, which also contains a colour sensor at the end for one type of segregated
object and the second belt also, has a colour sensor for the components separated by
the load cell and inductive sensor.
Puran Singh. et al. [6] discussed that design of a robotic arm with gripper &
end effector for spot welding. In this paper propose of this robotic technology makes
the spot-welding operation more flexible and time oriented. With the help of pick and
place mechanism the material handling has been easily carried out. The variation in
the mechanical structure and the angle of movement can be changeable. The human
hand design forms the basis of this project of developing a robotic gripper and is the
source of inspiration to achieve the sufficient level of dexterity in the domain of
grasping and manipulation if coupled with wrist and arm.
Vijay Kumar. et al. [7] described that the design and implementation of a
robotic arm based on haptic technology. In this paper, various aspects to design a
robotic arm based on the haptic technology considering various aspects of it, and the
basics of machine designing are observed that are explained clearly. These robots
have a wide range of industrial and medical applications such as pick and place
robots, surgical robots etc. They can be employed in places where precision and
accuracy are required. Robots can also be employed where human hand cannot
penetrate. The screen shot shows the designed robot and its functionality.
In this paper, a robotic arm with four degrees of freedom is designed and is
able to pick the objects with a specific weight and place them in a desired location. To
facilitate the lifting of the objects, Servomotors with a torque of 11 kg are used. The
programming is done on ATMEGA328 Microcontroller using Arduino programming.
The Microcontroller along with input pins is soldered on a PCB board. The input is
given using a remote, which is an arm, made of Polycarbonate fitted with
Potentiometers with a certain angle of rotation. The Potentiometers detect the angle of
the rotation and the signals are sent to the Microcontroller accordingly.
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This kind of the arms have many applications in the field of industrial robotics
where the automation is required. This Haptic Robot arm is used for various
applications, of them few are as follows:
 To lift heavier objects.
 To lift nuclear wastes without harming the humans.
 Prototype for a Bomb disposal robot.
Mohammad Javed Ansari. et al. [8] expressed to designing and developing of
a microcontroller (ATmega) based robotic arm has been described. The robotic arm
responds to the gesture as well as can be programmed to go along a definite path and
task. The system feels the movement of user’s arm and robotic arm replicates the
given input gesture. The gesture is sensed by a number of potentiometers which are
embedded onto a glove. The movement in potentiometer regulate the position for the
servo motors driving the parts of the arm.
Hye-Jong Kim. et al. [9] reported that the development of an inflatable robotic
arm system controlled by a joystick. In this paper, the author presented an inflatable
robotic arm controlled by a joystick to be used for healthcare applications. The arm is
constructed almost entirely of plastic elements: inflatable links, air bag actuators, and
acrylonitrile butadiene styrene (ABS) joints. It is softer and lighter than typical
robotic arms that are made of metal and heavy elements. A new control method is
proposed to be controlled with a joystick. Here an inflatable robotic arm with four
degrees of freedom (4 DOF) to obtain experimental results for the control
performance of the inflatable robotic arm.
Tae Mun Park. et al. [10] proposed a new concept of force feedback. The
system can overcome the bottlenecks of other feedback system in a user-friendly way.
Force sensor and laser distance sensor communicates the information from the
gripper's position to the teleoperator by using force feedback module on a glove.
Pneumatic pressure gives the operator distance information, while a
Magnetorheological Fluid (MR-Fluid) based actuator presents the gripper's force. It
shows the possibility of usage of such force feedback glove in combination with a
robotic arm.
G. Sen Gupta. et al. [11] revealed that the wireless master-slave embedded
controller for a teleoperated anthropomorphic robotic arm with gripping force
sensing. He described the effectiveness of the proposed method is available robotic
arm which is controlled by a prototype 6-DOF master unit. The robotic arm mimics
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the dexterity of the human hand and wrist. The prospective master control unit is cost-
effective and will have wide ranging applications in the fields of medicine,
manufacturing, security, extreme-environment, entertainment and ROV teleoperation
in undersea improvement or extra-terrestrial exploration vehicle.