Computer Integrated Manufacturing 2020

Module 4
ROBOT TECHNOLOGY

Robot is an automatically controlled material handling unit that is widely used in the
manufacturing industry. Robots are generally used for high volume production.

The term Robot was derived from Czech language in 1920 which means forced labor. The
official definition for the robot was given by Robot Institute of America (RIA).

Definition: "An industrial robot is a re programmable, multifunctional manipulator

designed to move materials, parts, tools (or) special devices through a variable
programmed motions for the performance of variety of tasks."

ADVANTAGES AND DISADVANTAGES OF ROBOTS

ADVANTAGES:

1. Environmental Safety.
2. Suitable for Hazardous. (or) Uncomfortable working conditions.
3. Performs repetitive tasks.
4. Low material usage.
5. Can operate for longer periods.
6. Robots can perform the operations with a very high accuracy.
7. Robots can be reprogrammable.
8. Reduces inspection time.
9. Reduces human error.
10. Performs multiple tasks.

DISADVANTAGES

1. Initial investment cost is high.

2. Cannot make decisions.
3. Cannot adapt changes automatically.
4. Cannot learn from Experience.
5. Requires skilled programmer.
6. Requires proper maintenance.
7. Leads to Unemployment.

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ROBOT ANATOMY

Robot anatomy is concerned with the physical construction of the body, arm of the machine.
The various components of the Robot are shown in figure

 Most of the Robots used in the industries. are mounted on a base which is fastened to the
floor
 Body of the Robot is attached to the base.
 Arm assembly of the robot is attached to the body
 Arm assembly consists of a series of links and joints.
 The members of the robotic manipulator are called as links.
 Joints are mainly responsible for the relative motion between two links
 At the end of the arm assembly wrist is attached.
 The Body arm and wrist assembly is called as manipulator.
 A Hand is attached at the end Of the wrist, and is called as end effector
 End effector is not considered as the part of Robot anatomy

Robot Joints

The members of a Robotic manipulator are called as Links. The Links are connected
together by joints. The relative motions between the links are mainly due to joints.

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Depending on the relative motion between the two adjacent Links, Joints are classified into
four types:

1. Prismatic joints
2. Rotational joints
3. Twist joints
4. Revolute joints

Prismatic joints: If the relative motion between two links of a joint is linear then that
particular type of joint is called as Prismatic joint. Here two links are joined such that they
can slide with respect each other. There are two types of prismatic joints

(a) Linear joints

(b) Orthogonal joints:
Linear type prismatic joints are denoted by 'L.

Orthogonal type prismatic joints are denoted by '0'.

Rotational joint: If the relative motion between two links of a joint is rotary then the joint
is called as a Rotational joint. Rotational joints are denoted by “R".

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Twist joint: If the two links are in a straight line and if there is a twisting motion between
the two links, then the joint is called as Twist joint. Twist joints are indicated by Letter “T'

Revolute joint: If the two links are perpendicular to each other and if one link revolves
around another link then the joint is called as revolute joint. Revolute joints are indicated by
“V”

ROBOT CONFIGURATION

Robot configuration specifies the possible movements provided by different robots. The
majority of present commercially available robots possess one of these four basic
configurations.

1. Polar Configuration.
2. Cylindrical Configuration.
3. Cartesian co-ordinate configuration.
4. Jointed arm Configuration.

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Polar Configuration (T-L-L Configuration)

 Polar configuration uses a telescopic arm that can be raised or lowered about a horizontal
joint.
 This robot consists of one Linear prismatic joint (L), a Rotational joint (R) and a Twist joint
(T), and hence is also called as T-R-L Configuration.
 These joints provide the robot with the capacity to move its arm in spherical space and hence
this robot is sometimes called as spherical coordinate robot.
 The workspace within which the polar configuration robot moves its arm will be spherical in
shape.
 Most of the commercially available robots possess polar configuration.
 Example: UNIMATE 2000 Series, MAKER 110.

Cylindrical Co-ordinate configuration (T-L-O Configuration)

 Cylindrical configuration robot consists of a vertical column and a slide which can be moved
up or down along with the column.
 The robot arm is attached to the slide so that it can move radially with respect to the column.
 By rotating the column, the robot can be able to achieve the workspace similar as cylinder.
 Cylindrical configuration robot consists of one Twist joint (T), one orthogonal prismatic
joints (0) and one linear prismatic joint (L) and hence is also called as T-L-0 configuration.

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 This type of robot has a rigid structure with a very high load carrying capability.
 A cylindrical configuration robot has very high repeatability with least error.
 Example: MIA- developed by GM.

Cartesian co-ordinate configuration (L-O-O Configuration)

 Cartesian co-ordinate robot consists of three perpendicular slides arranged in x. y and z

directions.
 By moving these three slides relative to one another the robot is capable of operating within a
rectangular work area.
 Cartesian co-ordinate robot is also called as xyz robot, rectilinear robot (or) Box configuration
robot.
 This configuration robot consists of one Linear prismatic joint (L) and two orthogonal
prismatic joints (0) and also called as L-0-0 configuration robot.
 Example: IBM RS-I

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Jointed Arm co-ordinate configuration (T-R-R Configuration)

 Jointed Arm configuration is similar to human arm.

 It consists of two straight components that correspond to human fore arm and upper arm.
 These components are connected .by two rotary joints corresponding to the shoulder and
elbow of a human.
 A wrist will be attached at the end of the arm.
 The workspace within which this robot can move its arm is irregular.
 Jointed arm configuration consists of no prismatic joints, but has two Rotary joint's (R) and
one Twist joint (1') and hence is also called as T-R-R configuration.
 This type of configuration has higher reach from the base.
 They are useful in continuous path generation and in applications like spray painting and
welding.
 Example: SCARA, Milacron T3

SCARA.

 The term SCARA is an acronym that stands for Selective Compliant Assembly Robot
Arm.
 It is ideal for high-speed assembly, packaging and other material-handling applications.
 The SCARA arm behaves somewhat like the human arm. However, the SCARA arm has
limited motion at the wrist; it can rotate but it cannot tilt. The limited motion of the wrist
is advantageous for many types of assembly operations such as pick-and-place, assembly,
and packaging applications.

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ROBOT SPECIFICATIONS

The Robot is mainly specified according to the type of drive system, work volume and type
of control system.

The other characters which are used to specify the Robots are:

1. Number of Axes 5. Operating environment •

2. Capacity 6. Performance Parameters.
3. Speed 7. Work volume
4.
Reach and Stroke 8. Type of drive systems.
1. Number of axes:

This specifies the number of independent degrees of freedom that (each part of the robot)
wrist end can manipulate.
2. Capacity:
 It refers to the load carrying capacity of the Robots.
 Higher the load carrying capacity lowers the accuracy.
 Capacity of the robot depends on the type of drive system used.

3. Speed

It refers to the distance moved by the tool in unit time. i.e, it refers to the time required to
execute a specific task.
4. Reach and stroke

 The distance covered by the end of' the wrist to the center of the body of Robot is
Called as Reach.

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 The distance covered by the wrist and along with the corresponding link without touching
the work part is called as stroke.
 Stroke is the maximum distance covered by the wrist end of the robot.

5. Operating environment
 It represents the environment where a robot can work effectively.
 Some of the different types of working environments specified for robots are

 Complex and contaminated • Ordinary and workable

 Extremely clean and dustless • Hot and Hazardous.
6. Performance Parameters
 The performance of Robot is measured in terms of Precision of Robot's movement
 The Robot's precision can be defined as the function of three important factors
 Spatial Resolution
 Accuracy
 Repeatability
7. Spatial Resolution
It refers to the smallest possible movement which a Robot can move in its work volume
Spatial resolution depends on two factors
 Control Resolution
 Mechanical Inaccuracies

(a) Control Resolution

The capability of a Robot to divide its work volume into smallest possible increments is
called as Control Resolution. These increment are also referred as addressable points.

(b) Mechanical inaccuracies

Inaccuracies in the Robots links and joints will have a effect on the spatial resolution.
Hydraulic fluids and other imperfections will tends to reduce the Resolution of the robot.
Mechanical inaccuracies will depend on factors like

 Load carrying capacity

 Speed
 Maintenance factors
These inaccuracies will be very high in larger robots than in smaller robots.

Accuracy

The ability to position the wrist end at a desired target with in Robots work volume is called
as Accuracy.

 Accuracy will be less when the robots links are in fully extended position

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 Accuracy will be very less when load carrying capacity is very high and when
speed is very high.
 Higher the resolution, higher the accuracy.

Repeatability

The ability to position the wrist of the robot at-the same point again and again is called
Repeatability

ROBOT MOTIONS

Industrial Robots are designed to perform productive work. The work is accomplished by
enabling the robot to move its body, arm and wrist through a series of motions and positions.

The movements in a robot are divided into two categories.

1. Arm and body motions

2. Wrist motions.

Arm and body motions

The arm and body movements are designed to enable the robot to move its end effector to a
desired position within the limits of the robot's size. Figure illustrates the different types of
Arm and Body motions that are associated with the robots.

(a) Vertical Traverse: The capability to move the wrist up (or) down to provide the desired
position in vertical direction is called as Vertical Traverse.
(b) Radial Traverse: The extension (or) retraction of the arm to position its wrist is called as
Radial Traverse.
(c) Rotational Traverse: The rotation of the arm about the vertical axis is called as Rotational
Traverse.

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Wrist Motions

Wrist motions are designed to enable the robot to orient the end effector properly with respect
to the task to be performed. Figure illustrates the different types of wrist motions associated
with the robot.

(a) Wrist roll: This involves in the rotation of wrist mechanism about arm axis. Wrist roll is
also called as "Wrist Swivel"
(b) Wrist pitch: This involves in the up and down rotation of the wrist. Wrist pitch is also
called as "Wrist Bend".
(c) Wrist yaw : This involves in the right or left movement of the wrist

WORK VOLUME

Work volume represents the space within which the robot can manipulate its wrist end.

The work volume is determined by the following physical characteristics of the robot

 Robot physical configuration.

 Size of the body, arm and wrist components.
 The limits of the robots joint movements.
 The work volume of a polar co-ordinate configuration robot is "Partial sphere'.
 The work volume of a cylindrical configuration robot is "Cylindrical"
 The work volume of a Cartesian co-ordinate configuration robot is "Rectangular
block"
 The work volume of a Jointed - arm - configuration robot is Irregular

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END EFFECTORS

In Industrial applications most of the work is done by additional devices called as Robot
peripherals. These robot peripherals include tooling which attaches to the Robots wrist.

End effectors are mainly classified into two types:

1. Grippers
2. Tools
Grippers

The function of a gripper is mainly to translate some form of power into grasping action of
the fingers. The power input either supplied by pneumatic, Hydraulic (or) electric means.

 Grippers include applications like Machine loading and unloading, picking the parts
from the conveyor, arranging the parts on the pallet and so on.
 Grippers are not only used to handle the work parts but also the raw materials.
 Grippers arc classified as Mechanical grippers and Non mechanical grippers
 Mechanical gripper’s uses mechanical fingers which are used to grasp the object. The
fingers are also called as Jaws. The different types of mechanical grippers are shown in
figure.
 Non-mechanical grippers do not possess jaws to handle the objects, but are used to
handle specific shapes of work parts. The different types of Non-mechanical grippers are
Vacuum cup grippers, Adhesive grippers, Magnetic grippers, Hooks and so on.

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Tools as end effectors

Some of the tools used as end effectors in robot applications include:

 Spot-Welding tools
 Arc Welding torch
 Spray painting Nozzle
 Drilling operations
 Grinding
 Water jet cutting tools
 Heating torches

ROBOT SENSORS

The interaction of the robot with the environment needs certain mechanisms known as sensors.
Robot sensors perform several functions like identification of objet, guiding the robot without
obstruction, identification of path, Object avoidance and so on.

There are basically two types of sensors

1. Internal sensors
2. External sensors

Internal sensors are used to provide the information like joint position, velocity, acceleration etc.
Orientation, speed.

External sensors provide the information about the external environment surrounding the robot.

External state sensors are used for Robot navigation, Object identification, Object handling and
many other functions.

There are two types of external sensors: Contact sensors and Non-contact sensors

During its function, Contact sensors will have physical contact with the object (or) surroundings
before providing the information. Non-contact sensors will not have anyphysical contact with
the objects (or) surroundings.

The different types of contact sensors are:

 Touch sensors
 Slip sensors
 Force and Torque sensors

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The different types of Non-contact sensors are

 Range sensors
 Proximity sensors
 Vision sensors

Touch Sensors

Touch sensors are used in the end effector fingers (jaws). These sensors are used to indicate
whether a contact has been established with the object or not. Also these sensors indicate the
presence of the object within the fingers of the end effector. These sensors act as a simple micro
switches.

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Slip Sensors

Slip sensors are arranged at the outer surface of the Robot.

These sensors are used to specify the contact made by the external objects and also determines
the force of contact.

Force and Torque Sensors

Force and torque sensors are primarily used for measuring, the reaction forces developed at the
interface of mechanical assemblies. In robots, these sensors are used to measure the reaction
forces developed at the joints and wrists. These sensors are also called as wrist sensors.

A simple force and torque sensor, which is mounted at the tip of the robot arm and end effector,
is as shown in figure

These sensors consist of strain gauges which are connected to potentiometers.

Any deflections in the robot are recorded by using these strain gauges and the force can be
determined.

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Range Sensors

Range sensors are mainly used to measure the distance between a reference point on the
robot and the objects present in its workspace. Range sensors are mainly used for
navigation and obstacle avoidance. These sensors use photoelectric devices to determine
the distance.

A simple method of measuring the distance by a range sensor is shown in figure.

Here object is illuminated by a narrow beam of light by using a light source. After
reflecting from the object, the detector is used to sense the light. The distance between
the object and the robot is found by simple formula.

d = b tan

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Proximity sensors

Proximity sensors are used to indicate the presence of an object within a specified
distance/ interval without having a physical contact with the object.

There are different types of Proximity sensors

 inductive semors
 Ultra sonic sensors
 Hall effect sensors
 Photoelectric sensors

Inductive sensor works on the principle of inductance to determine the presence of the
object. The working of a simple inductive sensor is shown in fig.Inductive sensor
consists of a magnet and an electromagnetic coil placed inside housing. When there is
no metallic object near the sensor there will be no movement of flux lines in the
magnet.

Since there will be no movement in the flux lines, no current will be induced in the coil.
If a ferromagnetic object enters into the field of the magnet, the change in the flux lines
induces a current pulse, thus recognizing the presence of object etc.

V ision sensors
 These sensors are used to recognize the three dimensional object in the form of
picture. o

 These sensors are also called as. Robot vision, Machine vision, (or) Artificial vision.

 It is one of the important sensor technology with many applications in industrial

operations.

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ROGRAMMING THE ROBOT

Definition: Robot programming can be defined as the path followed by the robot manipulator along
with its peripherals to perform a specific work.

There are four types of programming methods through which robots can be programmed.

1. Manual Method.
2. Walk through Method (OR) Manual lead through
3. Lead through Method (OR) Powered lead through (OR) ON-line method
4. Off-Line Programming.
1. Manual Method:
 This method is used only for small robots and for simple applications.
 This method involves in setting up the machine rather than actual programming
 This method is accomplished by setting limit switches. Mechanical stops (or) relays to
control the robot motions.
 This method is mainly employed for low technology robots with short work cycles.
Ex: Pick and place robots.

2. Walk through Method (OR) Manual lead through Method.

 This method is employed for programming the robots with continuous path controls.
 In this method the programmer/operator manually move the arms of the robot through
a motion sequence.
 Each movement will be recorded in the memory for subsequent play back during
production.
 The speed of movements can be controlled (or) varied during actual playback.
 This method is used to program the robots performing spray painting and arc welding
applications.

3. Powered Lead through Method (OR) On-Line Programing Method

 This method is commonly used to program robots with point-to point control.
 A hand held control box called as teach pendent is used to drive the robot through its
motion sequence.
 A teach pendent is a small, hand held device which consists of various switches and
dials to control various movements of the robot.
 Each movement is recorded in robots control memory for future play back.

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Advantages of Lead through Programming:

 This method is relatively easy and simple.
 No a special programming skill (or) training is required to perform this method.

Disadvantages of Lead Through Programming:

 This method cannot be used for large and heavy robots.
 Complex movements like curves cannot be accurately achieved through this
programming
 This method requires lot of memory to store the data.

4. Off-Line Programming
 This type of programming is not accomplished on the shop-floor.
 Off-line programming is performed on a computer, and after the program has been
prepared, it is entered to the robot memory.
 The advantage of such programming is that the production time of the robot will not
be lost, as in case of other types of programming.
 Case of other types of programming.
 This type of programming can be integrated with various CAD / CAM systems.

APPLICATIONS OF INDUSTRIAL ROBOTS

Application areas of industrial robots have been categorized into the following seven areas.
 Material Transfer
 Machine Loading
 Welding
 Spray Coating
 Processing Operations
 Assembly
 inspection

Material Transfer

 Pick and place operations.

 Transfer of material from one conveyor to another conveyor.

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 Palletizing operation, where robot picks material from conveyor and loads on to the
pallet in a required dimension.
 Depalletizing operation.
The application of material transfer is one of easiest and most straight forward of robot
application. Robots used in this task do not possess high technology.

3. Machine loading:
 This is the process where a robot is required to supply raw material to the processing
machine and unload the finished parts from the machine.
 In case of machine loading, robot works directly with processing equipment and in case
of material transfer function it will not.
 Machine loading application will be very useful in case of Die casting, Injection Molding,
Hot forging, and in Machining Operation such as Turning, Milling etc.

3. Welding:

Welding is one of the important application area in case of Robotic applications. The
application in welding basically is divided into two categories.

(1) Spot Welding (2) Arc Welding

Spot Welding:
 It is a process where metal parts are fused together at localized points by passing electric.
Current through the two parts.
 This is done-with the help of two electrodes.
 Robot is used to hold the electrodes in such applications and through these electrodes
electric current is made to pass into the metal parts.
 This application is widely used in Automobile Industry.

Arc Welding:
Different types of Arc Welding can be performed by using Robots like

 GMAW - Gas Metal Arc Welding

 MIG - Metal Inert Gas welding
 TIG - Tungsten Inert Gas Welding

Most of the times, Arc Welding is performed by Human Workers (Welders), who must often
work under hot, uncomfortable and dangerous conditions.

So, in order to improve workers safety robots are used.

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Advantages due to robots in Arc Welding:

1.High productivity. i.e. operations can be done at faster rate.

2. Improved safety.

3. More consistent welds can be obtained. -

But, there is a major disadvantage, if robots are used in Arc Welding. Arc welding is used in case of
low volume production. So, if robots are used, the cost of investment will be very high.
4. Spray Coating
Many industries will be having some form of spray coating application. Initially human
workers used to do spray coating, which may lead to health hazards.

 Spray coating/painting creates toxic atmosphere.

 Noise is produced.
 May result in fire hazard
So, in this regard, workers are replaced by robots in spray painting.
Advantage, by using robots in spray painting:

 Safe in operation.
 Coating consistency
 Lower material usage.
 Less verification requirements.
 Greater productivity.

5. Processing Operations:

These are performed by a specialized tools attached to the robots arm. These tools can do
lot of operations like drilling, Riveting, Grinding, Polishing etc.

5. Assembly:
Robots are widely used for assembly operations in industries, which' may result in increased
productivity. Also, robots can do repetitive tasks continuously, in case of assembly
operations.
7. Inspection:

 This is the new application area of robot.

 Previously the inspection process was difficult and very slow and tedious.
 Workers usually perform sampling techniques rather than 100% inspection. Now a days as
the quality of products became very important, each and every Product must be
inspected, and this can be accomplished by a robot.

Here, robots are equipped with mechanical probes, sensors and other measuring devices to
perform inspection process.

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