HAADBOOH OA

ADVAACCD
ROBOTICS
DV EDWARD I. JAPPORD, JR.
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ROBOTICS
Other TAB books by the author :

No. 523 Guide to Radio & TV Broadcast Engineering

Practice
No. 939 Handbook of Marine & Electronic/Electrical Sys-
tems
No. 1071 The Complete Handbook of Robotics
No. 1093 Radio Control Handbook-4th Edition
No. 1135 Radio Control Manual— Systems, Circuits, Con-
struction— 3rd Edition
No. 1174 Model Radio ControlSrd Edition
No. 1201 The Complete Microcomputer Systems Handbook
No. 1222 Advanced Radio Control, including Rockets &
Robots— 2nd Edition
No. 1245 Electrical Wiring Handbook
No. 1287 How To Build, Maintain, and Renovate Your
Home
 No. 1421
$21.95

HAHDBOOK OP
ADVAACED
ROBOTICS
DV EDWARD I. SAPPORD, JR.

TAB TAB BOOKS Inc.

BLUE RIDGE SUMMIT. PA. 17214
FIRST EDITION

FIRST PRINTING

Copyright © 1982 by TAB BOOKS Inc.

Printed in the United States of America

Reproduction or publication of the content in any manner, without express

permission of the publisher, is prohibited. No liability is assumed with respect to
the use of the information herein.

Library of Congress Cataloging in Publication Data

Edward L.
Safford,
Handbook of advanced robotics.
Includes index.
1. Automata. I. Title.
TJ211.S24 629.8'92 82-5697
ISBN 0-8306-2521-6 AACR2
ISBN 0-8306-1421-4 (pbk.)
 Contents T

Introduction

Acknowledgments XI

Definitions, Examples, and Ideas

Teaching a Robot— Emulating Human Actions— Grivet-Robot
Arm Dynamics— Artificial Intelligence— Who Is Programmed and
Why?— The Human Memory Problem— More on the Grivet
Robot— Role of Mathematics in Robot-Arm Operation— What Is a
Task?— Giving the Robot Some Intelligence— The Robot
Diagnostics— Robot Communication— Costs— The Feedback Ac-
curacy— Speed of Operation— Safety— Robotic Speech-
Summary

The Domesticated Android 45

The Android Explained— Some Mechanical Considerations—
What Will a Domestic Android Do?— The Automated Kitchen
Concept— How to Prevent Things from Getting Out of Hand—
What about Robot Personality?— Nuclear Inspection Robot
Concept— The Security Android — Path Control Con-
siderations—A Timed Program for Path Control— Computerized
Path Control— More on the Microwave Motion Detector-Sensor

Use, Operation, and Construction

of a Radio-Controlled Robot 73
Examining the Inside of Garcan— Inside Base
the Robot
Structure— Operation of Garcan Electronics— The Garcan
Motor-Control Circuit
4 Robot Control Programming 109
A Preliminary Look at Machine Communication— What About the
3
Robot That Learns?— Teaching the Cincinnati Milacron T
Robot— Doing Other Jobs with the Cincinnati Milacron T 3
Robot— Subroutine Programming for a Robot— The Computer
Output for a Conditional-Branch Subroutine— Brief Boolean
Algebra Refresher— More About Robot Branching Operations—
The Robot's Searching Function— More on the Search
Function— Computer-Use Summary— Some Considerations of
Robot Design— Some Considerations in Programming a Mobile
Robot— Computer Languages for Robotics— The Multiarmed In-
dustrial Robot— Tests Adjustments, and Repairs

5 Programming the Prab Versatran Robot 145

Concerning Accuracy of a Positioning Servo-System —
Programming an Industrial Robot: The Prab Versatran

6 Robot "Hands" and Arm Kinematics 191

Comparison to the Human Arm and Hand— Some Schematic
Symbolism— Examination of a Robot's Arm Kinematics-
Powering the Robot's Arms— The Planet Robot "Armax"— The
Hydraulic Drive System for Robot Arms— The Pneumatic Power-
ing System— Other Methods of Powering Robotic Arms— Some
Considerations of the Programmed Robot— The Patchboard
Programmed Robot— Servomechanism Definitions and Con-
siderations—Series and Parallel Servomechanisms— Robot
Hands and Human Hands— Closed-Loop Servosystems and
Feedback— Eliminating the Error— Details of Electrohydraulic
Servosystem

7 A Computer-Operated Hobby Robot 239

Looking at the Arm Design and Operation— Some Notes on the
Gripper Operation— Operating the Stepping Motors— The
Computer-Control Output— The Computer Interface— The
ArmBasic Command Computer Language— Programming the
Mini-Mover 5 Robotic Arm— Robotic-Arm Accuracies and
Power— Communicating with the Robot— Multiplexing in Com-
munications Systems — Some Examples of Pulse Code
Modulation— Some Design Criteria of Telemetry Systems-
Communications Signals Needed— Current Sociological Thinking
about Robots— How Some Executives Determine the Need for
Robots

8 The ASEA Robot System 279

Description— A Simplified Description of the Linkage Motion-
Operation— Giving the Robot a Sense of Its World— The ASEA
Robot's World— Loss of Memory Possibility with Micro-
computers—Signal Transference in the ASEA Robotic Sys-
tem—Controlling the ASEA Robot— Teaching the ASEA
Robot— Programming the ASEA Robotic Arm— The Control
Panel— The Grippers— A Comparison of Gripper Powering
Units— Hydraulic-Activated Grippers— The Pneumatic
System— The Electrically Operated Gripper— Summary on Grip-
per Powering Methods— Gripper Sensors— Position Sensors for
Grippers— Summary on Gripper Sensors
 9 Robotic Eyes 347
The Quest for Improvement of Industrial Robots— The Milacron
Three-Roll Wrist— The Robotic Eye or Optics Control— The Vision
Window— Using the Matrix Eye— Some Basics of Robotic- Vision
Coordinate Determination— The Recognizer, the Computer, and
the Control System— The System Concept of G.E. Optomation—
The Camera Robot Interface— Decision Generation in the Opto-
mation System— Optomation System Operation— The Industrial
Video-Inspection System— The CID Camera Construction and
Operation— Following the Video Signal— What Is Feature
Extraction?— The Data Analysis Section

10 More on Robotic Vision and Speech 381

The Spatial Data Systems EyeCom II— The Interface
Controller— Using the EyeCom System in an Inspect- Reject-
Acceptance Mode— The EyeCom Digitizer Flow Operation-
Investigations of Robotic Eyes Attached to Grippers— A Note on
One Industrial Development Trend Using Robotic Vision— Is
There an Advantage to a Talking Robot?— Some General Rules
for Verbally Communicating with Robots— Some Considerations
of Automatic Speech Recognition by Machines— Texas Instru-
ments Developments in Speech Circuitry

11 Ranging Systems 411

Principles of Circuit Operation Polaroid Ultrasonic Range
—
System Using a Sound Ranging System in Robotic Ap-
plications—A Ranging System Using Light

12 Numerically Controlled Robotic Machines 419

Changing Tools and Range of Operations— Future of NC
Machines and Robotics

13 Ideas and Discussions 423

Laws— Types of Hobby Robots— Who?— Remote Control of
Hobby-Type Robots— Magnetic Control — The Mountain
Hardware Supertalker: SD200— Checking Errors in Data Trans-
mission and Some Robotic-System Problems— The TRS-80 and
the Outside World— Planning a Robot— After Mobility and
Steering, Then What?— More Cheap Speech— Costs and
Accomplishments— What Is the Critical Path Approach-
Consulting the Experts— Robots around the World— Jobs— The
Computerized Home and Its Security and Controls— Some Steps
in Robotic Design

Index 463
To my Parents.
 Introduction

Robotics is more than it is a reality. It means,

just a word,
something with computer-controlled
essentially, the doing of
machines. These machines are different. They are different
as people are different and are given to different likes and
dislikes, tasks and interests. There are some who say that
robotics is an art, the art of getting the impossible from
machines. There are others who say that robotics is a science,
the science of doing with uncanny quickness and precision,
tasks which we as humans can do, but don't like to do, or find it
very boring to do. Then, there is the impossible. In this
category we find chores where breathing is impossible, or
where we would burn up readily.
Recall a machine that cleans the hulls of large ships: a
scrubber. It is equipped with fast rotating brushes of special
alloys and a gripping force to cause the scrubber to adhere to
the side of the ship under water. That little scrubber does all

its cleaning automatically, under programmed instructions

from its computerized brain.
There is a story about a man on an automobile assembly
line. He was a good worker, intelligent, and aggressive. He

became bored with the task of continually inserting bolts into

pre-drilled holes, hour after hour. One day he decided not to
insert the bolts as he had been inserting them in the past-
just to give his task interest and variation. He cross-
some
threaded them, used short bolts and sometimes didn't use any
bolts at all. Your imagination can fill out the further details of
this story and what interesting and imaginative things you can
come up with as you think about the various people who
bought those cars!
Robots can scrub or put bolts in holes forever-
assuming that the power is kept on and the mechanics don't
fail. Robots do not get tired or bored or even interested in

what is going on. They just do what their little computerized

brains them to do. Of course, some robots have really big
tell

human types to
brains but require knowledgeable, scientific
keep them operating smoothly.
You will, no doubt, immediately think of other applica-
tions for these machines. Although we hate to admit it, we can
come up with one more reason for having a machine do tasks
for us.They can do it better! Yes, it's true, they can do it better,
for a longer period of time, and more consistently than any
human can ever do. You see they have one advantage— they
do not get tired!
If we ask the fundamental question, will machines and

computers take over the world? We will find that we've a

disagreement on our hands. Some look at the exploding field
of robotics and say there is no doubt that someday machines
will control everything. These persons worry about jobs and
activities and— yes, it is true— a loss of control over the
machines by the humans who make them. They envision that
someday machines will be making machines which control
machines, etc. ad infinitum.
One thing is sure, no one has ever seen a machine
making love, so there may be hope. Indeed, there ishope for
all of us for an ever increasingly pleasurable future due to the
fact that machines are around and doing things for us.
I extend my gratitude to the many companies and indi-
viduals who provided me with information, discussions, ques-
tions,and answers for this book. Their illustrations are most
informative. Now, for a trip through the fascinating world of
advanced robotics, turn this page and keep going.
 Acknowledgments [[^

Thanks to the following companies for their cooperation in

making this book possible.
American Robot, P.O. Box 10767, Winston-Salem, NC, 27108
PRAB Conveyors, Inc., 5944 East Kilgore Road, Kalamazoo,
MI, 49003
Advanced Robotics, Newark Industrial Park, Hebron, OH
Texas Instruments, P.O. Box 1443, Houston, TX 77001
Quasar Industries, 59 Meadow Road, Rutherford, NJ 07070
Heuristics, Inc., 900 San Antonio Road, Los Altos, CA, 94022
Solfan, 665 Clyde Avenue, Mountain View, CA, 94043
Jerry Rebman Electronics, 5439 Doliver, Houston, TX, 77027
Robotics Today, The Strand Building, Peterborough, NH
03458
Cincinnati Milacron, 4701 Marburg Avenue, Cinnati, OH
45209
ASEA Electronics Division, Vasteras, Sweden
General Electric, Optoelectronic Systems, Electronics Park,
Syracuse, NY 13201
Spatial Data Systems, 508 Fairview Drive, Goleta, CA, 93017
Polaroid, Ultrosonic Ranging Marketing, 784 Memorial
Drive, Cambridge, MA, 02139

XI
Mountain Hardware, 300 Harvey West Boulevard, Santa
Cruz, CA 95060
Ohio Scientific, 1355 South Chillocothe Road, Aurora, OH
44202
Radio Shack, a division of Tandy Corporation, Fort Worth,
TX,
Microbot, 1259 El Camino Real, Suite 200, Menlo Park, CA
94025
Manca, Rockleigh, NJ 07647
Inc., Leitz Building,
Camac Kenetic Systems, 11 Maryknoll Drive, Lockport, IL
60441
Kilobaud Microcomputing, 73 Pine Street, Peterborough,
NY, 03458
ACE Radio Control, Higginsville, MO, 64037
Telesensory, Inc., P.O. Box 10099, Palo Alto, CA 94304
Planet Corporation, 27888 Orchard Lake Road, Farmington
Hills,MI, 48018
Robotics Age, P.O. Box 725, La Canada, CA 91011
Apple Computer, Inc., 10200 Bandley Drive, Cupertina, CA,
95014

xii
 Definitions,
Examples, and Ideas

•—
What is robotics? This is not a new word but it may be an
unfamiliar one. Automation is another somewhat similar word
that applies in many instances to the same idea or concept. It

is only through the magic of the big screen TV and science

fiction stories that theword robot has come into such promi-
nence. It is now almost a household word. The word robot has
come to be associated with the C3POs of other worlds; those
mechanical, man-like units of metal and electronics that play
roles in stories of the future. It is interesting that the word
robot can also mean an unthinking robot being who performs
some task automatically. It is not considered normal for a
human because that is the way machines are supposed to
operate.
Machines act and do not think— or at least do not think or
reason as humans think and reason .

Robots do have memory banks that are usually pro-

grammed in some manner. They do speak and seem able to
understand human speech. Because we have so many va-
rieties of solid-state circuits nowadays, no one is surprised
when a robot speaks, or a calculator, game, TV or automobile
speaks in a distinct monotone, but remember, they don't
think!
 The word robot comes from the Czechoslovakian word
robotnik meaning slave, servant, or compulsory service. The
word has been defined as being descriptive of an automaton or
a person who acts or works mechanically without thinking for
himself. By definition, a robot pilot is a device which serves
as an automatic pilot in an airplane for example. Note that the
word automatic appears in the definition.
During World War II the concept of an automatic pilot
was extended to guided missiles (also called robot bombs). It
kept them flying upright and capable of executing steering
commands sent from an automatic ground computer-
controller. This points to another link in the system— the data
or command transmission link.
robots of a much
The exploration of space has provided
more sophisticated variety. These mechanical marvels seem
to be able to think and act on their own as they travel into the
vastness of the cosmos. These robots have the ability to
sense situations and conditions. Automatically they extend
measuring or photographic instruments from protective hous-
ings and sample the ether, or planets, or asteroids. They
place the information in memory banks and then send it,
slowly, allowing plenty of time for accurate transmission,
back to the controller-computer on earth where the data is

assembled, enhanced, and displayed for human consideration

and amazement. When so programmed, these robot marvels
steer themselves down to a planet's surface. They land care-
fully, adjust themselves, and communicate their status, posi-
tion, and findings, new environment. It has been ru-
in this
mored that the Russianshave developed this type robot to
such a state of perfection that they land on the moon, take
samples, lift off, and return to earth without the assistance of
human control in flight or during on-planet actions. They act
like the mechanical men of Karel Copek's play/?. U.R. even if
they do not have humanoid appearance.
There can be no doubt that man is moving toward that
day when some type of machine will be used in almost every
human capacity. The scientists believe that people would like
to have this machine look somewhat human, and so they
spend considerable time in an effort to develop mechanical
 method of
eyes, ears, vocal chords, arms, hands, legs, and a
locomotion which simulates human walking. Everyone is de-
lighted when a mechanical machine, looking very much like a
Middle Ages knight-in-armour clumps around and performs
some act of a semi-useful nature, or utters sounds which are
human words, all in proper response to voiced human com-
mands.
While it all seems relatively normal, response of a
machine to human commands uttered vocally is not simple. It
is the world of algorithms which is what the scientists and

engineers call their magic equations. Algorithms instruct and

control the machine and everything it does. Associated with

every type of mechanical device which does anything, there is

some type of controlling device which reads an algorithm. In
order to understand and communicate directly, we should
also have some understanding of algorithms which are used in
both operational and developmental situations to make things
come alive.

When we consider all the parts of the world of robotics,

we are talking about robotics. In the Introduction I have
described this as being the art or science of controlling
machines such that they do something. We now consider what
that something might include and thus consider in more detail
what we might mean by saying that robotics is an art.
Art is defined as a skill acquired by experience or study.
It also has been defined as the systematic use of knowledge

or skill in making or doing things, and the use of skill

and imagination in the production of things of beauty, or the
things produced which are so considered. So it seems from
these definitions that robotics means machines, computers,
mathematics, algorithms, science, engineering, and some ar-
we try to come up with a simple kind of definition for
tistry. If

robotics we might try: The design, use, and operation of

machines, which are computer controlled by algorithm, to do
human-desired tasks.
This definition does not include any specification as to
the shape or size or type of machine, nor does it limit itself to
a definition of a physical output —although that kind of output
is usually associated with the word robot. Notice also that we
have indicated the machine must be controlled by an al-
gorithm and implied in this definition is some type of com-
puter. We try not to limit the machine to either fixed or
mobile construction, and we do not limit the machine to an
autonomous operating condition. You may take the extreme
position that the human brain is also a computer! This means
that waldos are also robots.
The incorporation of a human's brainsomewhere within
the flow pattern of operational commands for a mechanized
unit has to be considered at some stage, even though it may be
by-passed at later stages and in subsequent operations of the
electromechanically directed unit. If you ask what this means,
I would respond, "We are referring to the teaching stage in

development of a system which will then become autonom-

ous."
"What about self learning?" you might ask. That comes
under the heading of adaptive control, which simply means
that the machine can adapt itself to changing conditions of
input that determine its operational output. In this case the
machine is equipped with sensors that can recognize changes
in the position of objects that it is to pick up and convey to
another place. As it determines these changes, its sensor
input can cause changes or modifications to its control-
computer program so that the machine's mechanical move-
ments can be modified to adjust its pick up arm or hand or
gripper and continue to do its task without fault. Adaptive
control capability is still controlled by the original algorithm,
though.
The ability of a machine to do things of a constructive
nature depends upon the accuracy, sensitivity, number, and
type of it's sensors. Consider for a moment the human ability
to pickup a pencil. The sensors involved would be the eyes,
which determine at every instant the relative position of the
hand, arm, and fingers to the pencil, and the skin sensors,
which feel the pencil when it is touched. The sense of feel
allows the brain to determine the tightness of grip and posi-
tion of the grip necessary to pick up the pencil. The eyes help
the brain determine where to move the pencil. If the underly-
ing command of operation was 'Tick up the pencil and write
50 on a paper" the eyes would also have determined the
position of the paper, the skin sensors would have determined
that the paper and pencil met under the proper circumstances,
and then the algorithm causing the fingers to make the move-
ments to write 50 would have been initiated.
What the human machine is getting throughout this op-
eration is feedback from all the various sensors necessary for
this kind of operation. Sensors provide input signals of what
the hand is What the hand is doing is the machine's
doing.
output. When machine inputs signals from its own output
a
this is called feedback, and this is vital to the operation of any
machine considered under the heading of robotics. Feedback
is a concept long known in engineering circles and in the

world of servomechanisms. What is new in the world of

robotics is the type, size, and accuracy of the sensors, and the
ability to compute very complex equations very quickly to
determine exact operational signals for the robot.
The human body is one big mass of sensors. Almost
every point on the skin's surface is sensitive to heat and
pressure in ranges from the smallest puff of wind to the
largest rib-smashing blow, and from a bitter winter morning
to a humid summer scorcher. Add to this the hearing sensors,
the visual sensors, and the taste and smell sensors and you
have a pretty complex and sensitive package. To enrich your
thinking along this line, consider that pencil picked up a few
paragraphs ago. How does the brain know that it is a pencil
when the eye sensors see it? If you answer that the brain has a
stored image of a long slender multisided object with a sharp
you are getting close to the kind of thinking used to
point, then
define algorithms in robotics. Think of how many images our
brains must have in storage on a relatively permanent reten-
tion basis, and how it discards old images and incorporates
new images. Then consider this thought provoking definition:
Robotics is the science of making machines man-like in action
and operation.
To discuss a robot is one thing, to examine it is another.
Let's take a look at one kind of robot. The Grivet Series 5
industrial robot in Fig. 1-1might be a surprise because it
consists of a single automated arm that performs under the
direction of a control unit, the TARC (Fig. 1-2).
The Grivet responds to the teaching instructions of the
person holding the teaching box in Fig. 1-1. We are assured
that teaching this kind of robot to do important industrial
tasks is American Robot Corp. says that this
easy. In fact, the
unit is designed to be extremely simple to use and to main-
tain. What about maintenance? Robotic devices are electro-

mechanical machines and thus their ability to function and to

keep functioning for long unattended periods of time depends
on how the designer planned for maintenance— and possibly
troubleshooting, or diagnostics.
I am reminded of a situation concerning the development

of a new guided missile robot system. Many manufacturers

and scientists were present and deeply involved in the plan-
ning for the system. When it came time to consider mainte-
nance and repair, everyone agreed that the system would
"almost never" break down or need such attention. Just in
case it should, a testing unit was to be devised which would
automatically run tests and isolate troubles so quick and
effective repairs could be made. You guessed it! The complex-
ity of the testing unit was of such magnitude that it became

advisable to consider a testing unit to test this testing unit!

Wewant our robot systems to be as free from troubles
and maintenance as possible, but what testing and mainte-
nance they have should be easy to perform, consistent in
application, and totally effective in operation.
Look back at Fig. 1-1. This Grivet robot has been de-
signed for industrial applications where a job handling objects
weighing less than three pounds is the primary concern. It can
be taught what to do for a particular task with just a few
minutes of instruction, using the hand held teaching unit. A
close-up of this unit is shown in Fig. 1-3. Simplicity may be a
key to easy maintenance.

TEACHING A ROBOT
Robot Master John Galaher of the American Robot Corp.
informs us that this box controls extension and contraction of
 mq
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Fig. 1-3. The teaching unit (pendant) for the Grivet robot (courtesy American
Robot Corp.).

the arm and rotation of the hand gripper, wrist, elbow, and
shoulder. One sets this kind of robot into its permanent
location, programs it to accomplish the task desired, and then
removes the teaching unit. The arm, under direction of
TARC, will now go to work doing what you have told it to do.
In this case it may replace a person on a batch separation line,
or change objects from one conveyor belt to another. It is
man-like in that it can do the kind of job that a man did
previously.
"Robotics is the science of making machines man-like in
action and operation." This seems to be an accurate definition
and you will note that it does not say that the machine has to
look man-like (or woman-like) in appearance, although it

doesn't rule it out either!

EMULATING HUMAN ACTIONS

In many discussions of the capabilities of a robot arm
such as the one in Fig. 1-1, it is stated the arm will emulate
human actions. Perhaps you are familiar with this word. It
seems an important one.
'To emulate" means to strive to excel, or to exceed, or
to equal. In this case the arm emulates the task which was
formerly done by a human. Of course we have to consider the
possibility that the task will be a new one, or one in a new
environment or location which has never been performed by
anyone, human or not. We imagine that production will re-
quire a whole list of tasks, resulting in a final product or
service. We look at the performance of these tasks as an
example, and we have to make some comparisons, so we
naturally make the comparison between the machine ac-
complishment and a human accomplishment.

GRIVET-ROBOT ARM DYNAMICS

Let's examine that Grivet robot arm in more detail using
Fig. 1-4 to guide our thinking.
In A we see the static condition of the arm. It is tightly
positioned against its base, and it does nothing. In B it has

been sent signals to extend, and from the illustration we can

see through what angles rotary motion can be accomplished,
and also via these same angles a translatory motion is made
for the gripper. This is easy to understand if you imagine that
section 1 of the arm moves or rotates downward, while
section 2 moves or rotates back, and section 3, the wrist,
rotates downward to remain on a level line from the starting
position. Notice also that the arm itself can rotate through 360

10
 GRIPPER
OR ^Sl> feH
HAND 360° 360°

^
(1)

ttt n. Zi
(B) (A)

Fig. 1 -4. The statics and dynamics of the Grivet robot (courtesy American Robot
Corp.).

degrees around the base pedestal so that the gripper can

move an object from here to there, in a sideways motion.
How can it be said that this mechanical arm emulates a
human action? Let's take the situation where the arm, by
definition, is to excel a human capability; do it better than a
human can. To begin, assume the arm and the human are equal
in speed, accuracy, and general operation. Time passes, the
human tires, the machine does not. Now the machine excels
the human operation. One can also visualize that the machine
requires no breaks or time off for lunch and doesn't care
whether there is light in the area or not (unless it is equipped
with a visual type sensor). It doesn't care whether it is day or
night. Thus, perhaps, to use the word emulate is to state the
situation somewhat correctly. In this case emulate refers to
only those actions that the arm is capable of performing. It

obviously cannot duplicate everything a human arm is capable

11
of. This, of course, brings us to the type and kind of task
where the human emulates the robot. The robot performs in a
delightful manner as long as it is working properly and
nothing goes wrong, and as long as all conditions of its task
remain the same. But, unless it is an adaptive type robot, any
change in the conditions of its job or task will not be accounted
for until it has been re-programmed to compensate for those
changes. The human, naturally, compensates automatically.

ARTIFICIAL INTELLIGENCE

One definition of artificial is that which is made by man to

imitate nature. One can conclude therefore that artificial
intelligence is a man-made imitation of nature. One can also
assume that an imitation can never be equal to the real thing.
In robotics the actions of a machine may be of such a
complex and delicate nature that one almost assumes the
machine has a human-like mind direct its actions. Such
machines have enough logical capabilities that what they are
able to do seems uncanny. But if we fathom the human mind
slightly further we find out that there is one aspect of the
human mind which, so far as we now know, cannot be dupli-
cated by a machine. That is the ability of the human mind to
question. A machine analyzes, performs, has logic, and can
make selections, but does it ever ask why?

Scientists are learning more about the human brain and

its functions all the time. This marvelous electro- chemical
device is said to be capable of doing billions of operations per
second, of storing incredible amounts of information for ex-
tremely long periods of time, and of using such information in
the solution of both new and old situations. It has been said
that a human is the sum total of what he has learned— and he
learns all the time. Since everything is fluid and changing, the
human must constantly adapt and learn and adjust to meet
changing conditions and situations.
So, some say that the only tasks and operations a human
can perform are those that he or she learned to do previously,
either by instruction, or by trial and error. Understanding
this, one begins to think that a robot might be able to do as

12
much as a human if it has a computer with a large enough
memory bank to store all the information that comes to it in
the form of learning (structured instruction) or in the form of
feedback (trial and error). These trials are generated by some

interiorcommand arising from some need which its sensors

can determine. The machine then senses a need, and looks
through its memory banks for a solution. Finding none, it
takes the closest approximation to a solution— some action
which will cause the sensor information to change— tries it,
and senses the result. If an improvement in the original
sensed need results, the direction of the trial is correct. If no
improvement results, or the need gets worse, then the direc-
tion of the trial is incorrect.
example we find the machine doing what many
In this
humans might do to solve a problem. But nowhere in this
example is the concept of the machine stopping all operations
and asking itself "Why is there a need of this kind?" This is
what humans will do under similar circumstances. We do not
know how to program a machine to ask that kind of question,
exactly, although it may be approximated in complex pro-
grams.

WHO PROGRAMMED AND WHY?

IS

Are we all programmed? That is a philosophical question

which we, perhaps, might have to consider as we make
mechanical machines more nearly like humans. We think of
programming as a function related to computers and we think
of the microcomputer being closely associated with robotics.
These small, cheap computers have become the foundation
behind the concept of robots or automated and intelligent
machines. It is said that even computers are a form of ro-
botics. They do have mechanical outputs (printers and graph-
ing devices) as well as visual display outputs and many other
output devices. What kinds of orders do they obey?
In the beginning such a machine is told to do task one and
then do task two and from there it operates on certain condi-
tions. For this example, the orders have been stated as
follows.

13
 1. Do f then g
2. C then f else g
If

3. While C do f
What is implied, but not apparent, in using these orders
is that the computer may be evaluating and scrutinizing
masses of data which govern the use of these orders. It is far
beyond the ability of the human mind to evaluate this data in
the same systematic, logical, unemotional, and timely manner
that the computer does in arriving at, say, an implementation
of step 2 above. One might suspect that the human mind is
programmed to evaluate certain amounts and types of data,
and computers are programmed for another type. Human
conclusions usually must be a consensus before the conclu-
sions are accepted. We note that machines follow a man-
specified routine to evaluate even the greatest amounts of
data, but can only evaluate those types that man understands
how he evaluates!
We can think through this problem by imagining that we
are in a fast modern aircraft and suddenly, ahead, is another
aircraft bearing down on us. Should we dive, climb, turn left,
or turn right? What will the other pilot do? What if he maneu-
vers in such a way that the intercept possibility increases? It
is possible that you have had a similar experience while you
were walking down the sidewalk. Another human ap-
proached. You moved to your left, and he moved at the same
time to his right. You moved to your right, and he mived to his
left. There was no way you two could prevent bumping into

each other. The consequences here were not disasterous;

they would be disastrous in an airplane. Could a computer
have solved the situation in either case? The FAA says yes.
They have installed collision avoidance computers and con-
trol systems (robots, if you will), on board test aircraft for

futher evaluation. The results look very promising. Collision

avoidance systems are used on board ships at the present
time.
What can the machine do that the human cannot do under
these conditions? It has the ability to evaluate more data,
faster, and evaluate more complex routine than the
it in a
human mind is For example, using radar sensors
capable of.

the computer can determine in an instant if the other aircraft

14
is down relative to your position. It can determine
going up or
the speed of movement in all directions and predict or antici-
pate collision or no collision. The solution to the problem is
then flashed to the human in a form he can most quickly and
accurately assimilate— perhaps a light to indicate the direc-
tion he should steer his aircraft. The job is done well and
safely by the two minds, electronic-mechanical and elec-
trochemical, working together!
In a case where the human response time is too long,
delayed, or cannot be accomplished in the time interval
necessary, the secondary part of the machine operation— the
robot steering— takes over and for a few precious seconds
handles the aircraft. Aircraft autopilots, which steer aircraft
along precision courses, at given altitudes, have long been
recognized and accepted. They are being given additional
duties all the time and tests have been conducted flying a
passenger type aircraft from takeoff to touch-down without
human hands ever touching the controls.

THE HUMAN MEMORY PROBLEM

The problem is that we forget. We also cannot assimilate
much information at one time. It comes into our minds slowly,
we retain it when we use it, and we lose if it we neglect using
it for any length of time. Computers normally won't do that.
Failure can mean the loss of memory in a computer, but
normally the computer can accept, sort, and store all kinds of
information quickly and for a very long period of time. Many
computer memories today are magnetic tapes, magnetic bub-
bles, or various types of discs. Some are solid-state units
which have information "burned" into them, so that when
energized they immediately form voltages and currents
which translate into data.
Sixty executives, all presidents of corporations were
asked to select a number from zero to nine and they were
asked to do this 100 times each. At the same time a computer
was programmed to select, at random, a number from zero to
nine, and it was permitted to do this 100 times. It was

predicted that the presidents would choose the same number

at least 10 percent of the time. That was not exactly correct.

15
They selected the same number 12.3 percent of the time; at
least those who had increased their corporate profits during
the previous operating years did this. Those presidents
whose companies lost money selected the same number only
8.3 percent of the time. The computer selected the same
number 10 percent of the time as predicted by laws of proba-
bility. This test was said to indicate that the successful execu-

tive had strong and accurate intuition and the results were
reported in Time magazine. When these results were
analyzed it was said that man's inefficiency, emotions, and the
nuances with which a man reads data may inhibit his thinking
or affect the accuracy of his conclusions. Using a computer to
predict trends or to select courses of action based on evalua-
tions of reams of data and then tempering the prediction with
human judgment seems to be the best way to gain the utmost
from the two worlds.
When we consider the world of advanced robotics, then,
we must concern ourselves with the problem of how much
intelligence we can build into a machine, how it will use that
capability, and when we must insert ourselves into the con-
trol loops to achieve the best of the two worlds. We have to
decide when the machine can function alone, and when it must
be aided by human intelligence. Of course, it goes without
saying that we will be forever trying to fabricate a complete
mechanical-electronic-chemical mind which will permit hu-
mans to specify our commands and relax while everything is
done for us! It has been shown by R.S. Aha of Grumman
Aerospace that man's thinking process might be specified as
shown in Fig. 1-5. In this block diagram form we can easily
imagine how the brain of a very intelligent robot might func-
tion.

MORE ON THE GRIVET ROBOT

We learn still more from a deeper examination of the
Grivet robot's characteristics. The arm sections as well as
the whole arm itself are moved by direct current stepping
motors which have built-in integral shaft encoders. This
means that a motor can drive any arm section to within plus or
minus .004 inch of a given position when the same command is

16
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17
re-issued. The motors are driven by a single-board mi-
crocomputer which can be connected to, and accepts data
from, external lines. This computer has a built-in diagnostic
capability to pinpoint machine-operational problems. The
microcomputer uses a nonvolatile memory cartridge for
program storage. Its controller is a 16-line, optically isolated,
TTL-compatible unit.
Although the arm is electrically positioned, the gripper,
or end-effector or hand, is pneumatically operated. The robot
has a built-in air compressor to power this end unit. The use
of pneumatics means very fast responses are possible.

ROLE OF MATHEMATICS IN ROBOT-ARM OPERATION

In an earlier discussion we mentioned the algorithm, or
equation which a machine's computer solves to permit the
robotic machine to function as the designers desired it should
function. Considering the Grivet robot arm, we can gain a
good insight into what this means.
just
In Fig. 1-3 we examined the teaching pendant as the little
box is called. On it we have seen that there are switches to
control various movements of the various segments of the
arm. We imagine, then, that when we want the arm to do a
particular task, we just move the proper button and watch that
segment of the arm move until it is in the proper position for
the next segment to be moved. We next cause that segment to
move until it reaches the proper position, and then we change
switches to cause the next segment to move, and so on.
What if we make a mistake? If we are teaching the
machine by using the little pendant to control the arm, what
happens if we "overshoot" the desired position and have to do
some manipulating and jockeying around to get the arm seg-
ment into the proper position? Will the robot arm then also
jockey around each time it moves? What happens in this case?
You can imagine that a person manipulating that arm for the
first time would certainly not be able to handle the control

pendant switches so perfectly that the arm would move

exactly and precisely to each desired and necessary position
for the completion of the required task. You merely need to

18
try your hand at radio control of some small model with
reasonably tight control to verify this idea.
So, what happens? You guessed it! Within a robot is

placed a bit of artificial intelligence that is given the prime

directive to assist both the human and the arm so that each,
given its own faults, will not inhibit correct operation. The
human fault is jockeying the controls when teaching. If the
robot has a fault would be its eagerness to respond, which it
it

does with alacrity. So the computer's task is to eliminate the

human fault and compensate for the robot fault to bring about a
perfectly delightful operation which is pleasing to the human
and maybe to the robot also!
Let us look at the computer and bring it under tight
scrutiny for a moment. We know its job will be to solve
equations and in this case they have to be equations of motion.
We also know that when solving an equation of motion there
must always be a reference point. In this case it is the base
pedestal of the robot arm. Imagine that this pedestal is set
into the floor, or mounted thereto in such a manner that it
points north and thus the directions of south, east, and west
are also defined. Another way of looking at this coordinate
designation would be to say that north equals forward, south
becomes backward, or reverse, east is right and west is left of
the base structure. We can so define this arrangement if we
imagine ourselves being located in the space occupied by the
pedestal and have the specified body relationships.
From our location we look at the end point, or gripper, or
tool to be positioned which is mechanically fastened to the
end of the wrist. That is the point which we want to move to a
given location in compliance with a series of commands. We
will, of course, also want that end tool or gripper or whatever
to do something at each end point. It might pick up an object, it
might set down and release an object, it might position a
welding element, it might operate a paint sprayer, it might
draw a path from the beginning of movement to the end
movement such as is done in graphics, it might wire-wrap a
terminal or a series of terminals, etc. But the end point must
move from somewhere to somewhere else very accurately
and in such a manner that a duplication of its action will also be

19
exact— perhaps for thousands of movement operations. Its
repeatable positioning must be present and very accurate.
Remember the Grivet operation is within plus or minus .004
inch!
So what does the computer do? The computer remem-
bers the starting point and the end point of the gripper for
each cycle of operation. A cycle will be defined here as that
series of movements required to perform one task. The com-
puter then computes the best path through three-dimensional
space for the gripper to move to accomplish the task the
human led it through so laboriously, and the resulting path
equation or algorithm will be solved by the computer each
time it arm through that cycle. We thus learn that the
runs the
gripper may not go through the same points in three-
dimensional space that we put it through when we taught it
where it was to move. It might move along an entirely dif-
ferent set of spatial coordinates to accomplish the same task
better and more efficiently. It definitely will not remember
any jockeying we might have done, or manipulating we might
have had it do to get it where we humans desired it to be when
it finally got there. All those little breaks will have been

removed from the motion-path commands and the result, to

everyone's delight, will be a smooth, direct operation.

WHAT IS A TASK?
We have used the word task and it may have a different
meaning to different people. A task may mean one completed
action, or one complete cycle. Here it means a movement of
an arm-section point to one specified position in a series of
end-point positions in order to accomplish a job. The end-
point is the tip of the gripper or hand. Many tasks make a
cycle. We consider one job accomplished when one cycle has
been completed.
A vector is a line that has both direction and magnitude.
In Fig. 1-6 we lengths— VI, V2,
find three vectors with fixed
and V3— and these represent the three arm segments of a
robot such as the Grivet. They are attached to each other and
to the base at one point as shown. Each arm segment can
move independently. In this two-dimensional drawing all of

20
21
 VI moves up or down by opening
the angles cannot be shown.
V2 moves left or right (as
or closing the angle alpha (a).
shown here) by opening or closing the angle beta (/3). V3
moves up or down, and so moves its tip which we imagine to
be the robot's gripper, by opening or closing the angle gamma
(y). With a little imagination you can visualize the simultane-
ous movement of all three vectors such that the end point
might be moved up, down, left, right, or in a combination of
these directions as required by the tasks. Of course, V3 could
be longer so that if the angle gamma were reduced to zero, the
end point would come around to the first section point and,
equipment permitting, would coincide with that position. As
shown, the end point has been moved up 12 units and out
along the positive axis 26 units.
We might imagine that the end point is a welding flame or
contact point for an electric welding unit. We might also
imagine that we want the end point to move up from where it

is shown and that when doing this move-

to point above it,

ment, the arc will be energized by another command so that

welding would take place along the strip M. In your T—
mind's eye, visualize how the vectors must move through
keep that end point pressed against the metal
their angles to
being welded along the strip T— M. Angle beta will increase,
as will angle gamma. It is possible, but not probable that the
angle alpha would increase during this operation.
This is a two-dimensional drawing using just the up-
down and movements of the end point. In actual
left-right
practice a robot arm will move in three dimensions, so that
there would be a rotation of the vectors into and out from the
paper also. This might happen if the end point had a gripper
which was to pick up something from a conveyor belt on one
side and move it to another conveyor belt located on the other
side. The mathematics of the operation would then have to be
such that the gripper might move down along the T— M line
as shown, until the gripper tip was level with the origin point
(0) or in direct contact with the X axis.
In the Grivet-type robot — and others of this type— the
arm movement is specified to the computer in the form of the

first section point, the second section point, and the third

22
section or gripper point. When these points have been fed into
the computer for all the tasks needed to complete the job, and
in the proper sequence, the computer will solve the neces-
sary trigonometric relationships for the best movement to
reach each end point. you need to refresh your memory
If

concerning task and job definitions this is a good time to go

back and do so.

GIVING THE ROBOT SOME INTELLIGENCE

We have indicated that a robot arm might be able to pick
up objects from one conveyor belt and move them to another
belt. There might be many objects on the first belt and the arm
might be programmed just to pick up selected items and not
all of them. There are two basic methods of accomplishing

this. First, give the robot some eyes, and then match the

shape of things on the belt against memorized shapes in the

robot's memory. The memory bank here might be a cassette
tape, so that you wanted to change the shape of objects
if

recognized, you would simply change the cassette software.

Another method might be by identification of the posi-
on the first conveyor belt. With a constant
tion of the object
rate of movement by the conveyor, and precision dumping of
objects onto its surface, the objects should come by the robot
station in precisely separated distances. The arm could then
be easily programmed to pick up anything (within its gripper
capability) spaced that distance apart, move it, and return for
the next object. A problem might arise if the object belt
happened to slow down, the objects happened to be placed on
the belt incorrectly so the gripper could not easily grasp
them, the conveyor belt happened to speed up for some
reason.
One use of this idea is the welding of automobile bodies
by robots. The bodies come by at precise speeds and precise
positions. The arms move to precise positions also and weld
and weld and weld. and do a good job of it! In robot systems
. .

where some form of contact feedback is

intelligence in the
incorporated, if the body happens to be just a little out of line,
thearm will move to compensate for this discrepancy, also a
speed monitoring system on the conveyor track or whatever,

23
will keep the robot system informed so that even if the line
speeds up or slows down, the arm will adjust to compensate
for this change. No doubt you have thought of other ways in
which the robot might sense or determine or find objects on
that first conveyor belt. Some other means which have been
considered are: temperature of the body, size of the body,
and— believe it or not— actual recognition of the body even if
ithappens to be in some unusual orientation on the belt! This
latter case is very important because it means that such
robots can actually detect and pick out specified objects
among many other objects on a big tray or on the belt surface.
Thisis important in some assembly-type operations.

Giving the robot intelligence then means that it will have

a computer to solve motion movements, it will have sensors
to assistit in accomplishing its job, and it will have some kind

of anticipation and adjustment circuit in case its program

doesn't exactly fit every situation.
In many current situations where robot arms, or robots
with fixed locations, are used and there are a multitude of
robots "employed" on a line, it is possible to have one intelli-

gent robot controlling the operations of many other dumb

robots. The tasks may be similar, and the jobs may be the
same. In some cases the intelligent robot may control another
robot in such a manner that the second robot does some
operations or jobs which assist or complete the job the first
robot is performing. This is the case when one robot with one
arm actually needs two arms to do the job. The solution is to
get a second one-armed robot and program it from the first

one so that the necessary actions are then accomplished.

Another form of intelligence built into a robot such as the
Grivet is that of delay. This means, in human terms, the
programming necessary to cause the arm to wait for an object
to arrive on the conveyor belt, if it has not arrived when the
arm is moving to pick it up. Robot arms can move very fast. It

may be necessary to tell the robot to move arm into a

its
pickup position and then wait a specified time before moving
to actually pick up the object. Suppose a robot arm puts on a
bottle cap and then has to screw it down on the bottle. That
takes time. The arm must not move the bottle until the
screwing operation has been completed.

24
THE ROBOT DIAGNOSTICS
It has been said of an intelligent robot that it, like its
human counterpart, is always checking itself to see if it is

okay. A human begins moan when it gets a sore throat, or

to
when muscles ache, or when the stomach is upset. A robot
moans also, but in a different tone, as its sound comes from a
bell, or siren, or screeching of gears, or clang of parts. Both
the machine and the human must have some means of diag-
nostics to find out what the cause of the problem may be.
With humans there is conversation and a probe into
"memory banks" to find related experiences to give clues to
the trouble. Second there is a probe of memory banks to find
out what to do in case the problem justifies a more serious
approach than an aspirin, bed rest, or other nice homey
remedies. Probably the diagnostics will start with a tempera-
ture reading, then pulse reading, then X rays, and so on. Of
course it will involve a probe of the memory banks of some
good physician who will try to relate the problem to some-
thing in his experience. He will then probe for the cure used
or effective treatment to reduce or eliminate the problem.
With robots the approach is much the same. Within a
good robot system there will be sensors to monitor the
various moving parts. Simple remedies will be found in the
minds of attending humans once the robot has voiced its
complaint by means of its sensors and indicators. Within the
intelligent robot's brain will be found memory banks that
know what the motor speeds should be, when a motor or other
shaft has cracked or broken, when there is an oil leak or
pressure leak in a flexible line, or that there is no voltage or
incorrect voltage to some critical point in the system. The
memory banks recognize these problems because they have
been programmed with the correct operational conditions,
and thus, by comparison they can determine when something
is wrong.
Some robot systems constantly monitor all parts of their
systems just to make certain that a failure does not occur.
When the machine senses that something is going wrong, it
may alert its human operator and say that it needs mainte-
nance, or it may shut itself down while keeping its indicators
on to tell its human companion where to look and what to do to
25
get it going again. These kinds of systems run a diagnostic
check on themselves when they are first energized to see that
everything is all right.
In a previous paragraph we discussed the need for a test
system to test the tester, etc. If you combine that knowledge
with this series of paragraphs you can determine the differ-
ence in requirements. Here the memory banks of the comput-
ers have the necessary knowledge to know when an output is

correct or not. If the monitoring feedback, for example, does

not correlate with what is in the memory banks, either be-
cause the memory bank information has changed or the
monitoring information has exceeded specified limits, then
the system shuts down or reduces operation to a safe value.
Meantime there is an automatic alarm to the human super-
visor to do some checking and find out what the problem
might be. Alarms might be visual, in a high sound-density
situation, or even be a remote paging system in case the
human is not around. With the modern technological ad-
vancement in synthetic speech capability, the machine might
just start speaking to its human supervisor: "I've got a pain in
my tentacle!"

ROBOT COMMUNICATION
Let's expand voice communication slightly and think
about robots talking to robots. Some people write about the
danger of having robots communicate with each other. One
writer says, "Many Americans fear this new age of computers
that talk to other computers and operate machines. Technol-
ogy is moving so fast, in so many areas, that people are afraid
of it because they are not familiar with it."
In assembly line operations where many robots do the
same type of job, it is useful for one machine to direct the
work of other machines. The G rivet series, for example is
so designed that one might have four slaves and one master or
supervisor for these four units. It is said that the operation of
many such machines is "orchestrated" so that they can per-
form process control, handle inventories, handle outputs and
inputs to stockage areas, and control the flow of items in batch
lots on various types of moving tracks, belts, or whatever.

26
 Ask yourself what that word orchestrated means? If we
devote some thought to it, we realize that in a large orchestra
there are many different instruments, different parts to the
melody and harmonic effects which all blend together in order
to produce the final, ear pleasing sound. Thus we arrive at the
conclusion that orchestrating a group of robots means the
blending together of many different processes, automatically
performed in a timely, coordinated manner to bring about the
fabrication of something, or the completion ofsome process
comprised of many parts. It could, of course, also mean the
systematic and coordinated demolition of something if that
were the process desired! Robots take many forms even
when they work singly as shown in Fig. 1-7.
Yes, robots on assembly lines talk to one another. They
may communicate completed a task, they may
that they have
ask for help from a nearby machine so that two arms can be
brought to bear on a process instead of the one with which
each robot is normally equipped. They may govern the flow of
materials or regulate the inspection and processing of the
materials as required. We can imagine one robot at the end of
an assembly line, fit some parts together and finding
trying to
communicating via its own computer and connect-
it difficult,

ing lines back to the robot which is responsible for machining

the parts: "Hey Buster! Get on the ball down there! Reduce
your product by 1/10,000,000 inch!" We can also imagine an
old robot instructing a new one in the tasks it must perform.
One big problem in manufacturing is that there are many
small and different batches of parts and items which must be
made. This means, of course, that the robot assembly line
must change its actions and operations whenever a new batch
is to be handled. Consider an assembly line of up to 30 robots

in length. What a way to get into a new dimensional sys-

tem— 30 robots in length! Normally, people would simply use
new approaches and methods to handle the new and different
batches as they come down the line. What do the robots do?
If there is a change in products and there is good and

orchestrated communication between and among the robots

concerned, a human merely inserts a new program cartridge

27
into the master computer. The human changes the memory
for just one robot in this system and does not have to change
the memory of all the robots as he or she might have to do if
they were operating as individual units. It is advisable to have
good, complete communication among the robots in manufac-
turing or processing plants!
People who fear these connections, will learn that the
communication is not intelligent reasoning, as sometimes
takes place when humans communicate. Among robots, the
communication consists of a series of drive and feedback
signals, which cause the robot receiving the information to do
something. When it does what it is supposed to do the reverse
communication takes place which informs the master that it
did what it was supposed to do, and to what degree of preci-
sion it did it. If the reverse communication doesn't take place,
the master knows the slave isn't working properly.

COSTS
Of course robots cost money. They start at $10,000.00
per unit for manufacturing types, and $3,000 for some of the
android types we will discuss in another chapter in this book.
Android types are hobbyist's toys right now, but imagine that
someday they will be household servants and let us all live life
in Utopia!
But, what about costs in the manufacturing situation?
One might evaluate the cost of programming and operating a
robot vs the cost of using human hands to do the job in cost per
hour. Remember that the robot doesn't complain, doesn't
worry, doesn't take rest breaks or lunch breaks, is always on
time, and can work 24 hours a day without getting tired
(worn-out maybe, but not tired). Each robot has an operating
cost per hour which can be compared to the human cost per
hour and when the purchase has been amortized the relative
costs of the two will show something interesting. Although
the robot won't ask for a raise, its operating costs will in-
crease somewhat simply because the costs of energy will
increase, and it uses energy. It doesn't get tired, but it should
have some kind of normal maintenance routine and humans do
not normally have to be maintained on the job. It is true that

28
29
the robot machines will do lots of jobs humans don't like to do
and it will do them well. This will release humans to do other,
more profitable work. So, if humans are to become future
Robot Masters then they must prepare themselves now for
profitable and rewarding jobs. Technology will not stand still.

FEEDBACK ACCURACY
We show, in Fig. 1-8, a kind of illustration which may
indicate how the accuracy of measurement of the end device
position may affect the general operation of the robot as a
whole.
Along the X axis we have the physical position which can
be measured by the feedback potentiometer, ac wave com-
parison unit, pressure feedback, or whatever. Along the Y
axis we have the accuracy of repeatable operations which are
performed time after time after time. Note that we never
reach a perfect operational state. If nothing else, Murphy's
Laws will prevent that from happening. But we do reach a
close proximity to the state of blissful perfection, providing
that the feedback measuring elements each can provide the
high degree of accuracy required.
Wehave shown a linear drop off of accuracy. This may
not be exactly correct. Each machine may have a different
curve even though each machine may be constructed exactly
the same. The operational environment, the type of load, the
use to which the robot machine is put may well affect its
repeatable accuracy. From this illustration, then, we begin to
get some understanding of the complexity needed and the
precision required in order to exactly locate and assemble
small batch parts, or to perform operations where a few
millimeters of movement may be the whole ball park. We are
reminded that difficult measurements are not exactly impos-
sible. Back in the Dark Ages of the 50's when the atomic bomb

was being developed, there came a requirement to measure

extremely small amounts of U-235. Using a delicate, and
almost unthinkably precise, balance the scientists concerned
were able to measure U-235 in amounts of millionths of an
ounce. Of course you would not even dream that such a
measuring unit might be used in other than a laboratory

30
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operation— or would you? Think what that kind of measure-
ment possibility would mean in terms of precision feedback of
an advanced robot!
Now we are imagining the use of a machine robot to do
jobs that are being performed by humans using microscopes.
This requires them to move with slow, delicate precision
because the slightest error could be costly or irreversible.
We imagine that if such precision could be accomplished by
robots the costs of many items of modern technology might be
reduced and their reliability might be vastly increased. The
key to this precision is the ability of the machine to function
on the smallest of signals, and to physically measure the
smallest value we can think of.
This leads to another problem area— maybe it's Mur-
phy's Laws again. The smaller the signal or the more sensi-
tive the feedback, the greater the danger from extraneous
electrical and mechanical noise. Noise means error signals
and noise is the enemy which must be overcome in the fight
for greater precision and better computation.

SPEED OF OPERATION
In a study of servomechanisms, which form the basis for
all robotic operations, we find that the greater the speed of
movement the harder it is to prevent overshoot and oscilla-
tion. There mathematical solutions to many of
are, of course,
these kinds of problem, and they are used. We want to plan
beyond the present day capability and consider what the truly
maximum speed of operation of a robot system or an indi-
vidual robot might be. We are consideringpower behind the
movement, and such amounts of power that the overshoot and
problems again rear their ugly heads.
oscillation
How fast is fast? Why do we need to increase the speed of
operation? Is it useful, or required, or just a desirable de-
velopment? Is productivity, and therefore profits, dependent
upon speed of operation? Do we want to work toward that
we going as fast as
ultimate blinding speed of assembly, or are
we can go considering our knowledge, and capability of mak-
ing advanced robot machines. Consider the CYRO 5 + 2

32
advanced robot made by Advanced Robotics Corporation.
This machine has two coordinated arms instead of one to
accomplish welding operations. One hand has a five-axis
torch motion (x,y,z,c,a,) and the second hand has two-axis
standard motion. Both hands are said to move smoothly and
accurately to accomplish many tasks. Of course the coordi-
nated motions must be computer directed or program di-

rected.
Computers are being improved every day and their
speed of operation, output capability, and controllability in-

crease every minute. seems that we must expect physical

It

motions from our Advanced Robot machines to keep pace, and

these motions, at vastly increased speeds, must be ac-
complished without overshoot or oscillations. Also required
will be the ability to perform, for long periods of time, these
fastand precise operations, i.e. a high degree of reliability and
very low down time ratios. In Fig. 1-9 we illustrate the CYRO
5 + 2 type robot and some motions and jobs associated with it.

It is interesting that this robot is said to move in rec-

tilinear coordinates. One must envision that this is ac-
complished through computerization of the angular type
coordinates and movements which evolve from the move-
ment of the end device shown at B. It is said that rectilinear
type construction provides a stiffer structure for greater
accuracy and smoothness than would a comparable angular
movement type. Also, it is claimed that a rectilinear system
provides greater safety since people tend to think in rec-
tilinear coordinates and thus can anticipate the machines
motions.
one examines Fig. 1-9 (A) it is easy to see what is
If

meant by the rectilinear motion. The arm moves up and down,

in and out, and its support column can move left and right.
There is no turning of the arm or its support column elements.
There are rotary motions associated with the end gripper or,
in this case, the welder unit. No doubt some will say that
there are certain advantages for the rotary movement sys-
tems. That, of course, will be a function of what kind of
machine is being manufactured and its particular application. I

33
Fig. 1-9. (A) Gyro 5-plus-2 two arm advanced robot. (B) Movement of "end unit'
of Cryo 5-plus-2 (courtesy Advanced Robotics Corp.).

34
Fig.1-10.Cyro 5-plus welding (courtesy of Advanced Robotics Corp.).

Fig. 1-11. Cryo 5-plus-2 control panel (courtesy Advanced Robotics Corp.

35
would suspect that there is a use for each type of machine, and
thatusage may govern what type advanced robot is procured
by a manufacturer.

SAFETY
In advanced robotics we must always be conscious of
safety just as we would be conscious of this requirement in
any plant or operation where machines are used. For the
advanced type robots we have so far considered, we recall
that they are usually fixed in place, that they have a certain
radius of operation, or spacevolume in which their actions are
confined, and thus, regardless of how they move or what they
do, if we restrict ourselves from entering that action space
around each robot, we should be safe enough.
If there is which should, by some very
a malfunction
unique and very unusual condition, cause the separation of the
physical parts of a robot from its base structure, then, of
course, that might make unsafe any other volume of space
around the unit. But this is a case which is so rare that one
might consider it just doesn't happen. Normal safety proce-
dures such as are well developed and practiced in machine-
containing plants and operations, will normally suffice, and
will protect those humans involved when they are in the same
physical areas as the advanced type robotic machines. One
would wear protective glasses if the machine is producing
particles of any type which might be injurious, or if the rays
from the operation (welding) might be injurious to the eyes.
Clothing must be such that sparks or whatever type of
remnants might be cast off from the tasks performed will not
ignite or penetrate or cause other troubles to the human
contained therein. Proper footwear would be very nice to
have over your toes just in case you are close and the gripper
opens prematurely, dropping a large object to the floor. Nor-
mally, however, one would be walking or spending much time
near the robot assemblies. Observation is through instru-
ments and TV type tubes and visual inspection from isolated
and protected control booths. Only in the case of trouble with
a particular machine is human presence required in its par-

ticular space. Then adequate precautions are taken when

36
initiating the repairs and that will serve until that day when
the advanced type robots repair themselves!
The mobile type robot may present another situation. Its
volume of active space may also be confined but that might be
a large space and a moving space and one must then practice
safety as one does in the street with moving automobiles! We
can just imagine our reaction if we are in a large building and
suddenly, silently, this monster machine comes bearing down
on us with its four arms waving madly. The arms are mov-
ing—not because it is angry, for robots don't get that way—
because that is the way advanced robots normally move! Of
course we could be on the regular robot track as defined by
some invisible substance on the floor and it may be just
moving from one job location to another in accord with some
of its prime directives. Yes, unless it is programmed to stop
for obstructions it might well run over us! But even that,

somehow seems remote as a possibility. Certainly, any ad-

vanced robot of the mobile class will have such sensors that it
will stop and inquire— perhaps verbally— if it encounters
anything unusual in its path, or on its job, or during its
performance of its normally scheduled and programmed
tasks.

ROBOTIC SPEECH
Not many years ago it was considered almost impossible
to make a machine which could actually talk back to its
operator. As we well know, that impossibility has been re-
placed by fact. One of the companies in the forefront of speech
synthesis in Texas Instruments, whose Speak and Spell solid
state learning aid has started the machine talking revolution.
Figure 1-12 shows the chip which resulted from many years of
research and development in the speech producing effort.
The heart of TFs Solid State Speech systems is this little
monolithic speech synthesis chip which was invented by TI. It
when reproduced
actually generates electronic signals which,
on a loudspeaker system, sound like the human voice. The
chip models the characteristics of the human vocal tract.
Machines that speak, either to acknowledge or convey
information, are deemed the next area of the technological

37
Fig. 1-12. Voice synthesizer chip (courtesy Texas Instruments).

revolution according to TI. They are engaging in a big pro-

gram of research anddevelopment related to computers,
industrial machines, telecommunications, automobiles, and
to the entertainment market. Now even an automobile, prop-
erly equipped with a small diagnostic computer, will tell the
mechanic what is wrong or what needs adjustment in or on an
engine. How nice that concept is for the backyard mechanics!
If the machines will only explain carefully and in detail exactly
how to correct the problem, as well as telling you what the
problem is, made! That you will find more
then we've got it

and more speaking machines in every phase of our lifestyle is

almost guaranteed by such indicators as TI's separate speech
organization to serve as a focal point for all their new applica-
tions and developments in this field. Let's take a closer look at
that chip by examining Fig. 1-13. You can amaze yourself by
examining Fig. 1-12 and locating the Pipeline Multiplier chip
and then looking at Fig. 1-13 to see what is inside that little
device! But as you see from Fig. 1-13, that's only a part of the
circuitry involved.
TI defines synthetic speech as either a word, phrase, or
sentence, or a complete or unique sound. A lot depends on its

38
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use, duration, and application. A word, for example, is defined
as a second of "utterances", and only TI can explain what is

meant by that! Perhaps that is related to the 100 word vo-

cabulary of the chip in Fig. 1-12, which can be spoken or
uttered in 100 seconds. Of course improvements in vocabu-
lary, and if required, speed of making the sounds, will be

produced as the need arises. We are truly approaching that

day when all commands and instructions to our advanced
robots will be given by simple speech commands, and the
robots will also advise us of their condition and when they
need maintenance they will provide us with any other infor-
mation pertinent to the overall job, simply by telling us
verbally, or vocally, or making some sounds! -

As pointed out by TI it is relatively easy to increase a

robot's or machine's vocabulary. This can be done in many
instances simply by appending a sound to an existing sound.
In the polled-status mode, the host CPU (Central Processing
Unit) issues the address of a word, sets the talk command, and
polls this status bit to determine that the word has been
spoken. Delays between words and sentences are inserted by
addressing the particular delay word which is processed as if
it was just another word.

The monolithic speech synthesis chip uses Linear Pre-

dictive Coding (LPC), which duplicates the human vocal tract.
As this name implies, LPC is a linear equation which formu-
lates a mathematical model of the human vocal tract. Thus it is
possible to predict a speech sample based on previous sam-
ples. LPC is a technique of analyzing and synthesizing human
speech by determining from the original speech a description
of the time varying pitch
and energy using digital filters which
also reproduce human sounds when excited by random or
periodic inputs. Because digital impulses themselves cannot
be used to drive loudspeakers, it isnecessary to have, on that
same chip, a Digital- to- Analog (D/A) converter which trans-
forms the digital information into signals required to energize
the loudspeaker or earphone. On the chip shown in Fig. 1-12,
an 8-bit Digital-to-Analog Converter is used. This is iden-
tified in the lower right hand corner of Fig. 1-13. Codes for the
twelve synthesis parameters (10 filter coefficients, 1 pitch,

40
and 1 energy) serve as inputs to the synthesizer chip. These
codes may be stored in a ROM (Read Only Memory). When
the codes are decoded by on-chip circuitry (Fig. 1-13) they
produce the time varying signals descriptive of the LPC
model, or human voice sounds.
The input to the digital filter takes two forms, as we have
stated. They may be periodic or random. The periodic input is
used to reproduce voiced sounds that have a definite pitch
such as vowels or voiced fricatives (sounds formed and pro-
nounced by forcing the breath through a narrow opening
between the teeth, lips, etc, such as f, s, v, and z). In the TI the
fricatives are z, b, or d. A random input to the chip models
unvoiced sounds such as s, f, t and sh. The speech synthesis
chip has two separate logic blocks which generate the voiced
and unvoiced sound patterns. The output from the digital
filter, drives the Digital-to- Analog Converter and that drives

an amplifier which drives the speaker. The rest of the chip, as

shown in Fig. 1-13, consists of the integrated array multiplier
the advanced 10-stage lattice filter, the adder and multiplier,
and the delay circuits. A complex bit of circuitry, but since it

is all on a chip it is easy to obtain and use.

A final note about the speed of operation. With the unit
shown (and newer units will have a higher speed of operation)
the rate is about two inputs per each five microseconds. TI
says it takes twenty multiply and accumulate operations to
generate each speech sample, but the circuits can still gener-
ate up to 10,000 speech samples per second!

SUMMARY
Throughout this chapter I have presented a glimpse of
what the world of robotics consists of. We have found that it is
a vast world indeed, encompassing mechanical engineering,
electronic-electrical engineering, light, sound, chemistry,
atomic and computer engineering. Some disciplines which we
have not mentioned may be found in this field. So we learn
that it is and development. We
a big area of study, design,
have called advanced robotics a science and an art and we
have presented a simple type of definition: "The design, use,

41
and operation of machines, which are computer controlled to
do human desired tasks." We also indicated that within the
control framework might be a human brain as a part of the
computing system.
There isan organization, dedicated to manufacturing
type robotics which has given a somewhat different type
definition of a robot. The Robot Institute of America has come
up with a typical engineering type definition: A reprogram-
mable, multifunction manipulator designed to move material,
parts, tools, or specialized devices, through various pro-
grammed motions to perform a variety of tasks. The ma-
nipulator in this case iswhat we have called the end product
(or tool) holder, or gripper.
While it is true that robots of any type, industrial or not,
will get smarter as time progresses and will be able, through
use of many sensors which humans do not have, to accomplish
many tasks relating to jobs we have most
for them, in a
pleasing manner, they still must be programmed by someone.
The user may not develop the software necessary, but some-
one has to develop it, and someone has to develop the com-
mand instructions so that an android robot, for example, will
respond to your spoken commands.
Webster's dictionary has another definition of a robot,
and from this can be derived another definition of the world of
robotics: "A robot is a machine in the form of a human being
that performs the mechanical functions of a human being." Of
course, this has been the general concept carried about in
many human minds for a long time, but it is not necessarily a
true definition as we apply it to today's electromechanical
marvels. The Madison Avenue personnel devote hours and
hours to research and planning and burn much midnight oil to
prepare sales pitches which involve the magic word
"robot(s)", and in many instances what they define as a robot,
for sales purposes, is not a robot at all. We have to make
allowances for the kind of sales personnel who jump on the
bandwagon, and present things which are not exactly correct,
according to the definitions presented herein.
It is very interesting that the Lord Company of Erie,

Pennsylvania hopes to market, a robot hand made out of a kind

42
of sponge and filled with a grid of wires and sensors which are
so arranged that it will have an almost human sense of touch

and feel! Robots are here now! Let's move ahead in our study
of some advanced types, and some hobby types.

43
 The
Domesticated
Android

While industry plans and researches and builds toward an

automated improvement in their operations, there are some
companies who are looking into the possibilities associated
with the so called domesticated robots. These are special
household and office machines which, they say, will become
as familiar in the future as a household pet, and they will do
much more than any pet— even though it be well trained.
We now examine some types of domestic robots as they
appear today in various market places. Through the courtesy
of Quasar Industries, we show an example of what a domesti-
cated android might look like in Fig. 2-1. Particularly interest-
ing is the robot's somewhat formidable vision window, which
seems somehow to conceal things that we really shouldn't
know about. In the market place, trade fairs, on TV, and on
stage robots of the type shown are being seen more and more
often,and their capabilities are being enhanced every year so
that they are approaching the state where they might be
called android instead of robot.

THE ANDROID EXPLAINED

What is an android? In the field of robotics there is a good
and precise definition.

45
 android— A human appearing type of machine which
duplicates in appearance and some actions the human
body and its functions. May converse, and does respond
to external stimulii with pre-programmed responses.
This is the type envisioned by sci-fi writers as the
companion to the hero in far-out escapades.

I add, in this writing, that the conversation capability is now

enhanced by a capability to formulate responses by analyzing
the questions asked, and thus it does not depend solely on
programmed responses as was the case in the past. Also we
must now add that the android is capable of sensing and
analyzing to a much more advanced degree than it was in the
past.
So what is the definition of a robot? A natural follow up
question.

robot— A general term which stands for an automated

unit which does have some kind of human symbolization
in its operation or physical structure. It may not look
human, but it seems to be able to perform human type
functions and actions.

In this book we shall find that there are many industrial

robots in operation and that they do, indeed, perform many
human- type mechanical functions. Usually we will find that
they are programmed in some manner to perform the tasks
that they have to accomplish to do a job. We also note here
that the most advanced type of electrochemical-mechanical
machine it is possible to conceive of has been defined in these
same references as a cybert. So, while we consider the word
android because it is well known, and conjures up visions of
C3PO in Star Wars, when we consider household tasks we
reallyhave to think of a cybert. We will also use the word
robot because it is commonly used, and is understood to
represent a type of machine which can do things, as indicated
in our definition.
We find that one of the tasks confronting us at this
moment is sorting out what kind of machine we are to be
concerned with. The machine gets a different name each time
its intelligence and mechanical ability advance, it seems. In

46
Fig. 2-1. A domesticated android (on the right) (courtesy Quasar Industries).

order not to get lost in semantics, I suggest that you choose a

name which has meaning to you and use that. What we will be
considering is a thing like that in Fig. 2-1!

SOME MECHANICAL CONSIDERATIONS

Examine Fig. 2-2 for some of the mechanical details of
this kind of robot. Here we find something concerning the
dimensions and sizes of the various external parts of the body.
We also learn something of the movement of this type robot.
Of course these considerations can be changed with some

47
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adjustment of the drive motors and limit switches and control
mechanisms. It is to be noted that movement is accomplished
by electrical signals to two motors, one on each side of the
body, with two more wheels— fore and aft— used as stabiliz-
ers. One would suspect that the drive motors in some applica-
tions would be stepping motors driven by a series of pulses.
This permits very precise control. When the motors are in
step together and in sync the robot goes straight, and turning
capability comes when one motor is stepped faster than the
other. The amount of stepping difference governing the speed
of angular rotation, or turning.
The power supply would, in any type of autonomous
robot or android, be a battery. One would desire a light
weight, long life, easily and quickly re-chargeable, high am-
pere capacity unit. Of the types common at present the nickel
cadmium or silver-zinc batteries come closest to meeting
these ideals. Other types will be an outgrowth of develop-
ments for the space exploration programs, and for the ex-
pected electric automobiles which so many manufacturers are
now researching. An ideal robot will have its own charging
unit built-in and the unit will be able to find a wall socket itself
and govern its own charging operation. Some robots have
been built which can do this at the present date.

WHAT WILL A DOMESTIC ANDROID DO?

One of the questions posed is "What will it do?" If one is

planning beyond just the construction of a robot, then one

must plan tasks for it and determine how the robot will
perform those tasks. Here is a list of what Quasar Industries
believes a domestic android can be programmed to do:

•Answer the door when guests arrive. Take their gar-

ments, place them, and announce the visitors.
•Using a standard tray, serve pre-mixed drinks hors
d'oeuvres, and perhaps even meals, provided someone re-
plenishes the tray.
•Using several accessories, the robot will, vacuum
rugs, polish floors, and dust general living areas, being guided
by a computer program.

49
 •Monitor the average home or apartment for fire,
smoke, or unauthorized entry during any specified time
period.
•Constantly monitor the house temperature and adjust
by direct control (mechanical) or by remote control (sending
signals to another unit).
•Monitor children during play or rest-time, or monitor
convalescing persons sounding an alarm if the normal ac-
tivities change significantly.
•Respond verbally to verbal commands and questions
and provide information which is stored in its memory banks.
•Help provide education, amusement, and display cul-
tural information.
•Cut the grass, rake the yard, take the dog for a walk,
and other outdoor activities.

The ideas associated with "What will it do?" are not at

the zero level. There are more ideas in this area of thinking
than there are dollars to develop them. This means that the
most important tasks will be automated first and then the
smaller or less useful tasks and jobs will be accomplished
later. It could be interesting for you to sit down and with a

pencil and paper make a priority list of the tasks and jobs
around your home, carrying this list out as far as you can
possibly vision the work to be done.
Quasar gives us a titilating thought in an example of a
homemaker who is getting ready to go to work. Having
decided that the rug needs vacuuming, the command unit is
taken up and the homemaker commands the domestic android
quickly with the date, time, and function code. The robot then
sends a confirming reply. Even the concept of having a robot
prepare meals is not really far-fetched. It might be if the
meals were prepared manner shown in Fig. 2-3.
in the
However much amazement might be provoked by having
such a robot prepare meals, there is a certain danger when
such a machine fools around with flames, heat, or micro-
waves. The microwaves are not supposed to cause interfer-
ence, but they might!
One suspects that the meal-preparing robot chef will not
be a machine as shown in Fig. 2-3, but will be a built-in

50
expansion of the time-cooking oven which is currently on the
market. It would seem that we already have a computerized
cook, what we need is a mechanical preparer and a mechanical
device to get those dishes into a really good dishwasher. So,
perhaps a combination of machines is needed in the kitchen.
One, a robot to get things from cold storage and prepare the
dishes, another machine to cook them, and finally, the robot to
serve the meal, and place the dishes in the dishwasher. The
automatic garbage disposal for everything, papers, broken
dishes, bent utensils or anything, must also be present and in
operation to clean up the rest of the mess. We offer a diagram
in Fig. 2-4. As shown, you would simply tell the input mi-
crophone what the menu for the three daily meals is to be,
state the time the meal is to be served, and note that all
ingredients are on file. The computer takes over and directs
the conveyors and ovens and stoves and robots to the end that
the meals are prepared and delivered to the table at the times
specified. Of course the human responsibility will be to insure
that the bins and refrigerator stores are kept fulland in proper
placement. Eventually one might be able to eliminate human
errors in this job by getting food delivered in response to
computer instructions and sent directly to the food bins or
freezers, automatically. Thus, once the meals are planned for
the week, month, or year, the time frame being of your own
choosing, all one has to do is to be there on time and eat!
We see the use of mechanical-electrical androids or
robots in this example. Let us consider the same job from a
slightly more serious perspective. We then ask ourselves if it
is possible to completely automate a kitchen. The vision of a
completely automated kitchen does not have robots or an-
droids. It will have a multitude of machines and conveyors and
arms such as the ones we have shown in this book. The "pick
and place" one-arm industrial robots can do the task of picking
and placing various food items, mixing and combining ingre-
dients, and selecting various tools needed for those various
chores. Fixed-location two-handed robots are currently being
used in some factories for various types of assembly and some
machines have vision sufficiently well developed to be able to
pick out various things from other groups or items, so why

51
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isn't it likely that food could be an item from which selection
must be made.
Let us consider some types of robots currently de-
veloped and learn what they can do. The University of Rhode
Island engineers have developed Mark IV, a robot that can
select parts from a jumble of parts in a bin. Some people at
California's Stamford Research Institute have developed a
seeing robot arm which can select the proper tool from many
tools on abench and use that tool to bolt down the cover on a
small engine. At Carnegie-Mellon University they are work-
ing to enable a robot's brain to accept orders spoken in the
human voice and, they say, the machine can now distinguish
among some 1,000 words spoken to it, and it will ignore
strange type human sounds which are not words. Joseph
Engelberger of Unimation believes that the future world of
HAL type, and
humanistics will be laced with robots of the
this, you will recall, is the type robot which doesn't appear as
a robot at all, but is a space station controlled by computers
and machines. Here we are considering a kitchen in a house-
hold.

THE AUTOMATED KITCHEN CONCEPT

Examine Fig. 2-5. The premise upon which the sketch is
based is that you sit down at a serving table and speak aloud
what you desire. A computer will recognize the voice (it won't
serve anyone whose voice is not on record) and cause the
various plates to be prepared and served at the table in the
proper locations. Once the meal is concluded and you tell the

computer that a clean-up is in order, the plates and all will be

removed and everything will be returned to the pre-
preparation state— even to the ordering of such stores and
foodstuffs as are necessary to replenish those supplies used
in the meal!
Look again at Fig. 2-5. There are many loops of control
necessary. Here and there one will assume that there are
"pick and place" type robot arms, mounted to fixed stands.
These and place foods, equipment, and
select, mix, prepare,
utensils as necessary. As you will see there are many direct

54
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55
feed type units such as from the food supply bins. We assume
also that somehow these bins will have been pre-loaded,
either automatically or by human effort.

You need a lot of conveyor belting as shown by the

double lines. Then you will need quite a few "pick and place"
type robots and some quite intelligent robots which can de-
tect the various kinds of foods, do the proper mixing and
selection of plates and pots and pans and such in order to cook
the food. A small microcomputer directs the whole operation
and it receives its input from the people seated around the
table, this input being an order for whatever kind of food is
desired. Notice that the computer has a talk-back capability
so that if it does not understand, or you do not give it instruc-
tions in the proper manner it can request a repeat or correc-
tion. Even if you do have an automated system it must be told
every shade of every task and function that it is to perform,
otherwise it send the silver to the garbage and the
will
garbage into the dishwasher. If you are so inclined, take a
pencil and paper and improve on the system shown. It could
be easier to just have pre-planned meals and assign a code
number When you sit down to get breakfast you
to them.
simply say "Bring me A-21" and you can get your toast, eggs,
bacon, coffee, etc.
When we consider the automation of a range of activities
as shown in Fig. 2-5, then timing of the various processes is

very important. On an assembly line where it takes a finite

time for various items to reach various assembly or distribut-
ing positions, any delay in a sub-activity must mean that
somehow the computer will recognize this and delay the later
activities until the product has reached the position where the
next activity starts. We must also, then, realize that in the
completely automated kitchen (or any other activity related
to this concept) that there willhave to be many sensors along
the way which will feed information to the central computer
so that it knows what is going on every place at every instant.
This will also stop the machinery in the event of a malfunction
or a breakdown at some point in the system. Voice communi-
cation to the machinery is not at all impossible. It is being

56
done all the time. I've enjoyed playing chess with a vocal
computerized chess opponent and was delighted, once, when
it said in its charactertistic flat tone; "I lose." I have also seen
a device called a ROBOT 1, made by Heuristics, Inc. which
plugged right into an Apple II computer and enabled a person
to control a small battery operated car by voice commands;
forward, reverse, stop, left, right and straight. The system
used a radio link to the controlled vehicle and required a
special program to make the computer operate correctly with
the other parts of the system.
You will think of other examples of voice control and no
doubt you will realize that various Universities and research
organizations are working constantly nowadays to develop
voice systems which respond to only a few selected individu-
als. This prevents troubles which could arise from having
anyone being able to operate a system. The use of vocal
commands to computers enables the skilled person to free
their hands for more useful functions than trying to type on a
keyboard. With the added capability of recognizing a persons'
particular voice and taking the information that voice conveys
and turning it into some action, we have the essentials of the
man-machine integration in the world of robotics. Through
voice communication we have found a means to affect a nearly
instantaneous communication to, and with, machines; called
robots, or androids, or automated kitchens!
So we consider again Fig. 2-5 and imagine how such a
system would operate. Once the command for breakfast, for
example, has been given to the computer, the computer then
alerts the various parts of the system to be ready to comply
with later commands as they are issued.
on the right side of the figure, is a command to the
First,
food bin that releases the proper items in proper amounts
onto the conveyor belt. Commands also go to the refrigera-
tion unit and its controlling robot (the circle with the X inside)
so that as the refrigerated items are issued, the robot will
place them on the belt alongside the bin order. If the food is
frozen, then it must be sent to the microwave oven for thaw-
ing. This will take a little time and so a delay is now neces-

57
sary. When the food has properly thawed, the robot will place
it in its proper position so that it becomes a part of the order
on the belt.

As the meal ingredients move along the conveyor belt

they arrive at the second position. Here, those foods which
must be cooked are taken from the belt, placed into the proper
pot or pan which has been issued from storage. Some food
items may not need cooking and so will move on along the belt
to robot 3 who has the big job of combining all the prepared
food and placing it in the proper dish or bowl for table use.
This same multi-armed robot will place the empty pots and
pans on the return belt so that they will go to the dishwasher
where they will be cleaned and stored automatically. Can't
you just imagine this robot #3 being a four armed, multi-
digited unit, whirling and waving its arms, as it performs its
assigned tasks? Of course, remember that all the while every-
thing is going on, sensors are relaying information back to the
computer about everything that is happening and when and

how it is happening.
The food, in the proper dishes, the silver, etc., arrive at
the table and now robot 4 begins to serve the meals, each to
its proper recipient. The computer directs the order of serv-
ing by the order of voice commands, first voice is first served,
etc. After a reasonable time, or when ordered, robot number 5
begins to remove the dishes in some pre-programmed order.
Robot 5 puts the dishes on the converyor where robot 6 will
see to it that the garbage goes one way and the dishes and
silver return to the dishwasher to be washed and then pro-
ceed automatically on to the dish-silver storage shelves.

HOW TO PREVENT THINGS FROM GETTING OUT OF HAND

Prevention before cure, must be the motto concerning
automated operations. Think of the modern aircraft with their
many complex and intricate devices and their automated
electromechanical control elements. How do they prevent
mishaps? It is done through redundancy. Space robots are so
designed that they have duplicate and even triplicate systems
that function should the primary system fail or have a malfunc-
tion. In the coming world of robotics, redundancy and reliabil-

58
ity willmake the systems complex, but they will operate with
a minimum of failures and problems. The great wizards of
mathematics will manipulate their symbols and tell us exactly
whether a system needs to have duplicate, triplicate or qua-
druplicate systems in order to achieve reasonable reliability.
That means that in general the machine or system will oper-
ate correctly most of the time. It does not say that the system
will ever be perfect!
In a control system the product of the reliabilities of the
various sub units will make up the total reliability of the
system. For example, if you have ten units, each with a
reliability of 99 percent, then the total reliability to be ex-
pected will be the product of .99 taken ten times or about 88
percent. What this shows is that each subsystem must have a
reliability figure on the order of 100 percent— or as near to it

as possible— in order to ever get close to that 98.5 percent

total system reliability. You get close to 100 percent on a
subsystem by giving it duplication. Reliability engineering of
robots in the forthcoming age will be of immense importance
and responsibility and will attract the best engineers and
scientists that our educational systems can produce.

WHAT ABOUT ROBOT PERSONALITY?

The world of robotics means an integration between
people and machines and so some people have considered and
made studies of what it can mean to warm blooded, emotional
human beings to deal with non emotional, no-blood- at-all
electromechanical devices. The studies attach importance to
the types of machines which "seem to think," rather than
those which are simply complicated or complex. Homo sa-
piens are a difficult even when they are behaving cor-
lot,

rectly, so we are informed. It seems that it is much easier for

these Homo sapiens to work with machines if the machines in
some way reflect their own physical features. Thus we find
that some robot manufacturers such as Quasar spend a lot of
time considering how different personality traits might be
displayed by their display robots.
Figure 2-6 is courtesy of Quasar, and from it you can
begin to imagine the considerations that are being made to

59
insure that these promotional display robots attract and
amuse the human population instead of provoking and
generating fear. It is easy to understand how a robot's appear-
ance can range from friendly to frightening. Perhaps the day
has come when the box type robot or the barrel shaped robot
is passe.
The good engineer designs for fast operation, efficiency,
low maintenance requirements, and reasonable cost. He is
not concerned, really, with how the thing looks, or is pack-
aged, unless the size and shape must conform to a particular
volume some very pertinent reason. There are packaging
for
experts who can design appropriate housings for the elec-
tromechanical mechanisms. Perhaps they will be called in to
help shape the robot machines of the future when the field of
robotics demands that we have robots having personalities
and bodies to match.
Consider the inanimate human models that we see in
the fashionable department stores nowadays. Those models
aren't cheap, and the store wouldn't buy them if there wasn't
proof that they add to sales. same holds true for display
If the
robots or androids than we have to ask, "Just how human do
we want this robot to appear?"
The real "macho" type could be as lifelike as Yul Brynner
in Westworld, the movie in which robots run wild. The pretty
type could be as attractive as those female mannikins display-
ing the latest fashion gowns in the finest haute couture salons.
But, do we want them that realistic? The cost of cramming all
of the machinery into that kind of package would be tremen-
dous. Would the economic advantages of this type of robot
over one that looks like C3PO, in Star Wars, be worth the
development costs?
What about the bad psychological effects? Perhaps
people feel more comfortable working with a machine that
looks like a machine than they do with a machine that, due to
its personalizing, seems to possess some kind of non-
understandable intelligence. When a machine seems to be
alive it can and probably does, generate some kind of fear in
some Homo sapiens. That fear, of course, is usually a fear of
the unknown. Since we are conditioned objects in space, and

60
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Fig. 2-6. Display robots dress (sales promotional androids) (courtesy Quasar
Ind.).

61
since our conditioning is a what we see and hear and
result of
experience, and since we see monsters on TV, etc., then
perhaps the personalizing of machines may engender in the
subconscious some kind of relationship which could be det-
rimental. Who knows?

NUCLEAR INSPECTION ROBOT CONCEPT

It is a well-known fact that one of the primary areas of
robot functioning will be the ones in which mankind has
trouble operating. These involve deep space, anyplace where
there is low or high pressure or no oxygen, underwater
situations, extremes of heat or cold, and environments in
which there is high toxicity or possible nuclear contaminants.
A robot designed for this latter type environment has
been investigated by many companies, one of whom is the
Hughes Aircraft Industry with their Mobots. Another is
Quasar Industries of New Jersey. It is informative to us to
examine, by way of instrumentation and operation concepts,
what such a nuclear inspection robot are able to do in this kind
of nuclear contaminated environment, or in an environment
where inspection is necessary and malfunction means con-
tamination. With both the Hughes Mobot, which has multiple
arms, video cameras, and is remotely controlled from a
switchboard, and the Quasar BIOT, there is a mobility capa-
bility which permits moving the robot to an area within its

mobile range.
The BIOT is a four footed, mechanical, humanoid robot.
The designer says it is six feet high with a weight of 525
pounds, a width of 30 inches, and a ground clearance of some 3
inches. Its mobility is through wheels which would be self
inflating and self repairing. It uses batteries for power, and
the movements of its various limbs and tools and grippers is
controlled by electric units with hydraulic assistance. It, too,
has four arms, each with elbows and interchangeable hands. It
has a means of optical reconnaisance in color, a computer
control unit, and both hard-wire and radio frequency com-
munication and control. It could use voice recognition as one
means of decoding commands and instructions.
In order to have maximum operational and sensory capa-

62
bility the unit is envisioned as having two video color cameras
in its head-unit with an auto-couple-panning capability and tilt

and zoom control. Each arm bank would also be covered by a

TV camera. Other sensors would be a doupler and sidelook-
ing radar for guidance and inspection, X-ray close-scanning,
Sonic close-scanning, and Geiger probes for very close
monitoring. It would also have a gas analyzer as part of its
sensory equipment. The tool hands could include tri-pincers,
grip/lifts, adjustable torque wrenches, bi-pincer fine-tol-
erance grips, tool-steel pry level attachments, and a lift-hook.
Then there are hot and cold hands, the hot hand capable of
working in temperatures from 70 to 240 degrees and the cold
one from 40 on down. Power tools attached for some kind of
repair or connection include a rotor drill for Va to 1 inch bits,
an impact wrench, screwdrivers, a vertical torque rotator, a
horizontal torque rotator, a grinder, and a deep heat probe.
Quasar has gone far enough in design and engineering re-
search on this type unit to have gained a patent on the system
and they believe that such units will become acceptable and
used in industry in the forthcoming decade.
The chips and the CPUs
of computer units are sensitive
to elements of our normal environment, so one begins to
wonder what kind of shielding and what type computer units
will be developed to make the autonomous hostile environ-
ment robot a reality. Testing for operation, reliability and
durability will be a requirement, just as we now have a
requirement to produce environmental chambers in which we
subject space probe equipment to various temperature radia-
tion extremes before we launch them on their long cosmic
journeys.

THE SECURITY ANDROID

We need not dwell long on the dangers from other Homo
sapiens to ourselves in our modern, crowded world. Any
newspaper will provide adequate information on this subject.
What is is that some kind of security is needed.
important
This can be deterrent to all kinds of trespassers. Notice we do
not say that crime can be prevented. We simply say that with
adequate security the bad effects may be minimized.

63
 Does the robot or android have a future as a security
guard in such locations? Can one really be programmed to
detect alien objects which may appear, and which may pose a
threat to the regular and permitted inhabitants of the area?
Let us see what might be required and then think of what may
be possible in view of current technological developments.
If the robot or android is going to patrol an area, it must
be able to do so in a random manner. It cannot patrol in a fixed
operation where its appearance at any point of its path can be
stated as a function of time. All an invader would have to do in
this case is simply time the appearance at some point and
enter during the time the robot was absent, confident that
there would be a definite time interval before it reappears.
That the robot or android would follow a path of some
kind in such an area is probably a requirement. It must be able
to move itself to any location where its weapons or defense
mechanisms can be effective against an invader. If nothing
else, its alarm system must alert the proper people to come to
the battle. Thus a means of causing it to follow a random walk
on a prescribed path is necessary. This path, of course, must
not be obvious, nor must it be easily changed or de-activated
if it is an active element type of path.
One might suspect then that programming internally
might be the path-following criterion. In this case there is
nothing external to the robot or android which can be changed
to cause it to follow an erroneous pathway, or get itself into

trouble. With modern microcomputer capability it would eas-

ily be possible to select a general path and then randomize

sections of it so that only the computer would know when the

robot or android would reverse, backtrack, stop, wait, speed
up or slow down as it follows its general trail. It should also be
possible to change the movement program from day to day, or
at least from week to week so that one could not determine a
fixed pattern, no matter what it might be, by watching and
counting and timing the machine's movements. Also, by the
very definition of randomization, the machine's movements
along a general path could not be predicted.
The area would also be safeguarded by some kinds of
fixed sensors, such as terrestrial vibration units, which are

64
now available in such sensitivities that they can detect a fox
walking on the earth at distances of over 10 feet. Infrared
beams of light, invisible to the human eye, can also be used to
set up a penetration barrier, and
all such devices can be easily

arranged so they would signal the robot or android the mo-

ment they detect anything foreign to their habitat. The robot
then receives an over-ride signal which causes it to speed
back to the appropriate location immediately.
would seem that quick penetration of such barriers
It

might be accomplished. It would be getting out that might

prove difficult. Once the sensors have determined that an

invasion has taken place, a sufficient number of security
robots could immediately move into a tight and overlapping
coverage position so that escape from the inclosure would be
impossible. Disabling devices could then be used. This could
go as far as the aiming and firing of a gun-like weapon. Laser
light beams can cause a smallweapon to be aimed and fired,
just as they cause the big guns on tanks and aircraft to aim and
fire. Laser light, blinding in intensity might be used by first
causing the intruder to look at the robot. Sound waves, the
emission of gas, and other methods might also be used.
How would one pass the sentry if one had permission to
enter the area? Perhaps with an automatic device such as is

used to open and close garage doors. Pressing the button

would tell all devices that a friendly alien was coming inside
the guarded area. Thus they would be permitted to pass. The
code used in this case would have to be a carefully guarded
secret, and might be the only weak link in the chain of security
devices. It is a challenge to come up with a security system so
thatsome can pass and all others will be rejected, using some
means of distinction which cannot be compromised.
We have already mentioned one device which might be
used in the sensory role; the infrared light beam and receiver.
Another unit which might be adapted to this role is the
microwave door opener, manufactured by Solfan of Mountain
View, California. The unit projects a beam as shown in Fig.
2-7 from its microwave motion detector. When it sees any-
thing moving in this beam pattern it activates a relay which, in
this case, causes the door to open, but which in our application

65
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66
might cause an alarm to be sounded, or a robot to be sum-
moned. Also indicated in the diagram is a light beam unit
across the doorway which prevents the door from closing in
case a person stops in the doorway. Remember that the
motion detector operates on a doppler frequency shift caused
by a moving object. Thus, when the object stops moving,
there is no signal to the activating relay. The microwave
detector in this system operates on one of four channels
around the 10.525 Gigahertz region. The relay is activated by
a doppler frequency shift when a moving object penetrates its
beam. The beam pattern can be adjusted for width, length, and
depth. It is sensitive to movement from one inch per second
to as fast as sixty inches per second. It operates on 12 to 24
volts ac or dc. Its detection sensitivity can be adjusted using a
potentiometer control. Some of the antenna coverage pat-
terns are illustrated in Fig. 2-8. If you are a robot designer you
will no doubt think of many ways in which this little unit might
be used.
I offer one suggestion, illustrated in Fig. 2-9. Here, four
radar units are used to give the robot some self defense
features. No one could approach this robot without activating
its motion sensors and causing a triggering of its defense
mechanism features. One must realize that if a robot is used in
a security role, it must be able to defend itself, or at least alert
its master to the fact that it is being attacked.

PATH CONTROL CONSIDERATIONS

While it is true that some robots have been built that will
follow a prescribed path they do not all use the same type of

path control. Some use a computerized path specification

wherein the path is put into the computer's memory and then
the computer activates the steering section in accord with
these pre-determined, selected commands. The other
method is to use a type of cam. You can well imagine how such
a cam following system might be built. A rotating mechanism
of some type must turn a shaped cam so that it will make
contact with microswitches that in turn steer the robot. This
cam arrangement is very simple and reliable. It is not subject

67
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to interference and may be changed quite readily by changing

cams.
If we expand on cam concept we can imagine a the
machine which will shape a cam or cams as we push it around a
specified path. Then we simply have to put that cam into the
robot's mechanism and it will follow that path which we have
laid out, assuming, of course, that nothing happens along the
path to cause the timing of the cam steering to be incorrect
relative to the robot's present position.

68
 One can also imagine certain subtle variations in this
cam steering, motor-controlling concept. One might use
magnetic tapes generating tones of various types for various
actions. It would seem that with such programmed steering
and speed control, a house-movement robot or a lawn and
yard and garden movement robot can easily become an au-
tonomous reality!

A TIMED PROGRAM FOR PATH CONTROL

When we consider a robot following a particular path, be
it in or out of the house, we must remember that a robot will
be asking for some timed directions. A
timed direction is
simply a signal which says the robot should go for a specified
period of time. If the speed of movement of the machine is
known, for example assume one foot per second, then you, as
Robot Master, know that if you let that signal exist for five
seconds the robot should move five feet. I say should because
there might be some impediment to the machine's motion.
We begin to see that programming a robot for motion along
some kind of path, specified only by the internal timing and
speed of the mechanism, is not feasible.

COMPUTERIZED PATH CONTROL

How do we achieve computerized control of the robot for
the same path? Well, we first plan to have some kind of
feedback to the computer so that it can tell when the machine
it is controlling has done what supposed to do. For
it is

example, assume that we have some kind of sensor which will

send one pulse per wheel revolution to the computer. One
revolution will mean that the wheel has traversed a distance
of 2ttx inches where r is radius of the wheel in inches. When
the computer sends a signal for the robot to move forward, it
will be getting back a distance measurement pulse from the
wheel monitoring sensor. The computer can count these
pulses to determine distance. You might even have a pulse
generated for each quarter turn of the wheels. The computer
memory is used when you load it with software instructions
that tell it the number of pulses for each segment of the path.

70
The computer will be constantly checking against this
number with the direct input of pulses from the wheel sen-
sors.
There still some difficulties with this type of
could be
control system. The wheel could slip, indicating distance
traveled, even though the robot didn't move. And what about
when the robot is you assume one wheel is a pivot
turning? If

for the turning motion, then you can quickly see that the
wheel might rotate even though it is going nowhere. You have
to think about the turning problem and plan for it. The slipping
problem cannot be solved using wheel sensors.

MORE ON THE MICROWAVE MOTION DETECTOR-SENSOR

Consider the use of a device such as the Microwave
Motion Detector made by Solfan. AHMAD, a robot made by
computer technician Donald Dixon of San Jose, California, is
purported to be able to monitor a children's room. If they try
to leave that room, the robot tells them not to, and if the robot
encounters a prowler it will tell the prowler to go back. This
robot is also programmed to accept and deliver messages.
Our robot, when equipped with the radar motion
sensor-detector, can respond in a variety of ways to anything
moving in its field of view. Since the radar unit is normally
designed to activate a relay it would require a little change to
activate a verbal questioning unit, cause a light to come on, or
cause a loud barking to sound (from a tape).
If someone responds and the voice is not recognized by
the robot's speech identification circuits, a siren might sound
or lights might flash with a horrifying intensity.
There are good speech recognition and speech synthesis
circuits currently on the market, and more are being de-
veloped and these will certainly be used in robotic applica-
tions. The limit of what kind of talk might be possible with
speech-recognition and speech-generating circuits is limited
only by a person's imagination.

71
 Use, Operation,

and Construction of a
Radio-Control led Robot

He is called GARCAN, manufactured and displayed

and he is

by Jerry Rebman Electronics Co. They can supply all parts for
this type robot. He is a toy-like being that is capable of
wheeling around at parties and on display floors, under the
able and capable radio control guidance of his master, Jerry
Rebman, and he can converse with attendees either in groups
or single units. He can entertain with songs of any type, or
other 8-track recorded sound, through his concealed, high
fidelity speaker system. His purpose in life is to entertain and
to do this, like his human actor counterparts, he can change
his costume, and thus his identity, as simply as donning a new
outer shell covering.
GARCAN rugged unit and can withstand the pres-
is a

sures of children climbing up on his "garbage can" working

costume without sustaining damage. He has provided
amusement and entertainment for the most elaborate of high
society affairs, as well as for those youngsters who are con-
fined in hospitals for all the well known, but little understood,
reasons. His manner of speaking, at the moment, is through a
intercom unit which permits his master to listen to and talk
back to anyone who says anything to GARCAN when he is "on
the job," except, of course, during those moments when
GARCAN's internal tape player has been activated.

73
 My first encounter with this delightful unit is illustrated
in Fig. 3-1. I had been invited to the home of Jerry Rebman
and after a few moments he vanished outside this lovely
family room. A moment later, to the tune of purring electric
motors, GARCAN appeared in the doorway and with uncanny
accuracy and agility entered the room, flashed his "head"
lights at me, decided I was friendly and came closer (Fig. 3-2).
There he stopped and silently examined me and all the while I
watched the maze of lights flash like small bits of lightning
under his plastic, hemispheric, domed head-space. I noted his
rugged construction and how well the inverted 30 gallon
garbage can made a suitable body when mounted on the
circular, one inch thick wood or composition board base
platform. I could just barely see the front idler wheel which
gave the base platform good stability. I assumed, and cor-
rectly, that there would be two other wheels located further
to the rear of the platform and that these would not only
provide mobility, but also steering. I also noted how easily
GARCAN moved across the bare floor and the thick carpet.
There are countless types of display robots being used
now at expositions, fairs, on TV, in movies, at parties and
such, and it is safe to say that 98% of these are radio control-
led types. They may be more elaborate than GARCAN, who is
arms at present) because the addition of arms
a paraplegic (no
means much more complexity. Others may have arms and
wrists and hands, but these are all operated by control signals
sent from behind one-way windows in exposition booths.
Display robots of this type may also have a multitude of self
contained sub-programs which can be started or stopped by
radio signals, and these may range from
pre-programmed
a
path movement, to animated arm and finger movements, to
speech delivery, to music, to display of TV pictures on a
special built-in screen. We have found that the big companies
such as GE and Hughes and others have used such display
robots to present their messages or logos to the public at
various functions.
Display robots are a reasonably big business and will be
a larger business activity as time progresses. They cost from

74
75
Fig. 3-2. "Well, look me over!"

4 to 10,000 dollars each and they rent, with a Robot Master,

from $50.00 an hour upward after expenses are paid. Some
types are "quickly-put-together" units for profit, and some

76
are well built scientific experiments. In the display robot role,
these units have but one purpose for their existence; to
entertain, amaze, and delight those who see them. One way in
which this amazement encouraged is to add flashing lights
is

or other eye-catching devices which are clearly visible, under

protective covers, and which seem, or even may really be, a
part of the robot's internal control system.
We examine GARCAN closely because he gives us a
good insight as to what makes one robot "tick." He is a well
engineered model, and a person might expand his basic sys-
tem to include a multitude of sensors, computerized control,
TV eyes and such, if one is inclined toward experimentation
or design in this direction.

EXAMINING THE INSIDE OF GARCAN™

Now we examine the inside of GARCAN. It is easy to
loosen three bolts which hold the inverted garbage can in
place on the circular base structure. There is a multitude of
wires running from the base electronics to switches and
electronics inside the bubble-head. One has to be careful to
lay the garbage can down right next to the base as shown in

Fig. 3-3. Another view of the two parts can be seen in Fig. 3-4,
and a good view of the internal wiring is shown in Fig. 3-5.
Notice that there is lots of space should one desire to add

arms and the arm mechanisms. No attempt had been made to

cable the wiring and there are no special wires except one. A
wire from the radio receiver, located in the bubble, which
comes down to the motor control unit is a coaxial type. Coax
prevents stray signal pickup which could influence the con-
trol, steering, or drive signals to the base mounted elements.

In Fig. 3-6 Mr. Rebman points out a particular circuit holding

a standard radio control transmitter such as made by Heath
Co., ACE Electronics, Kraft, etc. The second robot is wear-
ing an armadillo suit covering. The electronics for the two
robots are identical, but different RC frequencies are used for
control so both may be operated simultaneously.
There are many other covers which can be used with the
base platform. One is a snowman, another is a Christmas tree.

77
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The armadillo covering is made of fiberglass, and on this
robot there is a forward jutting arm which is used to prevent
the robot from damaging its head
happens to run into
if it

something. On the reverse end of the covering

is a tail. This

has no electronic purpose or defensive purpose but is for

effect only. Because he is such a pet, the smaller armadillo
has been given the special name Minidillo, and he is shown in
closer view in Fig. 3-7.

INSIDE THE ROBOT BASE STRUCTURE

We look at a view of the base structure in Fig. 3-8 and we
can see how one drive motor and two steering wheels have
been mounted. The wheels project through the base. We can
see that the one on our right is connected to a electric bicycle
motor 0/4 horsepower) by means of a chain and some sprocket
gears. Each wheel you see here has its own motor.
With the swiveled front wheel, the three wheels will
form a triangle with a wide enough span so that very good
stability is achieved for the vertical structure. Also, not visi-

ble in this photograph, but present, is a deep charge 12 volt

automobile type battery which is located just behind the front
wheel and shown. Jerry
just to the rear of the tape cartridge
informs us that it is very important to get a deep charge type
battery as the motors draw some 30 amperes when stalled,
and about 5 to 6 amperes when running, and so for operation
over any length of time a really good battery is needed to
supply motive power. This same battery, with voltage re-
duced and regulated to a value of about 4.8 volts, is used to
power the radio receiver, and the radio control servos.
Switches control the larger power flow for the tape deck and
lights and such.
Since motive power is such an important first feature of
any robot of this type, we get even closer through Fig. 3-9 to
the motors and drive mechanism. Each rear wheel has an
identical chain drive and an identical electric motor of the
type shown. The speed of each motor is controlled indepen-
dently by radio command through the radio control transmit-
ter held by the Robot Master.

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85
 I wondered if it was a problem to synchronize the motors
to get forward travel. This, said Jerry, is not a problem. Since
the motors are nearly the same, and since he has independent
control over each motor's speed, he can easily— with
practice— adjust the RC sticks so that the robot moves for-
ward or reverses in a straight line. To make the robot turn,
you simply advance the speed of one motor while you reduce
the speed of the other motor. A tight turn results. It is also
interesting that a double gear-reduction via the chain drive
sprockets, is used to get the speed of motion down to about a

fast walk. Using a gear reduction you increase torque to the

wheels and thus the unit is able to operate over thick carpets,
grass, normal unevenness in concrete and such. A single
wheel for both motive power and steering of such a base
platform is not really practical except on smooth surfaces.
The arrangement shown here has turned out best and will
prevent tipping of the robot even on a steep grade.
A good side view of how the tape player is mounted, at an
angle above the motors, is shown in Fig. 3-10. You can see
that when a given tape is placed in the unit it cannot be
changed without removing the body from the robot. This
presents no problem, really, as you know ahead of time what
kind of tape you want inserted, and the tape is long enough so
it doesn't get boring during a demonstration. Another advan-

tage is that you can record your own jokes, stories, or what-
ever. With the 8-track unit, there is radio-control switching of
tracks. You know what's available on all of your tape, and you
simply command whatever track is appropriate at that mo-
ment. The commands for this function are sent to the regular
radio-control servos which are mounted so they open and
close the microswitches which operate the tape player, a very
reliable and positive method of control.
We can examine the gearing and chain drive system still
closer in Fig. 3-11. Notice that the driving wheels do not turn
to accomplish steering. The wheels are fixed in the plane
shown by means of rigidly mounted axles. To turn the base,
one of these wheels is made to go faster or slower than the
other. To the right of the nearest wheel is a black looking

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88
vertical stack. This is one of two heat exchanger mountings
for the powering transistors for the motors. These transistors
get really hot and must be mounted on a heat dispersing base.
The motors themselves also get very warm to the touch, but
they operate within the manufacturers specified temperature
limits. The wheels are obtained from a hardware store and the
gear is bolted to them. Bolt shafts can be seen on the nearest
gear, while in the background you can see the relative size of
this gear. The chains are smaller than the regular lawn mower
type, but very strong.
We have mentioned the use of the regular model airplane
servos as mechanisms to control function switching. In Fig.
3-12 we get a better idea of how this was done. By close
examination you can find the little servos with their plastic
arms which, when moved by radio command, open or close
the microswitch levers on each side of them. These servos
and switches are bolted down rigidly to a base plate of plastic
and this, in turn is fastened down to the supporting structure
above the drive motors. The use of micros witches is impor-
tant. Since they snap into contact or out of contact, they make

a positive connection quickly and thus may prevent burning or

pitting of points. Also, since they have a good rating in
conductivity, the points are large enough to pass all the
current required for the auxiliary items easily and without
loss.
Because the driving section of such a robot is usually the
biggest problem to those who would fabricate a robot, we take
another look at the drive motors and their mounting and the
chain link to the wheels in Fig. 3-13.
In this figure you can see, with a close observation, that
each end of the drive motor has been equipped with an
L-shaped mounting bracket. This, in turn is bolted down to
the baseplate. The use of such a bracket, which is bolted to
the motor, prevents the motor housing from rotating as the
armature turns. Sometimes you can use a cylinder case on a
motor and a strap around it to hold it down but if the strap
loosens, you have a motor housing rotating, or trying to, and
this causes problems. It is better to bolt a bracket to the

motor housing at each end of the motor and then bolt that

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91
down to the baseplate as shown. Observe, also, that this is but
one of the two drive motors required for steering and motive
power of the GARCAN robot.
have said that the drive transistors used with this motor
I

controller electronics system need to be able to pass high

currents which exist when the motor is starting and when
various speed changes occur. Going from a stopped position
to a full speed (approximately one foot per second) requires a
surge of about 30 amperes as opposed to the 6 amperes
needed to run the motors. Each motor requires four heavy
duty, high current transistors in order to accomplish the
switching required to permit variable speed control and re-
verse motor rotation. These transistors take the place of
relays and are more effective than relays in this application.
Since the transistors must be mounted on a heat absorbing
and distributing plate, they are mounted separately from the
printed circuit board used for the balance of the motor control
electronics. We can see four such transistors properly
mounted on a vertical metal plate with fins for heat dispersion
in Fig. 3-14. A terminal strip is bolted to the left side of the
plate to make connections positive and easy. These transis-
tors get very hot.
The balance motor control electronics can be seen
of the
in Fig. 3-15, in the center of the baseplate section. The heavy
duty 12-volt battery is normally located in the open space
toward us and away from the motor. The motor is the second
of the two required, and above it you can see the two-section
printed circuit board which contains all the necessary elec-
tronics to use the signals sent from the radio control transmit-
ter to its receiver— a series of pulses which change their
position with respect to one another and a reference in accord
with the stick movement on the transmitter. These circuit
boards convert these pulse positions into pulses of electric
current and feed these to the motors at a much higher current
level than the receiver is capable of delivering. The number of
these pulses per second determine the motor speed, and the
polarity governs the direction of motor rotation. Since two
drive-steering motors are required on this robot, two com-

92
Fig. 3-14. High current motor control transistors on a heat sink base which also
serves as a support structure.

plete motor-control circuits are required, using 2 radio con-

trol channels.
Notice that the mounting plates for the transistors are
located at each end of the photograph. They are also used as a
support for the second story deck on which the small radio-
control servos and microswitches are mounted, and to which
the tape recorder is fastened.

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 Before examining the circuit concept, we take a look at
Fig. 3-16 for another variation in this type of robot. This is a
Tall Boy unit with a high square body mounted to the base-
plate covering, and with its head bubble located at the top. It

stands some six feet tall, is painted black and when it comes
into a room it does create some excitement with its flashing
lights and strange noises!

Fig. 3-16. Jerry Rebman's 6 foot robot (courtesy Jerry Rebman).

95
 We have stated that these robots are paraplegic— no
arms. one decided to add arms, it would require additional
If

motor control circuits and motors. One motor and circuit

board would be needed for each arm as a minimum. With this
much additional equipment, the robot could be made to raise
and lower his arm— or with two such circuits, both arms
either singly or simultaneously. No elbows or wrists or grip-
pers would necessarily be used. Two more radio channels
than the minimum of three
(for motor control right and motor
would be needed. But one might use
control left and tape unit)
an 8-channel RC system (they are available) and cause the
closing of more microswitches to open and close pincers etc.,
if one wanted to experiment in this direction. Also, don't

forget that a person might use an 8-channel RC system for

many functions with that RC system operating on one fre-
quency and then incorporate a second RC system with another 8
channels operating on a second frequency! Since it would
operate on a different frequency no interference would be
experienced between the two. As we indicated earlier, the
limit as to what you can do with your robot will simply be
limited by time, effort, and money!

OPERATION OF GARCAN ELECTRONICS

Figure 3-17 shows how a computer may be interfaced to
drive a small radio-control type servomechanism. The impor-
tance of this circuit is that with it,you can interface a com-
puter to control your robot in either an autonomous or a
remote state simply by adding additional sections to the
GARCAN motor control circuit. Notice that the output of the
ICI 556A is driving a standard model airplane 3 wire servo. It
provides as output, the type of input necessary for the motor
control circuit of onemotor of the robot. You would have to
experiment with the addition of a second similar circuit,
connected to the computer output, or to the MC 14081-8 chip
to make a second channel to drive the second drive-steering
motor circuit of the robot.
you are ever to have an autonomous type robot, it will
If

have to have some kind of computer within itself. A domestic

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android type of household servant will never be achieved
without it! The best way to understand how this might be
applied to the GARCAN robot, is to examine the following
circuits. First take a look at a sketch of the RC transmitter.
From it learn how the various robotic functions are con-
trolled. Examine Figs. 3-18 and 3-19.
Notice that even the voice is controlled by a stick posi-
tion. When you are steering GARCAN, you will be holding
this type transmitter and you will be using the thumb of each
hand to position the two sticks. Jerry tells us that with some
practice you can control GARCAN easily and accurately. Both
thumbs would be working simultaneously as you can imagine.
All radio control bugs will love this type robot! Now study
Fig. 3-20.
It might be of help for us to point out that if you do not use
the radio control link, then there must be two signals from the
digital-to-analog converter. One of these signals must go to
the motor controlling circuit. The second signal must go to
several standard type RC servo units which control the off-on
switching for other functions. A motor for this application
should be relatively small, be either permanent magnet or a
field wound, 12 volt, direct current motor of about lA horse-
power. If the robot you intend to power is much heavier than,
say, 100 lbs, then you might think toward a 1/3-horsepower
motor. Each motor must be capable of being operated at
normal speed and load with an input of around 6 amperes, and
its stall current or starting current should not exceed the 25 to

30 ampere range specified for these two motors.

Since we have been discussing the computer addition to
the robot control system, it is interesting to look at a small
microcomputer system and its disc operating system shown
in Fig. 3-21.You can imagine typing in your commands on the
keyboard and transmitting them via radio link to your robot,
and if you let your imagination work a little harder, you can
imagine the robot's responses appearing on the CRT!

THE GARCAN MOTOR-CONTROL CIRCUIT

Jerry Rebman Electronics developed this motor control
circuit using as a basis, a circuit which appeared in the Feb-

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ruary, 1978, issue of RC
Modeler magazine. The circuit is
developed around the NE544
chip made by Signetics Inc.
Extensive modification to the original circuit was required by

Fig. 3-19. A commercially available 8 channel RC xmtr.

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Rebman Electronics, and it is with their permission that we
examine it here. In Figs. 3-22 and 3-23 we can see the circuit
layout.

From the left side of the diagram, we find the input which
has been prepared for positive pulses. Some RC transmitters
and receivers use a negative pulse arrangement. There are
circuits which convert those negative pulses to positive
pulses and ACE Radio Control is one place where such con-
version circuits might be obtained.
Next we find the ground, or common connection and at
the top the 5-volt positive input supply line. Notice that the
ground connection is common to both the 5-volt supply and
12-volt supply. Both supplies must have a common ground.
The input pulses, varying in spatial position, or time
position, in accordance with desired commands, are input to
terminal 4 of the chip. Thence the chip's connections are
made to various resistor-capacitor arrangements among
which will be seen the trim pot and the range pot, two
important adjustments. The trim pot is used to set the motor
speed to zero when the transmitter control stick is at neutral.
Refer back to Fig. 3-18 and see how the motor changes its
direction of rotation as the stick is moved up, or moved down.
When both sticks are at the center or neutral position, neither
motor runs and so the robot stands still. The range pot
governs how quickly current is applied to the motor. This,
then, in turn, governs how quickly the robot will start to move
when you move the stick from the neutral position. You
simply have to adjust this potentiometer to your own re-
quirement. You don't want the robot jumping forward, and you
don't want to have to wait a long time for it to start moving. So
you adjust the range pot for a condition suitable to you.
The switching of large currents to the motor is ac-
complished by the heavy duty transistors to the right in the
diagram. Two 90548 types are used as drivers, and the others
control the flow of current to the motor windings. These
transistors take the place of relays— if you want to think of
them that way, but they do a little more than a relay can do.
They can control the amount of current passed, as well as the
direction of flow of that current. A relay cannot do this. The

103
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4 - TO-3 TRANSISTOR SOCKETS
& INSULATING WASHERS

Fig. 3-22. The Motor control circuit for GARCAN. Two such circuits are required,
one for each drive-steering motor (courtesy Rebman Electronics).

104
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relay can turn the current on or off and it can control the
direction of current flow, when properly wired, but it cannot
control how much current passes its contacts. So, we have
direction of rotation and speed of rotation controlled by the
heavy duty transistors shown.
Finally, on the construction side of our discussion, we
note that in the following chapters we will supply information
about robot eyes, brains, and mechanizations, which may be
of help to you in expanding on this basic unit, should you
desire to do so. While it will be fun to operate the unit as is,
still it is possible that you might sit back and imagine your

robot doing useful tasks and jobs for you. To that end it might
need arms and all the joints and appendages which will make it
useful in a working capacity. Computer manufacturers have
developed systems which can be interrogated and operated

105
106
via telephone from anywhere. It is not beyond belief that one
could have a home sentry robot in the house when one leaves
home for a trip that would report by phone!

107
 Robot
Control
Programming

In the previous chapter we have discovered how a computer

might be integrated into an automated control system (a
robot) and we assume that the computer will take over and
direct the machine. This is what we want it to do. We also
have, deep in the recesses of our minds, the idea that the
computer will have been programmed by us, so that the
machine will do the things we want it to do. This may not be a
revolutionary idea, but it will be our working principle con-
cerning the incorporation of the computer into the system.
In this chapter, then, we want to try to examine some of
the ways in which we program such a computer. What types of
languages are used for control? How do they differ from other
computer languages which we might be familiar with? We
shall not restrict our examination merely to the hobby type
machines but will expand our knowledge by investigating
methods used in the commercial world of robotics. In a major-
ity of cases we will find that what applies to one situation will

apply to another.
As we well one of the closely guarded secrets of
realize,
the commercial robotics companies may well be how to com-
municate with a particular machine. There is a good reason
for this. The simplicity or the complexity of the language
governs the simplicity or complexity of the machine itself.

109
The software used with a commercial robot may be a vital key
into its most guarded operational secrets. New patents are
filed constantly. And just as there are new machines arising,
there are also new methods of controlling these machines.
For a variety of reasons, some manufacturers are reluctant to
reveal these methods.

A PRELIMINARY LOOK AT MACHINE COMMUNICATION

Since our communications to a robotic machine involves
telling the machine to do something, we must first have in our
minds the sequence of actions that we want performed. Let us
use a simple definition to expand that idea of action. Let us
call whatever the machine does an event. If it makes a light

flash, or it causes a visual blob on a TV screen, or it makes a

motor turn Vs of a radian, it is an event. It is the outcome of
having the machine perform an instruction, which we will
convey to it in some kind of language that it can understand.
So, one of the first premises that we must make is that we can
take something we understand and this will— through a con-
version device of an electronic nature— become an electroni-
cally coded signal which the machine can understand. When
we can do this, we can communicate with the machine.
Let us think of a simple example for a computer-machine
system. Suppose we choose a simple lettering arrangement
such as GF to mean to us that the machine must engage such
mechanisms as necessary to start the machine moving in a
forward direction. We must be clear in what we mean by
forward in this situation. If we have a machine which is mobile
(a robot such as GARCAN) this letter code would mean that
the drive wheels start up and both rotate at the same speed in
the same direction moving the robot in the direction it is
facing. We must have agreed with our self that this is how we
will define forward because there is no other reference used
in this robot system except its own body geometry. Notice we
have assumed that the robot can "face" in a direction! We
derive this from the human body which has a "facing" direc-
tion and a "rear" direction!
The letter symbols GF mean absolutely nothing to the
machine until they are translated into its language. The

110
machine uses electricity as a working element, and so GF
must convert to electricity in some unique and distinct man-
ner so it cannot be confuse with any other electrical signal(s)
which might be present in the system. The computer can take
the GF input from two keys on its keypad and from its
memory section produce, as a function of time, a very specific
series of pulses when each key is pressed, which, in turn,
represent a code inside the machine, which can cause things
to happen. As you know a pulse, is known as a "one", and the
non-existence of a pulse, within a specified time interval, is

known Each stream of pulses for each key is

as a "zero".
unique. In computer language a machine word has been
formed.
Let's make the case easy by assuming that we get a code
like 1111 when we depress the key with the letter G. On the
way to the big event, the four ones go to certain other circuits.
The four ones energize— in this example, four gate circuits
which will energize some solid-state or physical relay cir-
cuits, which could cause events to take place mechanically if

and when another code signal of the machine type energizes

the second input to the gate. So we now depress key F and
release another string of coded signals. This time we have
designed the memory bank to release a signal which looks
like0001 three zeros, or no pulses, and then a pulse, all in the
proper time relationship. These signals also go to those four
gate circuits. You've already guessed what happens: Three of
the gates having a one from the first letter now get a zero from
the second letter and so these gates do nothing! But that
fourth gate gets a one from the first letter and a one from the
second letter and so it activates its relay and that relay then
applies electrical power to the drive motor system of the
drive motors in such a way that the machine moves forward.
Now we can begin to imagine a program to cause many events
to take place. Such a program would simply be a series of two
letter commands, taken in proper sequence.
When we think of a program through a computer we must
also consider a time factor. In the previous example, how long
do we want the machine to go forward? If it is for a specific
length of time, such as, for example, the time it takes the arm

111
 swing from an end position to the start
of an industrial robot to
position, then we must
either have a clock timing the arm
movement or a sensor at the end position which, when acti-
vated will send a signal the machine can understand, back to
its computing section to tell it to stop sending forward signals

out of its memory.

So, what's the problem? The problem is to have a com-
puter that can convert the type commands we wish to issue
into suitable control signals for the mechanism to produce
events. Our commands may be of the immediate input form,
such as when we type them on the keyboard, or they might be
a stored typed on disc or cassette if we decide we don't want
command that unit all day! If the machine is to
to sit there and
perform many complex movements or operations or events,
then we will need subroutines performed in the proper order
and sequence so that no one— not even ourselves— can get all
mixed up and forget or omit some command which is neces-
sary to the whole operation. Very, Very, careful and accurate
programming, complete, and without bugs is necessary for
control of machines! Figure 4-1 illustrates this discussion.

WHAT ABOUT THE ROBOT THAT LEARNS?

We have mentioned a type of robot machine which is
taught what it must do by having it go through the series of

required movements and actions under the direct control of a

human One such robot is the Cincinnati Milacron T3
teacher.
Industrial Robot, shown in Fig. 4-2 doing a commercial weld-
ing job. The robot is an articulated arm, and here it works with
a robotic companion, to the left in the photo, which is a small
squatty unit which turns the work to various positions as
required. We know, just by looking at the photo, and with our
limited knowledge of welding, that the arm must be capable of
moving that welding wire and torch to just exactly the right
place for a spot, or along just exactly the correct line for a
seam. It must deposit just the right amount ofweld material,
with the proper heat, for a perfect joint. It does this under the
guidance of a computer.
Before moving further into the operation, let us examine
the physical aspects of this arm in more detail. This is benefi-

112
 GATES
CLOCK
TIMER

FEEDBACK
SENSOR

FORWARD
M
^
f

X
LEC
;
MOTORS
I MECH
OUTPUT
1/

4-ONES
PULSE
CIRCUIT EVENT 2
1h

3-ZEROS &
-HONE PULSE
1

CIRCUIT 3-ZERO's
^7 1-1

EVENT 3

SUB
ROUTINES
IF
USED

CLOCK OPENS GATES IN

SEQUENCE FOR SERIAL DATA EVENT 4

Fig. 4-1. An elementary concept of a computerized control system.

cial this type robot is in great demand in industry, and

because
as the demand for goods built to rigid specifications in-
creases, more and more of these type robots will be found in
the plants and manufacturing centers. They will do much
more than just welding operations or paint spraying. These

113
 §8
is

° °'is

cvi£.E

114
type robots, perhaps with some modifications and improve-
ments, will be doing assembly of intricate parts, moving
various batches of materials from place to place and so on.
They will in the final stages of an assembly line conduct the
testing and evaluating of manufactured items and will accept
or reject such items as necessary.
Examine Fig. 4-3, which shows the articulation of the
arm, and its ancillary equipment. Notice that both electrical
power units and hydraulic power units are used to obtain the
necessary movements. You can see the hydraulic piston in-
side the elbow, for example, and you know that electric
motors are used at the wrist and gripper because they furnish
adequate power and are fast and small and relatively light
weight. In Fig. 4-2, if you will refer back to it, you can see the

large electric motor which is located at the shoulder position.

It is of some interest to examine more closely the wrist
and gripper part of the arm as shown in Fig. 4-4. We see some
details as to the number of motors used. Their size, and how
the whole section designed so that there can be little open
is

space for dust and dirt to enter into the machinery is illus-
trated. Various types of grippers, the robotics word for fin-
gers, can be attached to the disc.
On the application shown, one must realize that there
must be a coordination between the arm and its companion,
the holding and turning unit. There is this coordination, and it
comes about by means of computerized control. Thus it is
incumbent upon the computer to know, exactly, where in
space the gripper is at any moment, and where the position of
the work is. A programmer had to figure out just how the arm
should move, that is, how much of a shoulder movement, how
much of an elbow movement, how much wrist movement, was
necessary to get the torch to the required points in space each
time a move of that torch-tip was required. As you can easily
see, there are countless movements of the arm itself and all

its moving parts which might be used to change the position of

the torch in space. But perhaps only one set of movements
will give the end product, the required movement in the
shortest time and in the most efficient manner. That kind of

115
116
Fig. 4-4. The wrist and gripper of the Cincinnati Milacron T3 robot (courtesy
Cincinnati Milacron).

movement must be the result of a good programmer's

software development!

TEACHING THE CINCINNATI MILACRON T 3 ROBOT

No, you do not have to be a programmer in order to
operate this robot. But, what you will need is a small teaching
control unit such as is shown in Fig. 4-5. You can examine the
photograph and see the types of functions controlled by this
unit. Essentially it will permit the movement of the arm
gripper to any desired position, and it permits a check on the
programming sequence by means of a replay, so that you
know if the actions you have taken the arm through are really
what you wanted it to do! Also, it is possible to have some

117
programs stored on cassette tapes so that you can use them
when appropriate. Change the arm movements with another
tape and then later, if it is needed, you can go back to the first
tape for the original movements.
Let us suppose that the job which we want to teach the
robot is simply a pick and place operation. That is, it must
move to an acceptance position. When the object that it is to
move comes along it will grasp the object, lift it and move it
around to another belt and then set it down, gently, and
carefully, and then return to the acceptance position to wait
for another object to come along. In this very simple example,
we aren't worrying about how the robot identifies the objects,
or if it is only to pick up certain objects from among many that
might be on the belt. We are just assuming that at very
precisely controlled intervals, along comes this thing which
the grippers on the arm are positioned to intercept. We aren't
even worried about the position of the thing. We assume it
will be so positioned that the grippers will be able to engage it
tightly in a proper manner and lift it without damage or
slippage.
Let us examine the teaching unit of Fig. 4-5. Notice that
we have some buttons which we can depress which will move
the arm, the wrist, and the grippers, in a multitude of direc-
tions.At first we proceed slowly trying to make the arm
swing around and set its gripper down on the belt in the
proper position to intercept the thing. If we make mistakes,
we can delete them and try again. Now we want to make the
arm remember this segment of operation and so, through the
proper button on the teaching device, we enable the computer
to memorize those movements we have had the arm perform.
We want to be sure. So we manually bring the arm around to
some arbitrary position and we engage the section which
causes a replay of our operation. The arm should move around
to the desired position and open its grippers ready for the
thing when it arrives. But, notice! The arm did not necessarily
move in exactly the same manner we moved it! Now what? Is
the arm beginning to think for itself?
No, the computer has taken all our little pieces of move-
ment and examined them and then, using the software de-

118
 The teaching unit for the Cincinnati Milacron T3 robot arm. Step-by-step
Fig. 4-5.
movements are stored in the robot's minicomputer; the computer simplifies
these directions and controls the arm movements.

119
signed by some expert programmer, has done some re-
calculation and determined that the way we moved the arm
isn't the best way to move it. So the computer works out a
new spatial trajectory and moves the arm in its own manner.
The arm moves to exactly the position we want it to move to.
It orients itself in exactly the manner that we had it orient

itself and the only difference is the way the arm moves in
space to get there.
Now we need a thing and we need to slowly steer the arm
so it picks up the item and moves it over to the new location
and sets it down carefully on the belt and releases it. We take

the arm through those movements, using the button control-

ler. We then check our operation by a quick replay and if all is
all right we commit that section of movement and operation to
the computer memory. Finally we cause the arm to return to a
starting position where it will lie in wait for the next thing to
come down its hungry jaws!
the input belt into
Because we don't want to make this seem too simple—
although the teaching operation is relatively quite simple—
we present the following description of motion as stated by
the manufacturer:

"During the teaching, the operator has available

three different spatially coordinated motion sys-
tems; that is, paths along which he (or she) can
move the arm from point to point.
"Cylindrically coordinated motion moves the arm
around the vertical axis of the robot and in-or-out
from that axis.
"Rectilinearly coordinated motion moves the arm
along (x,y, and/or z) coordinate lines.
u
Hand-coordinated motion moves the arm through
as many as all three of the T 3 's available axes (x, y
z, orroll, pitch, and yaw) simultaneously. Because

all axes are coordinated, the arm moves only in a

straight line from point to point and maintains
orientation even though all three axes are in mo-
tion.Hand coordinated movements of the robot
arm can be compared best to the movement of the
human hand which goes from place to place in the

120
 shortest straight line path without any regard to
any other spatial orientation of the body.
"All three of these motion systems are selected by
pushbutton on the program entry terminal (teach-
ing unit)."

DOING OTHER JOBS WITH

THE CINCINNATI MILACRON T 3 ROBOT
The reason that this arm can do other things is that it can
be equipped with sensors, and the arm is programmed from a
computer directed base. This means, that like all com-
puterized activities, software has been developed which
makes it possible for the robot arm to understand human
commands. Let's examine what the robot can do in a materials
handling role. Figure 4-6 shows the arm stretched out at a low

Fig. 4-6. The robot arm selects a "thing" and picks it up and moves it (courtesy
Cincinnati Milacron).

121
level to enable its grippers to grasp a thing. Next we can see
how the arm contracts as it moves upward.
Note in the lower right corner the display unit of the
computer cabinet. It is possible to look at the computerized
program for this robot on that display screen, and program-
mers will be happy to know they can delete or add or even
build a program using this display unit without having to
actually move the arm at all. It might be somewhat similar to
writing a program at home on your home computer. This
screen also will display diagnostic information, should that be
needed.
Finally, we mention that the reference point in this
system is that spatial point where the gripper tool meets the
workpiece. You have to know where that is, visually, if you

program with the little control box, but not necessarily

mathematically. The computer
will mathematically find out
and determine the space coordinates of that end point.

SUBROUTINE PROGRAMMING FOR A ROBOT

A subroutine for any computer generally means some
pre-defined action which will be called at some point when an
appropriate command or signal appears in the general pro-
gram. In a way it is an aside action, and the overall operation
of thecomputer is stopped while this side action is in effect.
When it has been completed, the computer will then pick up

where it left off in the main program and, possibly using the
information from the side action, continue on its main pro-
gram operation.
With a computer which controls a robot machine, the
subroutine is sometimes called a branch action routine. This
simply means that the movement of the robot arm will be
made to follow something other than its normal movements
when an appropriate activation signal causes it to go into the
subroutine programming. We need to examine a situation
which illustrates this.
A truly general-purpose industrial robot system must
have some way of selecting or altering the normally pro-
grammed path and functions of its arm based on changes in the
working environment in which it operates. The name given to

122
this ability may vary from manufacturer to manufacturer, but
the purpose of the operation will always be the same. When
the robot's moving part reaches some point it will pause to
see if there is another signal at that point. If that signal exists,

then the robot will move into a subroutine. If, when the robot
looks for that subroutine input signal, it finds that it does not
exist, then the robot will continue its normal operations in
normal sequence.
In Fig. 4-7 we see a diagram which shows a mainline
program movement of a robot's arm, and a branch or sub-
routine break in that normal program movement. The exit
into the subroutine movements occurs at C when an appro-
priate signal comes into the robot's input. Normally the arm
will move on the trajectory A, B, C, D, E, and back to A. We
can also assume that when the arm is not working it will be
retracted to the position X, and that it must first extend from
X to A before it goes around that mainline trajectory. We will
imagine that the arm picks up something at A and moves it
around to E, drops or positions it there, and then comes back
to A to get another part.
Now let us see what could happen if an input signal
comes at the proper time when the arm pauses at C. Suppose,
just for an A may need to
example, that the part picked up at
have something else attached to it at F, G, and H before it is
ready to be placed or positioned at E. The branching input
signal then could mean that this part needs to go to all the
stations. The main program trajectory line is changed to
accommodate this required action.The arm goes into a branch
trajectory or into a subroutine program at point C and exits
that subroutine at D whence it is back on the mainline pro-
gram trajectory once more. Notice that if the arm pauses at
(C), and no input signal arrives, the arm will move on from C
to D and will not go through the subroutine operation. It is

important to realize that this is not a real-life example, but

just a discussion and illustration to show what a branch pro-
gram or a subroutine program is.

In practice there usually is a large number of these

subroutine programs in operation. For example, if during
inspection of a machined part some defect were found, the

123
124
robot might branch to another part of the program that would
dispose of that defective part, alert an operator to the fact that
was there, and then the robot might just shut
a defective part
down operations (as specified by the subroutine) until the part
was repaired or replaced or whatever.
The method discussed called standard branching is the
simplest way to change the robot's path programming, but
these standard branches are limited because each branch
must be associated with one particular input signal to the
robot's control system. This means that if there are X signals
required there should be X lines to carry this information to
the control system. It is possible to have fewer lines if an
external decision-making element (a computer) is available
which can look at all input signals simultaneously before
specifying the branching or subroutine operations. With 8
8
lines there are 2 or 256 different conditions for branching
that can be identified by the computer. In the Milacron Robot
System the extension of the standard branch is called a condi-
tional branch or subroutine.

THE COMPUTER OUTPUT FOR

A CONDITIONAL-BRANCH SUBROUTINE
Let us see now what kind of computer output could result
from having the computer look at all 8 input lines and the 256
possible conditions for branching. We are agreed, now, that
the computer will look at all these possible inputs and will
activate a subroutine or branch program if, and only if, the
voltages present on the 8 lines represent a certain signal. For
example, if the arm were programmed to branch into a sub-
routine at point B computer was told,
of Fig. 4-7, but the
"Branch B 1,-5,7-8," then that subroutine would be entered
into if, and only if, signal input 1 is on, and input signal 5 is off,
and input signal
- 1 is on, and input signal 8 is off! If the
computer looked at these particular signal inputs and found
any of them different from the specification, then it would not
command the subroutine branching at B and the arm would
continue on its normal trajectory to C. Notice that it is possi-
ble to express the robot's operation completely in Boolean
Algebraic expressions.

125
BRIEF BOOLEAN ALGEBRA REFRESHER
Boolean Algebra is called the algebra or logic. It was
invented by George Boole, mathematician and logistician, in
1847. This is the algebra of automatic control and switching
devices in today's world.It permits one to present switching

symbols and then to manipulate those

circuits with algebraic
symbols according to the laws of algebra so that one can find
the simplest manner in which to accomplish complex switch-
ing and operation of various electronics and electrical cir-
cuits.
Boolean Algebra deals with truths and non-truths that
relate well to switching devices that are either on or off.
Digital devices use "states" to represent one or zero which is
roughly equivalent to a switch being on or off. Therefore,
Boolean Algebra is well suited for digital work. Let us apply
this concept to a simple circuit.
Let us say we have a circuit with a switch and a light in it.
We can say several things about that circuit:

(A) The circuit is on

(B) The light is on

Algebraically we can use the letter symbols of these state-

ments to indicate and express the condition of the circuit and
the light. For example:

1. A.B (meaning A times B) means that the circuit is on

AND the light is on.

2. A+B meaning either the circuit is on OR the light is

on.
Finally we can write:
3. A«B where the bar over the B means NOT or a
negative. Thus, the circuit is on and NOT the light.

These are the three basic functions of Boolean algebra, they

are the AND, the OR, and the NOT functions.
When this kind of algebra is applied to circuitry, it is

common to use the multiplication function for series connec-

tions,see Fig. 4-8A. For parallel connections one would use
addition (Fig. 4-8B), and a negative situation is at Fig. 4-8C. It

126
 o A

INPUT OUTPUT

CIRCUIT EXPRESSION = A • B
BEFORE AN OUTPUT IS OBTAINED

A .

o
INPUT w OUTPUT

CIRCUIT EXPRESSION A + B
BEFORE AN OUTPUT IS OBTAINED

^L
INPUT OUTPUT

CIRCUIT EXPRESSION OUTPUT = A

OR OUTPUT = B
BEFORE AN OUTPUT IS OBTAINED

Fig. 4-8. Some Boolean algebra expressions illustrated.

127
is common to use a zero for an open circuit output and a one
for a closed circuit condition.
With this concept of algebraically stating the condition of
circuits, it is customary to express the Boolean conditions as

follows:

LAWS OF BOOLEAN ALGEBRA

(a) A«B + A-C = A(BH-C) (•= and)

(b) A+A =A (+ = or)
(c) A-A =A (A = NOTA)
(d) A+A = 1 (Key)
(e) A-A =
(f) A+A*B =A
(g) A+B =(A-B)
(h) AB =(A+B)
(i) A(A+B) = A-B
© A+A«B = A+B

Note that the dot is sometimes dropped, just as in algebra, and

order is from left to right, unless specified by parentheses.
It is common to take a circuit and develop a Truth Table
of its operations. This is a chart in which all the outputs for all

the conditions of the switches are stated, one at a time. Then

letters are assigned to the switches, and, as you have seen,
the expressions of the truth table lines can then be put into
Boolean algebraic expressions which can be reduced to the
simplest expression. By re-converting the letters back to
switches or switching circuits, a person is then able to draw
the best circuit, and the simplest circuit, for that device.
One can quickly see how such a mathematical tool can be
of tremendous value in the field of advanced robotics. As we
have indicated in the Milacron robot, there might be many
inputs to the machine under various conditions of operation.
There have to be conditions of multiple switching inside
will
the robot's mechanism to make it do what the inputs call for.
Being able to mathematically state the operation using Boo-
lean algebra helps to arrive at a cost-effective unit which will
do its job in the prescribed manner.

128
MORE ABOUT ROBOT BRANCHING OPERATIONS
To illustrate one use of conditional branches, imagine
that you have a material handling situation in which a super-
visory computer is being used, and this computer is also being
used for other automation functions. Remember that the
number of lines required for a given robot's operation can be
stated in powers of 2, then, if the robot machine requires 16
signal inputs, the robot will require only four lines to convey
to it all the information it needs to get the proper branch
program into operation.
In many applications of a robot machine in industry it is

desirable for the robot to have a method for creating a branch

operation that can be used at a number of points in the robot
cycle; a branch that can effect its movement sequence, re-
gardless of the physical location of the robot arm, when the
branch operation is requested. For example, when the branch
operation affects the robot's gripper position and/or its wrist
orientation.
Some kinds of applications require another kind of offset
branch, where the branch can be entered, not only at specifi-
cally programmed points, but anywhere or anytime in the
normal cycle of operation. When a proper input signal is
received by the arm-control unit the signal can cause the
robot to enter into an interrupt offset branch operation. One
example is that illustrated in Fig. 4-9. In this illustration one
can see that the arm is caused to move on trajectory 0B01-
0B02 when the interrupt signal is received at point X on the
normal trajectory from M005 to M001. Notice also that at
each position M002 and M003 and M005, the robot's arm will
go into the type of branching operation specified by the OA
numbers. Notice that the type of movement for each of the M
points is exactly the same when the branching occurs in the
OA series, as shown in this illustration. So the same sub-
routine called for at point M002, can be called for at M003 and
M005.
The question as to what an interrupt branching operation
might consist of may be answered by considering that it could
be a twisting, jerking, series of movements of the robot's arm

129
 INTERRUPT POINT
0B02

0A02

0A02

STANDARD OFFSET = BRANCH OA

INTERRUPT OFFSET = BRANCH OB

Fig. 4-9. Offset branching of a robot arm (courtesy Cincinnati Milacron).

which would cause a welding gun tip to be loosened from a

stuck position on the work piece. A sensor of some type
would have to monitor the gripper movement, and in event it
becomes stuck or does not move along smoothly as it should,
then this sensor generates the signal which causes a special
routine to be implemented immediately by the computer.
That, of course, in turn, activates the arm into the special
motions described.
Extending this concept one can realize that special
routines might be required for many applications. If the
robot's arm handled the moving of objects which normally are
spaced a given distance apart, and timed precisely on arrival
at a given position, then if something disturbs the flow, a
sensor would generate, perhaps, a wait or delay signal to the
arm.

THE ROBOTS SEARCHING FUNCTION

In addition to altering its cycle by entering branches, a
robot system such as the Milacron can adjust the position of

130
data points within an existing cycle, based on changes in
external equipment and workpieces. In a way, this might be
called adaptive control where the current condition of some-
thing specifies what the future operation will be.
One example of how this type of adaptive control might
be used is in stacking, or handling operations from a stack,
where the items may have a variable thickness, or the stack
may vary in thickness or height. In this case you can readily
realize that the arm must progress from some fixed-level
starting point, where it begins to "pick up" the parts, and
descend to lower and lower levels each time a part or work
piece ismoved out of the stack. The control operation in this
type of movement is called a search function.
The data comprising a complete branch sequence in the
robot control can be rewritten with data from the external
computer system. Thus, if the position or orientation of a
workpiece varies, the robot's movements and functions can
be adjusted by the external device so that it will properly pick
up or perform the required operations on the workpiece. If an
emergency situation is detected, a branch can be replaced
with other branch data which will enable the machine to
handle this specific emergency condition. The speed at which
this data is fast enough
can be transmitted to the robot control
to complete the communication in a fraction of a second, so
this type of branching has been and is called adaptive branch-
ing.

MORE ON THE SEARCH FUNCTION

The search option on Cincinnati Milacron's robot can be
used in stacking or unstacking applications. In teaching the
robot the task, two points, one above the stack and one at the
bottom, are programmed. Then a tactile sensor on the robot's
hand is used to send an interrupt signal to the robot control
system whenever the hand encounters an object in its path, as
itmoves between the two programmed points. The interrupt
signal causes arm motion to cease immediately. Then the
function associated with the subroutine is executed. The arm
then proceeds to the next point in the main program which
may be back to the original starting point.

131
 In an example, imagine that the robot arm is to pick up
some automobile windshields from a stack of them, and place
them one at a time on a conveyor belt, off to one side of the
stack. Recall that only the starting point above the stack and
the bottom point, at the bottom of the stack, are necessary to
be known by the robot's control machine. Thus, when the arm
goes from the start position down the stack, it stops itself
when its sensor contacts a windshield. The gripper then grips
that unit, and immediately moves it along a prescribed path to
the conveyor belt and deposits it there. Then the arm goes
back to the start position and resumes the operation all over
again. It is not necessary for the program to include the
specific pieces of work on on the
their positions, the sensor
robot's arm takes care Only when the robot's arm
of that.
reaches the second point, or stop position— meaning it is at
the bottom of the stack— will the arm move to some rest
position and stop moving.
Of course we realize the possibility of interrupting a
normal branching operation with an interrupt signal. This
signal might cause the arm to skip some movements and
move on to others, or go into an entirely new routine. Of
course any routine must have been taught to the computer by
moving the arm, with the teaching unit, or must be specified
by signals on a cassette or other similar type tape.

COMPUTER-USE SUMMARY
So we have learned that a computer can direct a ro-
bot—which, of course you already knew— and we now have
some concept of how the computer does this. The output of
the computer will be a series of signals to a bus which might
have, in our case, say, eight lines or terminals. When various
keys are pressed on the computer keyboard, the closing of the
key-switch contact will cause the computer, through its in-
ternal circuitry, to energize some combinations of these ter-
minals. Since a terminal status can be specified by being
either on or off— a two state condition— we can then consider
the permutations and combinations of eight things taken in
two conditions and we find that there are 256 possible states

132
of output, each being completely different. Of course if we go
to a 16 line or terminal type output on the I/O board, then we
will have 2 16 unique states for control. We leave it to you to
determine the numerical value of this possibility.
In order to control the higher values of voltage and
current necessary to really operate the control system of a
robot, some isolation condition must exist between the com-
puter and the controlled circuitry. This can be accomplished
by using optoelectronic circuits, or reed relays, or some kind
of similar devices. The computer output then operates these
devices and they, in turn, will operate the higher current and
voltage control lines.
When sensor input is required to the computer, these
signals come from sensors attached to the robot's position-
ing and moving elements or from scanning elements such as
TV microwave, sonic, or thresh-hold switches. Sensors such
as piezo crystals generate a current proportional to the force
on their containment cases. This voltage then must be di-

gitized as it originates in an analog form from the sensor. In

other words, it exists as a continuous level of current or
voltage and must go to some circuit which will convert it
it

into a computer word. As a very simple example suppose that

the amount level of the sample is one volt, then the word
might be 00000001 for an eight bit word. If the voltage level is
two volts, the word might be 0000001 1 and so on. In any event
a particular series of off-on pulses or bits will now represent
the sensor level signal to the computer.
The computer can work with this. It routes the pulses to
various addresses which in turn release new signals to the
I/O board which then passes them on to the control circuitry
for the robot's moving elements. Notice how the computer
might get a particular feedback signal from a sensor, and when
this signal goes to the memory banks it might cause a sub-
routine program to be initiated.The subroutine will be unique
and special and non-duplicable by any other input signal. So,
anytime it is necessary for the robot to move in accord with
this particular subroutine program, that particular signal of
ones and zeros must be received by the computer.

133
SOME CONSIDERATIONS OF ROBOT DESIGN
The robot ismachine and can be a very complex
a
machine if the situation and conditions warrant this type of
development. The robot falls into a category of machines
which are usually studied under the heading of feedback
servo mechanisms. This is really a fascinating subject and it
embodies the best application of such mathematical concepts
as the LaPlace Transforms and Fourier Transforms to ex-
press mathematically how such machines will operate and
react to various input or operating conditions. When design-
ing such a robotics system one takes into account such things
as:

The system environment

Noise
Nonlinearities which can exist in the system
Component limitations
Undesired disturbances
Size and weight and space and power requirements
The random inputs which may occur.
If you get into the design of such devices, then you should be
familiar with such mathematical techniques as the Maximum
Principle of Pontryagin, Bellman's Principle of Optimization,
and Wiener's Least Squares Optimization . Some suggest that
classical calculus variations of these should be understood.
These mathematics enable a person or designer to put down
on paper the design of a system and the analyze its operation
before building it. Thus when it is built, it can be expected to
operate in a given manner and within a given type of specifica-
tion range. Computers enable one to solve the most complex
of problems easily, so all one has to know is what mathema-
tics to use and how to set up the problem for computer
solution and what the computer solution actually means!
We have mentioned adaptive control in connection with a
robotics system. might be important to examine this con-
It

cept just a bit more Adaptive control means, simply,

in detail.
that the machine will adapt its operation to a change in either
its external or internal environment. A self adaptive control

system is one which has the ability to change its operations

134
through a process of measurement and evaluation and adjust
itself to a new set of conditions in which it operates.
What a robot design engineer is always looking for is the
optimum response or operation of the system. That is, the
system must not work too fast or too slowly, but at the right
speed for the process or job at hand. If there is some change in
its environment— say that this might be the speed at which

parts are sent to it— then it should be able to adapt itself to the
new speed of arrival of parts and continue on merrily and
happily without any problems.
To make system which does things at the right speed,
a
as an example, we make an assumption that we know what the
right speed is. We then program this speed into the machine
and provide it with sensors which can determine at what
speed it is operating. Then, inside the machine, some comput-
ing element compares its speed at present to the speed which
we say is ideal, and the machine can then take the difference
between these two and uses that as a control signal to adjust
the speed of operation. Of course, you might imagine that the
speed signal we send into the machine when the operation
starts is just a priming signal. Once the mechanism is in
operation, this signal is constantly adjusted by adaptive cir-
cuitry so that the optimum or best response for that situation
is accomplished.
In the advanced world of robotics design you make use of
sampled data systems as well as adaptive control systems.

SOME CONSIDERATIONS IN PROGRAMMING A MOBILE ROBOT

It will be beneficial to consider some aspects of pro-
gramming a robot that can move about. We know that if a
sensor senses something which might call for some move-
ment of the robot, what that sensor really does is to cause a
signal to be generated which then calls a subroutine that
causes the necessary electrical power to be applied in such a
way that the movements are accomplished. Let us consider
how we might program a robot to move in a given way in a
given area.
As a first consideration we are faced with the basic
question, "Where is the robot? What are the robot's X and Y

135
coordinates at any second? What reference plane are those
coordinates on? Luckily for us, some manufacturers have
developed what is called a stepping motor. It can help us
answer the basic question.
As you know a stepping motor is one which revolves a
given amount when supplied with a pulse of electric current.
That amount might be five degrees or it might be twenty five
degrees. If pulses are supplied in a continuous train, the
armature of such a motor revolves in a continuous manner,
and if the pulse rate is fast enough we will not be aware that
there is any difference between the rotation of this type
motor's armature and the armature of any other motor. Both
revolve smoothly and quickly, but, there is a difference, and
an important one to us.
With a stepping motor we can govern distance traveled
or arm movement quite precisely. If we have a motor which
turns five degrees with each applied pulse, due to the way it is
built there must be a space (no-pulse) following each pulse, or
it won't work right. Divide 5 degrees into 360 to get the
portion of a turn each pulse represents. This number times
the circumference of the motor wheel ishow far that wheel
willmove on a floor with each pulse. Next we make a small
diagram of the movement our mobile robot should follow as
shown in Fig. 4-10.
What we do is to program a number into the computer
memory, for this example the number 11. Next we program
the computer so that when this number has been counted
down a subroutine will activate which will cause the steering
wheels to turn as shown through the angle alpha. The com-
puter knows that this has been done by monitoring a voltage
proportional to the angle the steering-drive wheels make
with the robot's frame, which can come from a potentiometer
mounted on the steering section of the robot. Now a second
drive subroutine count-down section begins and at the same
time the steering wheels will equalize in speed turning
straight ahead almost immediately after the robot starts mov-
ing. It will move straight along the X path for 8 pulses, turn
again thru the pre-set angle and continue 4 pulses to the stop
position. If you try to make such a robot, some experimenta-

136
137
tion will be required, but this concept will enable
it to do what

you want it to, if you program the pulse count-down correctly,

and make the turn-angle sensor equipment properly.
This is just an example. There are other alternatives.
One alternative would be to put a small magnet on the face of a
drive wheel which is driven by a regular electric motor. Each
time the drive wheel makes one revolution a pulse is gener-
ated which can be used to make a computer circuit count
down. Or if a more precise robot position location is needed,

then two such magnets, moving by a fixed coil spaced 180

degrees apart will give two pulses per wheel rotation.
One might use the wheel pulses by sending them to a
circuit which will accumulate them into a voltage and when
this voltage is high enough, it can trigger a relay or some such
device which will cause other circuits to energize. Now that
you have the idea, you can build on this concept to achieve
something satisfactory to your own needs and capabilities. It
is a fun project and when you can make your robot move

around a room without hitting anything, or stopping, or get-

ting off track, then you will really have done something!
In the industrial sense, the previous example shows how
a robot's arm might be programmed during a cycle. Then if the
program is repeated over and over, the cycle will be repeated
as long as the program is run.

COMPUTER LANGUAGES FOR ROBOTICS

There are no fully defined, recognized languages for
robot control. Individual manufacturers tend to put together
whole systems, including CPU, and define each movement in
by typing in a short code word.
a subroutine that the user calls
These subroutines are, of course, in machine language, and
the programmer at the factory that made the robot had to use
machine language because it is the only language that allows
the level of intimacy with the internal workings of a given
CPU necessary for programmed control. Limiting the user to
those routines that the original programmer foresaw a need
for is not the best use of the system's capability. Allowing
complete programmability appeared preferable, but there are
problems here too.

138
 First, many programmers lack the combined hardware
and software knowledge needed to do control programming.
Second, the company is understandably concerned about dis-
seminating too much information dealing with the internal
control of a machine that they have invested years of design
work and money in. Third, most companies installing such a
system would probably not want to hire a programmer just to
do one job (though this is changing) and a short term contract
with a specialist is pretty expensive. There is a solution
though, and most companies will probably be going to this
method eventually, though today most are still using the first
method discussed.
There are high-level languages that are very easy to
program in but do not compile down to very efficient machine
code. Most of them have the capability of linking subroutines
that are already in machine language to a program being
compiled. So the manufacturer writes a group of very efficient
routines for directly controlling the robot, and supplies them
as a library of added functions to a language like BASIC or
FORTRAN.
There have been some studies of robotics conducted at

Stanford Research Institute in which FORTRAN has been

used. In one such study a mobile robot was programmed to
move about a floor space and was asked to move certain
objects, by pushing them, into various positions in that space.
This study was conducted for the Advanced Projects Agency
of the Rome Development Center, Griffith Airforce Base,
New York. It is interesting to examine a portion of their
report.

'The robot system is capable of executing a

number of functions that vary in complexity from the
simple ability to turn the drive wheels a certain number
of steps, to the ability to collect a number of boxes by
pushing them to a common area of the room.
"Of the functions mentioned the simplest are cer-
tain primitive assembly language routines for moving
the wheels and tilting the head (TV), reading a TV
picture and so on.

139
 "Two examples are MOVE and TURN. MOVE
causes the robot to move in a straight line by turning
both wheels in unison, and TURN causes the robot to
rotate about its center by turning the drive wheels in
opposite directions. The arguments of MOVE and
TURN are the number of steps that the drive wheels are
to turn (each step resulting in a robot motion of l/32nd
inch)and status arguments which allow inquiries to be
made about whether the function has been completed or
not.
"Once begun, the execution of any function either
proceeds until completed in its normal manner, or
it is

until it is halted by one of a number of abnormal cir-

cumstances such as the robot bumping into unexpected
objects, overload conditions, resources exhaustion, and
so on. Under normal operation if the execution of the
MOVE command results in a bump, motion is stopped
automatically by a special mechanism on the vehicle.
This mechanism can be overridden by a special instruc-
tion from the computer, however, to enable the robot to
push objects.
"The problem solving systems for MOVE and
TURN are trivial. They need only to calculate what
signals shall be sent to registers associated with the
motors in order to complete the desired number of
steps.
"At a level just above MOVE and TURN is a func-
tion whose execution causes the vehicle to travel to a
point specified by a pair of X,Y coordinates. This func-
implemented in the
tion is FORTRAN routine called
LEG. The model used by LEG contains information
about the robot's present X,Y location and heading,
relative to a given coordinate system, and information
about how far the robot travels for each step applied to
the stepping motors."

"Ascending one more level in the system we find a

group of FORTRAN two-letter routines whose execu-
tion can be initiated from the control machine keyboard.

140
The action unit system now ceases to be strictly hierar-
chical (arranged in a graded series or sequence) since,
now, some of the two letter commands can cause other
commands to be executed. This means a branching type
subroutine operation.
"In this system, developed and studied at SRI, one
two-letter command (EX) takes as an argument a series
of X,Y coordinate positions in the robot's world. Execu-
tion of EX causes the robot to travel from its present
position directly to the first point in the sequence,
thence, directly to the second point in the sequence,
etc., until the robot reaches its final destination as pro-
grammed. Another two-letter command (PI) causes a
picture to be read after a TV camera is aimed at a
specific point on the floor to see if there is an object
there or not. The ability to travel by the shortest route
to a specified goal position along a path calculated to
is programmed by the two- letter com-
avoid obstacles,
mand TE. Execution of this command requires that the
computer solve the path coordinates using a special
problem solving system which is activated by the two-
letter command PL."

"As SRI ascended to higher functions of operation,

the required problem solving process had to be more
powerful and general. They wanted this robot to be able
to perform tasks which, quite possibly, would require
complex, logical deductions. What was needed then for
this type ofproblem solving was a general language in
which problems could be stated, and a powerful search
strategy with which to find solutions to these problems.
They chose the language of first order predicate calculus
to state the problems to the robot. The problems were
then solved by an adaptation of a question answering
system based on resolution theorem-proving methods.
One example of such a problem for the robot to consider,
stated in plain English is, "There exists a situation s and
a place p such that three objects called 0B1,0B2 and 0B3
are all at place p in situation s."

141
 Now the problem as the robot sees this is that the three
objects may not all be at place p, nor are they in situation s. So
the robot must move them until this problem statement is
satisfied. Notice that the command is not given to the robot to
find OBI and push it to place s, find 0B2 and push it to place s
and find 0B3 and push it to place s 2 .

In this case one would suspect that the robot would move
its camera eyes around until it could identify OBI either by
color or shape or both, and then track it down and move it to
place s where s has been indicated to the computer in the form
ofX,Y coordinates. The proof of the action would be that the
would look at the space s and if it
robot, from a position x1 ,y
1

there found the form of OBI, it would then look around for
0B2, etc.
We have included this information on this study because
it indicates some methods of programming robots, and the
use of a two-letter FORTRAN language. In this study, the SRI
group also used LISP language. It is stated that
Another LISP program enables commands stated in
"...

simple English to be executed. It also accepts simple

English statements about the environment and trans-
lates them into predicate calculus statements to be
stored as axioms.The English processing by this pro-
gram based on work by L.S. Coles: "An On-Line
is

Question-Answering System with Natural Language and

Pictorial Input". (Proceedings 1968 Conference of
ACM, Las Vegas, Nevada, August, 1968.)
In a survey of the languages which have been used in

work on artificial intelli-

robotics control in the past, and in
gence, we names as PLANNER, CON-
find such descriptive
NIVER, SAIL, STRIPS and QA4.

THE MULTIARMED INDUSTRIAL ROBOT

If we consider the manner in which a Homo sapien
accomplishes a given physical task, such as the assembly of
one part to another using a bolt, a nut, and perhaps some
washers, we find that not only are two hands and fingers used,

142
but also, in some cases the fore-arms and even an immobile
device such as a vice, which holds the work to which the piece
is to be bolted. In a manner of viewing this situation one can
say that the human has provided himself with another hand or
two in order to hold everything together so that the bolting
process can be accomplished. In the simplest sense, the two
parts are held by a vice, one hand inserts and manipulates the
bolt, and the other hand holds and /or manipulates the nut onto
the bolt, after first placing the washers in position.
From this example then, we should be aware that a
system of assembly in an industrial situation might involve a
robot machine with three or four arms. Actually the device
which positions the workpiece can also be called a part— even
if it is a remote part— of that particular robot system, and so

we now have to consider that a robot may not be an integrated

entity all in one frame or piece, but may consist of many parts
which are tied together by means of command system. In the
operation of such a unit, coordination among the various
pieces is affected by a computer which may have as an input,
the outputs of many smaller computers, and its output may
become the input for the smaller computers, thus effecting
the control and timing of all elements of the system.
It seems that we might be approaching the concept of

HAL in the story 2001 -A Space Odyssey. The series of com-

puters form the nerve networks and sub-brains associated
with a complete automated plant's operation. This can be
especially true if we consider that everything done in a given
plant is to produce a product at the output, and there must be
coordination and timing and productivity of the various parts
as well as assembly stages and testing stages in order to
finally send the finished product off the assembly line at the

plant's output. Under this concept we do not have a series of

robots here and there, but in effect, a gigantic robot with all

the complexity needed to start with raw materials, and pro-

duce finished products on a constant 24 hour operation basis.
Even suppliers, distributors, wholesalers, and retail outlets
might provide demand inputs to the controlling computer.
The concept becomes mind-boggling!

143
TESTS, ADJUSTMENTS AND REPAIRS
Even now we have computers with diagnostic programs.
One can envision in the robotics systems of the future that the
machine itself, when it gets a signal from some source that
something is not going exactly right, will stop, initiate its own
diagnostics program to find out what is wrong, and then, using
visual and audible communications, tell its human supervisor
verbally to fix the bolt on number 4, left hand, third finger
digit. In all the current studies, at least to date, one doesn't
find robots capable of repairing themselves without human
help.
Also, these robotics systems must have diagnostics
programs written, and fed to it by human hands or voices. The
need for people in such systems is still current and in evi-
dence. A diagnostic program is really just a check-through of
the operation to see if all the movements and operations
required are accomplished with the normal input signals. If, at
any stage, the robot's response is not correct, then a signal
will inform the supervisor that some adjustment, testing, or
repairs are needed.

144
 Programming the ff^
Prab Versatran Robot )^

Prab Conveyors, Inc. have developed the Versatran robot

which may be operated by a microcomputer, and is similar, in

its learning operation, to the Milacron which we have just

examined. Prab robots are also designed such that they can be
programmed with a type of memory drum control, that is, it is

possible to insert pegs into a revolving drum in such a way

that these pegs will close electrical circuits, and open them,
in the proper time sequencing so that various desired opera-
tions of this type robot can be accomplished. Also, this type
robot can be controlled by limit switches, switches which
open circuits at movement, or when certain
extremes of
velocities of movement are reached. They also can cause an
arm to stop moving by limiting it physically— a mechanical
stopping method.
Wehave mentioned the palletizing operation of an in-
dustrial robot. Look at such an operation, using a Prab Versat-
ran robot in Fig. 5-1. We see the gripper holding a bale, in the
upper left side of the illustration, the arm will move to deposit
it onto the stack in the proper orientation for stability of the
stack. At the extreme right of the illustration you can see the
control panel which governs the movement of the Versatran
arm. We might not necessarily associate this automated

145
machine with the concept of a robot, such as we imagine from
science fiction tales, but it is a robot in every sense except
physical appearance.
We can view some other applications of this type robot in
Fig. 5-2, wherehas an arm moving from a shoulder section
it

to make plastic automobile parts. Also, we can obtain another

view of this machine in operation in Fig. 5-3, where it is

serving a five-station machining system which produces 80#

ring gears.
Each of these units has a microcomputer type brain that
isprogrammed by teaching the arm the various positions it
must reach, and the sequence in which it must reach them.
This done by entering these desired positions, in the
is

proper order, on the microcomputer keyboard. The software

then causes the arm to move properly and in the most efficient
manner to accomplish the desired objective.
Each machine must have feedback signals so that the
computer can determine when a given limit of movement is
reached. To do this, the machines are equipped with limit
switches, potentiometers, various types of encoders (devices
which can tell the computer how much a shaft has turned,
perhaps by generating a pulse for each fractional rotational
movement) and resolvers (a selsyn type of unit that generates
an ac signal whose phase change is directly proportional to
the amount the shaft has turned).
Programs for this type robot are written according to the
manual data input, and can be recorded on magnetic tape
cassettes. Other computers may be used with these robots
The users may write their
using a special interfacing unit.
own programs for the machine. The Prab Versatran robot can
move to any of 4,000 points in space.

CONCERNING ACCURACY OF A POSITIONING SERVO-SYSTEM

If we consider that a positioning system depends upon
feedback as the control element in determining the system
error or operative voltage, then we must look at those points
from which feedback occurs. Recall that the operating or
error voltage or signal for a positioning servo is derived
basically from a comparison of an input signal command to the

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148
149
feedback signal which is generated from the position of the
output member in question. If we assume that the command
signal is simply a reference, then it is the magnitude of the
feedback signal and its polarity or phase which will govern the
effect of the two signal comparison, and thus govern the size
of the error signal. Since the system power unit operates on
the difference (error) signal, then the closer the output arm
comes commanded position, the smaller the signal
to the
becomes. At some point this signal becomes so small that it
will not cause power to be applied to move the arm further.
Where is the arm, or end appendage at that moment? Is it
precisely where the command calls for, or is it within some
tolerance, perhaps in the thousandths or even ten-
thousandths of an inch from that position? It cannot be per-
fectly positioned, thus it is within some tolerance.
Now, to gain a full appreciation for the complexity of
these systems, note that when moving the end appendage, the
system must reach many positioning points. First, for exam-
ple, the arm must rotate to a given azimuth and stop there
within the tolerance accuracy. Next the arm must extend to a
given distance and stop there within a specification accuracy.
The end appendage may have to rotate about two axes within
given accuracy specifications, and finally that end appendage
may have to advance a given distance to within a specified
tolerance. One notes, then, that errors in one element may
effect the errors in another element. The errors may become
cumulative, affecting the overall precision.
It has been argued that because the end device generates
a feedback signal of its own that all other errors in the
system's moving parts will be compensated for. However,
there is still velocity and acceleration control that must also
be within tolerance.
If a robot were used where it puts a bolt through a small
tolerance hole, then the tolerance or accuracy of the robot's
positioning of the bolt must be within the hole tolerance or
better! In a case where the robot simply grasps something
from a conveyor belt, such tight precision may not be neces-
sary. The point is, it is the overall accuracy of the robotics

150
system which, in large part, controls its cost! The more
preciseit must be the higher its cost.

PROGRAMMING AN INDUSTRIAL
ROBOT: THE PRAB VERSATRAN
Through the courtesy of Prab Conveyors we will now
examine their Versatran robot to learn how it is programmed.

General Information
Versatran robots combine electronic, mechanical and
hydraulic action with flexible programming to provide gen-
eral purpose machines capable of performing highly accurate
and precisely controlled work functions. The object of the
Versatran System is to drive the robot arm through a combi-
nation of motions and directions to perform a specific task.
The Versatran System is classified as a point-to-point
automatic system. In a point-to-point system, program com-
mands define specific positions or points in space to which the
robot arm is to travel. The robot arm will move simultane-
ously in all axes (directions) requiring change to reach the
defined position. In this way the most direct route will be
taken to the new position. In the basic 3-Axis Versatran
System, the Horizontal, Vertical, and Swing axes are pro-
vided. Optional wrist motions, including Rotate, Sweep, and
Yaw axes, can be added to the tooling end of the robot arm to
extend its work Also a Traverse motion can be
capability.
added when it is move from one
desirable to have the robot
location to another in performing its operation.

Instruction Codes. The model 600 Control Unit con-

tains a Program Teach Panel which is used by the operator
(programmer) to construct a sequence of instructions which
direct the robot to perform a specific task.
A name is assigned to each instruction which in some
way describes what the instruction does. Each instruction is
made up of two (2) parts: The Function Command, which
informs the Control Unit of the general task to be done; and
The Function Value, which identifies specifically what action
should take place. Coding the instruction is simply the act of

151
combining a function command with a function value to pro-
duce a definite action.
Programming Rules. Programming or "teaching" the
Control Unit is simply the act of establishing a sequence of
coded instructions which directs the Control Unit to perform
a particular task.
Programming is only as successful as the operators abil-
ity to understand the fundamental activities of the task to be
performed. A good, sound structuring of a program is advis-
able to keep programs simple, clear and complete. The fol-

lowing five (5) step procedure to successful programming

should be employed when preparing a program:
RULE 1. Define the Operation: This is a brief description of
the operation. The description should be prepared in a way
which tends to identify the activities of the task.
RULE 2. Chart the Sequence of Events: This is a detailed
description of the specific operation to be done. Each step of
the operation should be listed in the sequence of which it is to
be performed. (Depending on the complexities of the opera-
tion, it may be necessary to prepare sketches or flow charts in
order to identify each step).
RULE 3. Code the Program: From the detailed description,
prepare a coded instructions in the sequence in which
list of
they are to be "taught". This list of instructions is referred to
as a Source Program from which the Control Unit operates.
RULE 4. Teach the Program: This is the ENTRY of the
Source Program into the Control Unit in the sequence estab-
lished by the Source Program.
RULE Check the Program: Once the program has been
5.

entered into the Control Unit, a review of the program in-

structions is advisable in order to assure that all instructions
are in their proper sequence and the CONTROL UNIT will
execute them properly.
Program Teach Panel. The Program Teach Panel is

divided into five (5) basic categories. Prior to preparing any

program, it is necessary for the operator to thoroughly under-
stand the purpose of each control.
(a) Operational Controls: These controls are used primarily
for the operator to execute certain operational assign-

152
 ments such as teach, run program, erase program, etc.
(b) Manual Controls: These controls are used primarily for
establishing, recording, and modifying the robot arm posi-
tions.

(c) Program Function Controls: These controls are used

primarily for entering a set of coded instructions in a
sequence that establishes a particular task for the robot to
perform.
(d) Program Review Controls: These controls are used to
execute each instruction, one at a time, in order to assure
the program fulfills the intended task or to begin the
program at a sequence other than with the first instruction.
(e) Program Editing Controls: These controls are used to

alter or change the program or program sequence when

corrections are necessary.

Operational Controls

The Operational Controls are used to assign certain

responsibilities to the Control Unit.
These Controls consist of the Mode Select Key, Program
Number Control, Program Erase, Lamp Test, and Cassette or
Hand Held Teach Unit operation.
Mode Select Key Switch. The Mode Select is a turn-
key operated switch used to select the Auto-Run mode of
operation, Teach mode of operation, Test Run mode of opera-
tion, or the Single Step mode of operation,
(a) Auto- Run: The Auto-Run is the normal mode of
position
operation when the robot used to perform a specific task.
is

Placing the key in this position and pressing the Run

Program button on the Operator Control Panel causes the
robot to proceed with the task (program) identified by the
Program Number Indicator,
(b) Teach: The TEACH position is used for preparing new
programs or for checking and modifying existing pro-
grams. The new programs can either be manually entered
with the use of the Manual and Function Controls, or
electronically entered through the use of the Tape Cas-
sette unit.

153
(c) Single Step: The Single Step position is used when it is

desirable to review each instruction in sequence.

(d)T est Run: The Test Run position is used to check the
movement and positions of the Robot Arm as established
by the program instruction sequence. The Robot Arm is
allowed to complete its cycle without interruption which
may normally be required by the program.
Program Number Request. Selecting the PROG
NUMBER Control will allow the operator to request any of
the programs (within memory) to be run. THERE ARE 64
POSSIBLE PROGRAMS WHICH MAY BE SELECTED.
PROCEDURE:
(a) Place the MODE SELECT key in the desired position.
(b) Press the PROG NUMBER Control on the program teach
Panel. (The lamp will light indicating the request).
(c) Select the desired program number on the function
keyboard (1-64).
(d) Press the ENTER pushbutton under the keyboard (the
PROG NUMBER indicator lamp will go off and the Pro-
gram Number selected will be displayed in the PRO-
GRAM NUMBER INDICATOR).
The Program is now available to be modified or run.
If the program selected is a valid program, the Mode
Select key can be placed in the Auto-Run position to operate
the program. If there is nothing in the selected program,
turning the Mode Select key to any of the run modes will
result in a code "130" display.

-CAUTION-
When operating the JOG control observe that the Robot
Arm travels a path which is free of any obstructions. If the
Robot Arm cannot be jogged to position without striking an
object, release the JOG pushbutton and operate the manual
axis request and axis direction controls to move the robot arm
around the obstruction, then continue operating the JOG
control until the robot arm arrives in position.
Program Erase. The Program Erase control is used to
clear the program identified by the Program Number Indi-
cator from memory. Once the program is erased all instruc-
tions and recorded positions are cancelled from the program.

154
PROCEDURE:
(a) Place the Select key in the TEACH position.
Mode
(b) Select theProgram to be erased from memory by using
the Program Number Request Procedure.
(c) Press three (3) times in sequence: PROGRAM ERASE
then ENTER. (Three times are required to prevent acci-
dental erasures.
Lamp Test. The Lamp Test is a Control Unit exercise
which scans all of the functions of the Unit. In this way a
self-test operation can be performed. Each control button on
the Program Teach Panel which normally lights will be
lighted in sequence, beginning with the PROG NUMBER
control at the upper left of the panel and continue to the right.
At the same time the Digital Indicators will display eights

each digit position. All light-operated switches on the

(8's) in

Operator Control Panel will remain lighted during this test.

Normally this test is performed with the MODE
SELECT key in the TEACH position.

-CAUTION-
Pressing the LAMP TEST during operating modes other
than TEACH will cause the hydraulics to shut down and the
operating program to stop.
Cassette & HHTU Connectors. The HHTU is used
primarily to record and modify positions for precise control
from a remote station. The HHTU utilizes a thumb pressure
contact switch called a "dead man switch" as a safety measure
for operating the robot arm while standing in the vicinity of
its' working area. In the event unwanted motions are encoun-
tered which may cause damage or personal injury, releasing
the "dead man switch" will cause the hydraulics to automati-
cally shut down and immediately stop the arm motion.
(HHTU = HAND HELD TEACHING UNIT)
When the HHTU is connected to the Program Teach
Panel manual controls are automatically transferred to the
all

HHTU. Two procedures are outlined which describe the

method for recording new positions and for modifying exist-
ing positions with the use of the HHTU.
PROCEDURE: (Recording Positions)
(a) Mode Select key to the TEACH position.

155
(b) Select the desired Program Number to be used.
(c) Establish and record the HOME position (position 1).

Manual Controls
The Manual Controls are used for setting, recording, and
modifying the robot arm positions. These controls consist of
axis request, axis direction, record position, modify position,
and next position number controls.
Setting the Position. Each one of the seven (7) possi-
ble axes has its specific request control. All axes are iden-
tified with yellow lighted pushbuttons for operator selection.
(a) Axis Request: When a change in a particular axis is de-
sired, the corresponding Axis Request pushbutton should
be selected. Once pressed the Axis Request control will
light as an indication of the request.
NOTE: If an incorrect axis has been selected, pressing the
desired Axis Request control will automatically change to
the intended axis.
(b) Axis Direction: The Axis Direction controls are identified
as ADVANCE and RETRACT. These controls will move
the robot arm in the corresponding direction relative to
the particular Axis Requested. Depressing and holding the
Axis Request control will result in acceleration to pre-
determined velocity, while tapping the control will move
the axis one count for each tap of the control.
NOTE: Motion of the robot arm requires hydraulic as-
sisted devices and therefore the HYDRAULIC UNLOCK
and PUMP ON Control on the Operator Control Panel
must be actuated.
When moving the robot arm with the Advance or Retract
Controls, either control must be pressed and held until the
robot arm arrives at the desired position. If the direction of
motion is opposite the intended direction, operating the other
Axis Direction control will provide the desired motion.
Movement of the robot arm to the desired position is a
result of operating the individual Axis Request and Axis
Direction Controls until their combined motions place the
robot arm in the desired position, that position should then be
recorded.

156
 Recording the Position. Motion of the robot arm can
be achieved by operating the manual axis request and axis
direction controls in any of the MODE SELECT positions,
other than the Single Step Position. However, to record a
MODE SELECT KEY should be placed in the
position the
TEACH position.
SAMPLE 1: Assume the robot arm is in the position A as
shown by the heavy solid lines of the drawing in Fig. 5-4. The
objective is to record the two positions indicated by the "x".
PROCEDURE:
(a) Place the MODE SELECT key in the TEACH position.
(b) Activate the hydraulics.
(c) Select the desired program number which is to be used.
(d) HORZ Axis Request and operate the AD-
Select the
VANCE CONTROL until the arm is in the desired out-
ward position.
(e) Select the SWING Axis Request & operate the AD-
VANCE Control until the arm is over the target. (1)

ADVANCE
ING
TARGET 2 V-
^0" 1 = TARGET (1)

/
^ HOME
(A)

ARM MAY
TAkT
MPvt TUIO DPTI IDM \ POSITION 1
I nio nciUnrM
1

OR GO FROM 2 TO
ON A CYCLIC
1

BASIS

ikf<
r.

Fig. 5-4. Manual movement of the Prab Versatran robot arm (courtesy Prab
Conveyors).

157
(f Press the RECORD POS control to record the position in
memory (position indicator will display the position
number just recorded.)

(g) Select the Swing Axis Request and operate the RE-
TRACT Control (if necessary) until the arm is directly
over the second target.
(h) Press the RECORD POS Control to record the position in
memory.
NOTE: Always attempt to record position number 1 (A) as

the HOME POSITION.

Next Position Number Request. The Next Position
Number control is used to select any particular recorded
position within the program. Requesting a Next Position
Number can only be done in the TEACH mode of operation.
PROCEDURE:
(a) Place the MODE SELECT key in the TEACH position.
(b) Select the desired program number which is to be used.
(c) Press the NEXT POSITION NUMBER control (the lamp
will light as an indication of the selection).
(d) Select the desired position number on the keyboard. The
Position Indicator will display the position number re-
quested and the JOG lamp will light.
Jog to Position. After making the Next Position
number request, it may be desirable to move the robot arm to
the position requested. A simple procedure for testing the
movement of the robot arm between any two positions is
provided below.

-CAUTION-
Keep in mind, the Versatran System is a point-to-point sys-
tem. Consequently, the combined motion of the robot arm
will take the most direct route from one position to the next.
Care must be taken to assure that the robot arm has a free
A JOG to Position, after making a position
path to travel.
number request, will test the path of travel for the robot arm.
(a) Place the MODE SELECT key in the TEACH position.
(b) Select the desired program number to be used.
(c) Select the Next Position Number of interest.
(d) Press and hold the JOG switch button until the arm

158
 arrives in position. (When the robot arm arrives in posi-
tion the JOG lamp will go off),

(e) Select the Next Position Number of interest and repeat

step (d).

NOTE: If any obstructions are within contact of the robot

arm, releasing the JOG pushbutton will stop the motion of the
arm. Travel between these two (2) positions cannot be ac-
complished and therefore the robot arm will have to be pro-
grammed to bypass the obstacle. (See Fig. 5-5)
Modifying the Position. After setting and recording a
position in memory it may be learned that the particular
position is not quite correct. The position can quickly and
simply be modified without the need to change the program.
PROCEDURE:
(a) Place the MODE SELECT key in the TEACH position.

3(B) 2 = (A)

mift
Programmed arm moves around obstacle (courtesy Prab Conveyors).
Fig. 5-5.
The robot arm comes to an abrupt stop at the home position and immediately
resumes its motion toward the next position (3) or (2).

159
(b) Select the desired program number to be used.
(c) Select the Next Position Number of interest.
(d) Operate the Axis Request and Axis Direction controls
until the robot arm is in the desired position.
(e) Press the MODIFY POS Control. The Control Unit will

accept the modified position in memory for the position

number displayed on the indicator.
NOTE: If attempt is made to modify the position with the
RECORD POS control, the requested position will not be
modified. The Record Position Control will record only new
positions.

Function Controls

The Function Controls are used for establishing and

entering a set of coded instructions for the Control LJnit to
execute in performing a particular task. An instruction ^ode is
made from combining a general function command with a
specific function value. In this way, an instruction is provided
to the Control Unit which directs a defined action. The follow-
ing is a brief introduction to instruction code sets including
examples using the instruction code.
Next Program Number: (Instruction Code NPN
. .xx). When the Function Command NEXT PROG NUMBER
is selected it is to be followed with a function value of no less
than 1 and no greater than 64. The NEXT PROG NUMBER
function command requests the Control Unit to go to another
program in memory, while the function value (1-64) specifies
which program in memory. When the Control Unit encoun-
ters an instruction code NPN. .XX, the Control Unit will
execute the first instruction (sequence 1) of the program
specified by the function value.
If it is desirable to repeat the same program, the NPN

. .XX instruction code should contain the number of the pro-

gram making the request.
EXAMPLE 1. Next Program Number (NPN. .XX)
(a) Purpose: To repeat the same program.

(b) Detail: Identify the Program Number to run.

"
STEP 1: REPEAT THE PROCESS
(c) Source Program:

160
Sequence Function Function Instruction
No. Command Value Enter Code
BEGIN; Prog Number 1 (.;PGN. . .1:)

1; Next Prog Number 1 (1:NPN. . .1:)

NOTE: A POSITION MUST BE RECORDED BEFORE

ANY PROGRAM CAN BE VALID.
NOTE: Although the source program of example 1 is a single
instruction program, if "taught" to the Control Unit, it would
be a perfectly acceptable program. The instruction to do
program 1 would be repeated indefinitely until the program
was stopped.
(d) Teach:
—Mode Select key to the Teach position.
—ENTER the Source Program in sequence starting with
BEGIN.
—Record a Position (Press RECORD).
(e) Check:
-Mode SELECT key to the SINGLE STEP position.
-Press the SINGLE STEP FWD Control to review the
instruction.
Call Position (Instruction Code CPN XXXX). When
the Function Command CALL POS is it is to be
selected,
followed with a function value no less than and no greater
1
than 9999. The CALL POS function command requests the
Control Unit to direct the movement of the robot arm, while
the function value (1—9999) specifies the particular position.
When the Control Unit encounters an instruction code
CPN XXXX it will cause the robot arm to move in the most
direct route to the position identified.
EXAMPLE 2. (Call Position CPN XXXX)
(a) Purpose: To move the robot arm from one position to
another and repeat the process.
(b) Detail: Identify the program number to be run.
STEP 1: START AT HOME AND GO TO NEXT POSI-
TION.
STEP 2: RETURN HOME
STEP 3: REPEAT THE PROCESS
NOTE: It is advisable to establish position 1 as the Home
position. Position 1 is always the beginning position of any

161
program. Also, it is good practice to place the Home Position
(position 1) at a point which is out of the way. When the last
position called in the program is the Home Position the robot
arm will coine to rest (out of the way) when a COMPLETE
PROGRAM THEN STOP is activated,
(c) Source Program:

Sequence Function Function Instruction

No. Command Value EnteF Code
BEGIN; Prog Number 2 (.;PGN. . .2:)

1 Call Position 2 (1;CPN. . .2;)

2; Call Position 1 (2;CPN. . .1:)

3; Next Prog Number 2 (3;NPN. . .2:)

(d) Teach:
( i) Mode Select key to the TEACH position.
( ii) ENTER the Source Program in sequence starting
with BEGIN.
(iii) SET and RECORD positions 1 and 2.
(e) Check:
( i) Mode Select key to the SINGLE STEP position.
( ii) Press the SINGLE STEP FWD Control to review
each instruction in sequence.
NOTE: If desired, the JOG switch button can be operated
each time it lights to move the robot arm to each new position.
This practice is advisable to assure the operator that the arm
has a free path to travel.
(f) Operate the Program:

( i) Mode Select key to the AUTO RUN position.

( ii) Press JOG to move robot arm to HOME (Positi on 1).

(iii) Press RUN PROGRAM to execute the program.

NOTE: The program in example 2 will operate the Control
Unit's predetermined speed. Faster or Slower operation will
require instructing the Control Unit Velocity and Accelera-
tion Codes.
Set Velocity: (Instruction Code SVL. .XX). When
the Function Command SET VEL is to be followed with a
functional value no less than 1 and no greater than 16. The
SET VEL function command requests the Control Unit to
direct the motion of the robot arm at a speed which is

specified by the function value (1-16). The function values

162
1-16 are incremented from V2 IPS to 37V6 IPS with function

value 1 IPS and function value 16 represent-

representing V2
ing 37V2 IPS. See Table (5-1) for a complete listing of velocity
selections. (IPS = inches/per/second)
NOTE : Once a velocity value is selected, it remains in effect
movements until such time as a new value is
for all following
selected. This also true when the Control Unit transfers to
is

another program in memory.

Generally, when specifying a velocity for the arm to
move, an acceleration value should also be indicated.
Set Acceleration/Deceleration: (Instruction
Code SAD. .XX). When the Function Command SET
ACC/DEC is selected, it is to be followed with a functional
value no less than 1 and no greater than 16. The SET ACC/
DEC function command requests the Control Unit to direct
the rate of change of speed of the robot arm to its maximum
specified velocity. The acceleration/deceleration rates are
specified by the function values (1-16) following the function
command.
The function values (1-16) are incremented from 15
inches/sec/sec/ to 600 inches/sec/sec/ with the value 1
representing 15 inches/sec/sec/ and the value of 16 repre-
senting 600 inches/sec/sec. See Table 5-1 for a complete
listing of acceleration/deceleration selections.
It is common practice, and recommended, that the func-
tion values of velocity and acceleration are referred to with
the velocity value first and then the ACC/DEC value last.
(i.e., the values 5/4 represent velocity 5/acceleration 4). In

thisway, good communications with others involved with the

program will be maintained.
The velocity and acceleration instructions (SVL. .XX
and SAD. .XX) should generally precede the CALL position
instruction (CPN XXXX) when movement to that position
requires velocity and acceleration changes. When no VEL or
ACC/DEC is specified, the Control Unit will resort to the
present values of 5/4 as in the program of example 2.
NOTE Once an ACC/DEC value is selected, it remains in
:

effect for all following movements untilsuch time as a new

value is selected. This is also true when the Control Unit

163
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164

- —
transfers to another program in memory.
EXAMPLE 3: Set Velocity & Set ACC/DEC (SVL. .XX &
SAD. .XX)
(a) Purpose: To move the robot arm from Home position to
another position and return home at a medium high veloc-
ity and acceleration.
(b) Detail:
Identify the Program Number to be used.
STEP 1: MOVE AT MED/HI VELOCITY
STEP 2: MOVE WITH MED/HI ACC/DEC
STEP 3: START AT HOME AND MOVE TO NEXT
POSITION.
STEP 4: RETURN TO HOME
STEP 5: REPEAT THE PROCESS
(c) Source Program:
Sequence Function Instruction
No. Command Value Enter Code
BEGIN; Prog Number 3 (.;PGN. .3:)

1; SETVEL 12 (1;SVL 12:)

2; SET ACC/DEC 10 (2;SAD. .10:)
3; CALL POS 2 (3;CPN. ..2:)
4; CALL POS 1 (4;CPN. . .1:)
5; Next Prog Number 3 (5;NPN. . .3:)

(d) Teach:
( i) Mode Select key to the TEACH position.
( ii) ENTER the Source Program in sequence starting
with BEGIN.
(iii) SET and RECORD positions 1 and 2.
(e) Check:
( i) Mode SINGLE STEP position.
Select key to the
( ii) SINGLE STEP FWD Control to review
Press the
each program instruction in sequence. If desired, the JOG
switch button can be operated each time it lights to move
the robot arm to each new position. This practice is
advisable to assure the operator that the robot arm has a
free path to travel.
(f) Operate the Program:
( i) Mode Select key to the AUTO RUN position.
( ii) Press JOG to move the arm to HOME (position 1).
(iii) Press RUN PROGRAM to execute the program.

165
EXAMPLE 3: Set Velocity & Set ACC/DEC (SVL. .XX &
SAD. .XX)
(a) Purpose: To move the robotarm from Home position to
the next position at a medium-low velocity and return
Home at a high velocity, then repeat the process.
(b) Detail:
Identify the Program Number to be run.
STEP 1: MOVE AT MED/LOW VELOCITY
STEP 2: MOVE WITH MED/LOW ACC/DEC
STEP 3: START FROM HOME AND GO TO NEXT
POSITION
STEP 4: MOVE AT HIGH VELOCITY
STEP 5: MOVE WITH HIGH ACC/DEC
STEP 6: GO HOME
STEP 7: REPEAT THE PROCESS
(c) Source Program:
Sequence Function Function Instruction
No. Command Value Enter Code
BEGIN; Prog Number 31 (.;PGN. . .31:)
1; SET VEL 6 (1;SVL . .6:)

2; SET ACC /DEC 6 (2;SAD. . .6:)

3; CALL POS 2 (3;CPN. . .2:)

4;
SET VEL 14 (4;SVL .14:)

5;
SET ACC /DEC 12 (5;SAD. .12:)

6; CALL POS 1 (6;CPN. . .1:)

7; Next Prog Number 31 (7;NPN. .31:)

(d) Teach:
( i) Mode Select key to the TEACH position.
( ii) ENTER the Source Program in sequence starting
with BEGIN.
(iii) SET and RECORD positions 1 and 2.

(e) Check:
( i) Mode SINGLE STEP position
Select key to the
( ii) Press the SINGLE STEP FWD Control to review
each instruction in sequence. If desired, the JOG switch
button can be operated each time it lights to move the
robot arm to each new position. This practice is advisable
to assure the operator that the arm has a free path to
travel.
(f) Operate the Program:
( i) Mode Select key to the AUTO RUN position.

166
 ( ii) Press JOG to move the Robot Arm to Home (position
1).

(iii) Press RUN PROGRAM to execute the instructions.

Round Code ROP
Off Position (Instruction
XXXX). When a function command ROUND OFF POSITION
is selected, it is to be followed by a function value of no less
than 1 and no greater than 9999. The ROUND OFF POS
function command requests that the Control Unit direct the
robotarm to the position specified by the function value.
However, motion arm to and from the specified
of the robot
position is accomplished at program velocity. As the arm
approaches the position, the deceleration value of the pro-
gram is ignored, consequently, the robot arm arrives at the
position still moving at maximum specified speed and ab-
ruptly stops. Further motion to another position ignores the
acceleration value of the program and immediately assumes
maximum specified speed.
SAMPLE 2 (see Fig. 5-5):
The desired motion is to move the robotarm between posi-
tion 2 and 3. However, direct motions between these
posi-
tions would cause the arm to strike the obstacle in its path. It
is further desired to move the arm between position 2 and 3

with a constant velocity. Rounding off the Home position (1)

and passing the robot arm through this position can essen-
tially achieve the desired motion.
EXAMPLE 4: Round Off Position (ROP XXXX)
(a) Purpose: To move the robot arm between two (2) targets
avoiding an obstacle in its path and repeat the process.
(b) Detail:
Identify the Program Number to be used.
STEP 1: START AT HOME AND GO TO TARGET A.
STEP 2: INITIALIZE VELOCITY (MED-LOW).
STEP 3: INITIALIZE RATE (MED-LOW).
STEP 4: CALL HOME.
STEP 5: GO TO TARGET B.
STEP 6: INITIALIZE VELOCITY (MED-HIGH).
STEP 7: INITIALIZE RATE (MED-HIGH).
STEP 8: CALL HOME.
STEP 9: REPEAT

167
NOTE: According to the detail of example 4, the robot arm
will move from position 2 to 3 and continuously operate
between these two positions. Movement from position 2 to
position 3 is done with a med-low velocity and the return to

position 2 is done with a med-high velocity. Position 1 is set

as the home position such that when the robot arm stops at the
end of the program, it is in a position that should be out of the
way of the work area targets A and B).
Sequence Function Instruction
No. Command Value En ter Code
BEGIN; Prog Number 4 (.;PGN. . .4:)
1; CALL POS 2 (1;CPN. . .2:)

2; SET VEL 6 (2;SVL . .6:)

3; SET ACC /DEC 6 (3;SAD. . .6:)
4; ROUND OFF POS 1 (4;ROP. . .1:
5; CALL POS 3 (5;CPN. . .3:]
6; SET VEL 10 (6;SVL .10:)
7; SET ACC /DEC 9 (7;SAD. . .9:)
8; ROUND OFF POS 1 (8;ROP. . .1:

9; Next Prog Number 4 (9;NPN. . .4:)

(d) Teach:
( i) Mode Select key to the TEACH position.
( ii) ENTER the Source Program starting with BEGIN.
(iii) SET and RECORD position 1 (Home), 2 and 3.
(e) Check:
( i) Mode SINGLE STEP position.
Select key to the
( ii) Press the SINGLE STEP FWD Control to review
each instruction in sequence. If desired, the JOG switch
button can be operated each time the lamp lights to move
the robot arm to each new position. This practice is
advisable to assure the operator that the arm has a free
path to travel.
(f) Operate the Program:
( i) Mode Select key to the AUTO RUN position.
( ii) Press JOG to move the robot arm to Home (position
1).

(iii) Press the RUN PROGRAM switch button to execute

the program.
Time Delay & Interlock Dwell Instructions (TDL
NXXX & ILD. .XX;ILD.10X). When the TIME DELAY
Function Command is selected, it is to be followed with a

168
 number to be set at no
function value that identifies the timer
less than second and no greater than 99.9 seconds. The
.1

TIME DELAY requests one of ten timers to be set for a

specific period of time andimmediately begin counting down
to zero. The period be selected from 0.1 seconds
of time can
to 99.9 seconds in 0.1 second intervals. Choosing one of ten
timers is accomplished by recording the first digit (most
significant digit) of the four digit number as the timer number
and the remaining three digits with the desired time interval:
i.e., timer number 3 to be set at 6.5 seconds; the function
value should be set as 3065.
The timers are numbered from 0-9. When using timer
number 0, it is not necessary to specify the timer number
prior to setting the desired time delay value: i.e., timer
number desired to be set at 6.5 seconds; the function value
should be set as . . 65. The INTLK DWELL function command
has two significant purposes; (1) Wait for external source
command before proceeding y and (2) Wait for timer to time out
before proceeding. The WAIT FOR EXTERNAL SOURCE
Command is determined by the function values 1-32 following
theINTLK DWELL selection. This instruction requests that
the Control Unit sit and wait until a signal is received from
one of the selected 32 input lines. When the selected input
line becomes "true", the process will continue, until such
time the program will be stalled; i.e., wait for part to get into
position (assume position signal is received on line one); the
function value should be set as ... 1; when the part arrives in
position, a signal willbe sent on line one which informs the
Control Unit to resume the program.
The WAIT FOR TIME OUT Command is determined by
the function value 10 plus the particular timer number. This
instruction requests the the Control Unit stop the program
until the specified timer reaches zero: i.e., wait for timer
number 3 to time to zero; the value should be set as 103;
function when timer number 3 reaches zero, the Control Unit
will resume the program.

EXAMPLE 5: Time Delay & Interlock Dwell (TDL NXXX &

ILD.XXX) Wait for Time Out Q LD.10X)

169
(a) Purpose: To move the robot arm to position 2 and wait for
two (2) seconds and then move to position 3 and wait for
two (2) seconds. REPEAT THE PROCESS.
(b) Detail:
Identify the program number to be used.
STEP 1: START AT HOME AND MOVE TO
TARGET A.
STEP 2: SET TIME (2 SECONDS)
STEP 3: WAIT TIME
STEP 4: INITIALIZE VELOCITY (MED-LOW)
STEP 5: INITIALIZE RATE (MED-LOW)
STEP 6: GO HOME
STEP 7: GO TO TARGET B.
STEP 8: SET TIME (2 SECONDS)
STEP 9: WAIT TIME
STEP 10: INITIALIZE VELOCITY (MED-HIGH)
STEP 11: INITIALIZERATE (MED-HIGH)
STEP 12: GO HOME
STEP 13: REPEAT THE PROCESS
(c) Source Program:

Sequence Function Instruction

No. Command Value En ter Code

BEGIN Prog Number 5 (.;PGN. . .5:)

1 CALL POS 2 (1;CPN. . .2:)

2 TIME DELAY 20 (2;TDL .20:)

3 INTLK DWELL 100 (3;ILD;100:)
4 SET VEL 6 (4;SVL . .6:)

5 SET ACC /DEC 6 (5;SAD . . .6:)

6 CALL POS 1 (6;CPN. . .1:)

7 CALL POS 3 (7;CPN. . .3:)

8 TIME DELAY 20 (8;TDL. .20:)

9 INTLK DWELL 100 (9;ILD.100:)
10 SET VEL 10 (10;SVL .10:)
11 SET ACC /DEC 9 (11;SAD. .9: .

12 CALL POS 1 (12;CPN. . .1:)

13 Next Prog Number 5 (13;NPN. . .5:)

(d) Te ach:
( i) Mode Select key to the TEACH position.
( ii) ENTER the Source Program starting with BEGIN,
(iii) SET and RECORD positions 1 (HOME), 2 and 3.
(e) Check:
( i) Mode Select key to the SINGLE STEP position

170
 ( ii) Press the SINGLE STEP FWD to review each in-

struction in sequence. If desired, press the JOG pushbut-

ton each time the lamp lights to move the robot arm to its
new position. This practice is advisable to assure the
operator that the arm has a free path to travel.
(0 Operate the Program:
( i) Mode Select key in the AUTO RUN position.
( ii) Press JOG to move the Robot Arm to Home, (posi-
tion 1), Fig. 5-5.
(iii) Press the RUN PROGRAM switch button to execute
the program.
EXAMPLE 5.1: Interlock Dwell (Wait For External Source)
(a) Purpose: To move the robot arm from target A through
HOME to target B. Wait at target B until ready to accept
payload and repeat the process.
NOTE: The program purpose would be to release the payload
at the robot arm tooling end only when the receptacle is

"ready" to receive the payload.

(b) Detail (refer back to Fig. 5-5):
Identify the program number to be used.
STEP 1: START AT HOME AND GO TO POSITION 2.
STEP 2: INITIALIZE VELOCITY.
STEP 3: INITIALIZE RATE.
STEP 4: GO HOME.
STEP 5: GO TO POSITION 3.
STEP 6: WAIT FOR "READY TO RECEIVE PAY-
LOAD".
STEP 7: GO HOME.
STEP 8: REPEAT THE PROCESS.
(c) Source Program.

Sequence Function Instruction

No. Command Value En ter Code

BEGIN Prog Number 51 (.;PGN. .51:)

1 CALL POS 2 (1;CPN. . .2:)
2 SET VEL 6 (2;SVL. . .6:)
3 SET ACC /DEC 6 (3;SAD . . .6:)
4 CALL POS 1 (4;CPN. . .1.)
5 CALL POS 3 (5;CPN. . .3:)
6 INTLK DWELL 1 (6;ILD. . .1:)
7 CALL POS 1 (7;CPN. . .1:)
8 Next Prog Number 51 (8;NPN. .51.)

171
NOTE: TEACHING the Source Program of example 5.1 to
the Control Unit without a valid external command signal on
arm motion to cease at position 3
line 1 will result in the robot
where it will wait indefinitely for the resume command. To
execute the above program without a valid external command
signal; press CONTROLLED STOP, then RUN PROGRAM
Controls on the Operator Panel. The interlock will be by-
passed and the program will resume with the next program
sequence instruction.
Output Command On & Output Command Off In-
structions: (OCON. .XX & OCOF. .XX). When either an
OUTPUT COMMAND ON or OFF is selected, to be
it is

followed by a function value no less than 1 and no greater than

32.
The OUTPUT CMD ON or OUTPUT CMD OFF func-
tion command requests that the Control Unit energizes or
deenergizes the mechanism connected to the output line
specified by the function value. Typically this would be the
end-of-arm tooling designed to perform a specific task (such
as grippers, welders, drills, etc.). Also the specified output
line can be various other equipment (such as milling
machines, motors, etc., or external devices which are to be

controlled with the process to performing the task).

Other functions of the OUTPUT CMD ON/OFF are
identified and described in the following section of this man-
ual.
EXAMPLE 6: Output Command On and Output Command
Off
(Instruction Codes: OCON. .XX & OCOF
. .XX)
(a) Purpose: To move the robot arm to target A and pick-up
part. Move part to target B avoiding obstacle and release
part. Repeat the process (again refer to Fig. 5-5).
(b) Detail:
Identify the program number to be used.
STEP 1: START AT HOME AND MOVE OVER
TARGET.
STEP 2: SET TIME V2 SECOND
STEP 3: WAIT TIME

172
 STEP 4: PICK UP PART
STEP 5: SET TIME V2 SECOND
STEP 6: WAIT TIME
STEP 7: INITIALIZE VELOCITY (MED-LOW)
STEP 8: INITIALIZE RATE (MED-LOW)
STEP 9: GO HOME
STEP 10: GO TO TARGET B
STEP 11: SET TIME V2 SECOND
STEP 12: WAIT TIME
STEP 13: RELEASE PART
STEP 14: SET TIME V2 SECOND
STEP 15: WAIT TIME
STEP 16: INITIALIZE VELOCITY (MED-HIGH)
STEP 17: INITIALIZE RATE (MED-HIGH)
STEP 18: GO HOME
STEP 19: REPEAT THE PROCESS
(c) Source Program:

Sequence Function Instruction

No. Command Value Er iter Code
BEGIN Prog Number 6 (.;PGN. . .6:)
1 CALL POS 2 (1;CPN. . .2:)
2 TIME DELAY 5 (2;TDL . .5:)
3 INTLK DWELL 100 (3;ILD.100:)
4 OUTPUT COMD ON 1 (4;OCON. . .1:)
5 TIME DELAY 5 (5;TDL. . .5:)
6 INTLK DWELL 100 (6;ILD.100:)
7 SET VEL 6 (7;SVL . .6:)
8 SET ACC /DEC 6 (8;SAD . . .6:)
9 CALL POS 1 (9;CPN. . .1:)
10 CALL POS 3 (10;CPN. . .3:)
11 TIME DELAY 5 (11;TDL . .5:)
12 INTLK DWELL 100 (12;ILD.100:)
13 OUTPUT CMD OFF 1 (13;OCOF. .1 .

14 TIME DELAY 5 (14;TDL .5:) .

15 INTLK DWELL 100 (15;ILD;100:)

16 SET VEL 10 (16;SVL .10:)
17 SET ACC /DEC 9 (17;SAD . . .9:)
18 CALL POS 1 (18;CPN. . .1:)
19; Next Prog Number 6 (19;NPN. . .6:)

(d) Tcjach
( i) Mode Select key to the TEACH position.
( ii) ENTER the Source Program starting with BEGIN.
(iii) SET and RECORD positions 1 (Home), 2 and 3.

173
(e) Check:
( i) Mode SINGLE STEP position.
Select key to the
( ii) Press the SINGLE STEP FWD Control to review
each instruction in sequence. If desired, press JOG
switch button each time the lamp lights to move the robot
arm to its new position. This practice is advisable to
assure the operator that the arm has a free path to travel.
(f) Operate the Program:
( i) Mode Select key to the AUTO RUN position.
( ii) Press JOG to move the ROBOT Arm to HOME
(position 1).

(iii) Press the RUN PROGRAM switch button to execute

the program.
Call Subroutine Instruction (CSR. .XX). When a
Function Command CALL SUBROUTINE is selected, it is to
be followed with a function value no less than one and no
greater than 64. The CALL SUBROUTINE function com-
mand requests a departure from the operating program to
another program in memory. Any departure will require the
eventual return to the main program. A return to the main
program is accomplished when a NEXT PROGRAM
NUMBER instruction is encountered which has its function
value the same as the program making the request (NPN
SAME:). When the return to the main program is ac-
complished, the main program will resume with the next
instruction following the CALL SUBROUTINE instruction.
A single subroutine can be repeated indefinitely as long as a
return to the main program occurs before calling the sub-
routine again.
A return to the calling program from any subroutine is
executed when the subroutine encounters a NEXT PROG
NUMBER (NPN) instruction which has the program number
specified to be the same as the program making the request.
The executive program logic executes a sequence of instruc-
tions which accomplish the task as shown below when any
NPN instruction is encountered.
All subroutines return only to their calling program at the
program sequence number following its call subroutine in-
struction.

174
 RETURN TO CALL
PROG & DO INST
FOLLOWING DE-
PARTURE
POINT
YES

DO PROG
IDENTIFIED SAME AS
PROG MADE
BY THE NPN ^REQUEST,
REQUEST
NO T NO
»"f
1

/DICNv /did\
DO YF
tbc
/^XT PROG\
—<\aux
NO
yt^EQUESTV
\^ COMPLETE
S^^ J
AUX -« REQUEST >* TO
STOP "1 PROG THEN
PROG \ RUNprog/
/ sOCCURR/ STOP

1 YES
/" EXT PROG "\
STOP
V^ REQUEST J ( J

Fig. 5-6. A Flowchart for the Versatran robot Executive Program (courtesy Prab
Versatran).

One subroutine calling from another subroutine is re-

ferred to as "nesting". Nested subroutines form a chain of

subroutines which are linked to the original calling program.
Ifthe second subroutine calls for another subroutine prior to
returning to the first subroutine, the chain, or "nesting",
grows. Up to twenty (20) levels of subroutines can be nested
in this manner.
The return to the original calling program, from where
was called, is accomplished in the reverse
the first subroutine
order in which they were called.
NESTED SUBROUTINES:

MAIN PROGRAM #1 SUBROUTINE #2 SUBROUTINE #3

BEGIN ; PGN. . .1: BEGIN ; PGN. . .2: BEGIN ; PGN. . .3:
1 ;TDL .10: 1 ; TDL. .20: 1 ; TDL. . .5;
2 ; ILD. 100: 2 ; ILD. 100: 2 ; ILD. 100:
3 ; CSR. . .2: 3 ; CSR. . .3: 3 ; NPN. . .3:
4 ; NPN. . .1: 4 ; NPN. . .2:

175
 The main program calls for subroutine #2 at instruction

sequence 3. Similarly, subroutine #2 calls for subroutine #3

sequence prior to returning to the main
at its third instruction
program. Therefore, subroutine #3 is nested to the main
program through subroutine #2.
Once subroutine #3 has completed its program, it re-
turns to subroutine #2 at instructions sequence 4. Con-
sequently, subroutine #2 returns to the main program at
instruction sequence 4 and the process is repeated.
Twenty (20) levels can be nested in this manner prior to
any one subroutine returning to its calling program. Sub-
routines which are not nested can be repeated indefinitely, as
long as they return to their calling program prior to being
executed again.
UNNESTED SUBROUTINES:
MAIN PROGRAM SUBROUTINE #2 SUBROUTINE #3
BEGIN ; PGN. . .1: BEGIN ; PGN. . .2: BEGIN ; PGN. . .3
1 ; TDL .10: 1 ; TDL. .20: 1 ; TDL. . .5:
2 ; ILD .100; 2 ; ILD .100: 2 ; ILD .100:
3 CSR.
; . .2: 3 ; NPN. . .2: 3 ; NPN. . .3:
4 CSR.
; . .3:

5; NPN. . .1:

The main program calls for subroutine #2 at instruction

sequence 3. Once subroutine #2 completes its program, it

returns to the main program at instruction sequence 4. At that

time, subroutine #3 is called (from the main program) and

executed. When its program is finished, subroutine #3 re-

turns directly to the main program at instruction sequence 5.
Once a CALL SUBROUTINE instruction is encoun-
tered, all movement of the robot arm is relative to the
further
arm at the time of the instruction: e. the Control
position of the i. ,

Unit considers the position of the arm where the departure

occurred as the HOME POSITION (position 1) of the sub-
routine.
The samples as shown in Fig. 5- 7a and 5- 7b are showing
the motions of the robot arm for the main program and the
subroutine program respectively.
If a CALL SUBROUTINE instruction occurs while the
robot arm is at position 3 of the main program, that position

176
177
becomes the HOME POSITION or position 1 of the sub-
routine. All motion of the robot arm in the subroutine is

therefore relative to position 3 in the main program (see Fig.

5- 7c). Upon returning from the subroutine to the main pro-
gram, the next instruction following the CSR instruction of
the main program will be executed. It is therefore advisable
that the last position called for in the subroutine is the same
position as the starting position of the subroutines in order to
resume the program with the robot arm in the position it was
when the departure occurred.

EXAMPLE 7: Call Subroutine (CSR. .XX)

(a) To OPERATE THE MAIN PROGRAM with a
Purpose:
CALL SUBROUTINE instruction occurring at position 3.
(b) Detail:

MAIN PROGRAM
Identify the program number used.
STEP 1: INITIALIZE VELOCITY
STEP 2: INITIALIZE RATE
STEP 3: START AT HOME & GO TO
POS2
STEP 4: GO HOME
STEP 5: GO TO POS 3
STEP 6: DO SUBROUTINE 12
STEP 7: GO HOME
STEP 8: REPEAT THE PROCESS

SUBROUTINE
Identify the program number used.
STEP 1: INITIALIZE VELOCITY
STEP 2: INITIALIZE RATE
STEP 3: START AT HOME & GO TO
POS 2
STEP 4: GO HOME
STEP 5: REPEAT THE PROCESS

(c) Source Program:

178
 MAIN PROGRAM
Sequence Function Instruction
No. Command / Value En ter Code

BEGIN; Prog Number 7 (.;PGN. . .7:)

1; SET VEL 6 (1;SVL . .6:)

2; SET ACC /DEC 6 (2;SA/D. . .6:)

3; CALL POS 2 (3;CPN. . .2:)

4; CALL POS 1 (4;CPN. . .1:)

5; CALL POS 3 (5;CPN. . .3:)

6; CALL SUBROUTINE 12 (6;CSR. . .12:)
7; CALL POS 1 (7;CPN. . .1:)
8; Next Prog Number 7 (8;NPN. . .7:)

SUBROUTINE
BEGIN; Prog Number 12 (.;PGN. .12:)
1; SET VEL 10 (1;SVL .10:)
2; SET ACC /DEC 10 (2;SA/D. .10:)
3; CALL POS 2 (3;CPN. .2:) .

4; CALL POS 1 (4;CPN. .1:) .

5; Next Prog Number 12 (5;NPN. .12:)

(d) Teach:
( i) Mode Select key to the TEACH position.
( ii) ENTER both Source Program starting with BEGIN.
(iii) SET and RECORD positions 1 (HOME), and 2 on
the subroutine program.
(e) Check:
( i) Mode SINGLE STEP
Select key to the position.
Press the
( ii) SINGLE STEP FWD Control to review
each instruction in sequence.
CAUTION: It is recommended that the JOG switch pushbut-
ton is operated each time it lights since the subroutine arm
motions are RELATIVE TO THE POINT OF DEPARTURE.
In this way avoiding obstructions or pegging the arm against a
mechanical stop can be assured.
(0 Operate the Program:
( i) Mode Select key to the AUTO RUN position.
( ii) Press JOG to move the Robot Arm HOME (position
1).

(iii) Press the RUN PROGRAM switch button to execute

the program.
Skip Sequence Number Instruction (SKIP. .XX).
The SKIP SEQUENCE NUMBER instruction is a conditional

179
jump which bypasses the next instruction in the program
sequence when the condition of the specified input line is

"true."
When the SKIP Function Command is encountered, the
Control Unit will check the condition of the line specified by
the function value (1-32). If the line is "true," the next instruc-
tion in the programming sequence is skipped, consequently,
the one following the skipped instruction will be executed.
However, if the specified input line is "not true" the next
instruction will not be skipped.
EXAMPLE 8: Skip Sequence Number (Instruction Code
SKIP. .XX)
(a) Purpose: To move the robot arm from target A to target B
avoiding any obstacle and check target B for a part. If part
is in position pick-up and move to target A; if part is not in

UNTIL PART
position do subroutine IS IN POSITION,
THEN REPEAT THE PROCESS.
(b) Detail:
Identify the program number to be used.
STEP 1: INITIALIZE VELOCITY

STEP 2: INITIALIZE RATE

STEP 3: START AT HOME AND GO TO

TARGET
STEP 4: RELEASE THE PART
STEP 5: GO HOME
STEP 6: GO TO TARGET B
STEP 7: CHECK FOR PART; YES :

BACK: STEP 8: DO SUBROUTINE

STEP 9: CHECK FOR PART: YES 1
YES: STEP 10: GO BACK TO 8 BACK :

STEP 11: GO TO TARGET B

STEP 12: PICK UP PART
STEP 13: GO HOME
STEP 14: REPEAT THE PROCESS

NOTE: Upon return from a subroutine, the next instruction

following the CALL SUBROUTINE is executed. The pro-
gram desires to repeat the subroutine if the part is not at

180
target B. Therefore after returning from the subroutine call
the next instruction is to check for the part again, if it is not
there an immediate jump back to step 8 (Do subroutine)
instruction is executed. An immediate skip instruction is
coded by a Function Command SKIP SEQ NUMBER and a
function value of 1000 plus the program sequence number
desired. (Hence STEP 10 of the source program, SKIP 1008:)
(c) Source Program:

Sequence Function Instruction

No. Command Value Enter Code

BEGIN PROG NUMBER 8 (.:PGN. . .8:)

1 SET VEL 6 (1;SVL . .6:)

2 SET ACC /DEC 6 (2;SAD . . .6:)

3 CALL POS 2 (3;CPN. . .2:)

4 OUTPUT CMD OFF 1 (4;OCOF. . .1:)

5 CALL POS 1 (5;CPN. . .1:)

6 CALL POS 3 (6;CPN. . .3:)

7 SKIP SEQ NUMBER 2 (7;SKIP. . .2:)

8 CALL SUBROUTINE 12 (8;CSR. .12:)

9 SKIP SEQ NUMBER 2 (9;SKIP. . .2:)

10 SKIP SEQ NUMBER 1008 (10;SKIP 1008:)

11 CALL POS 3 (11;CPN. .3:) .

12 OUTPUT CMD ON 1 (12;OCON. . .1:)

13 CALL POS 1 (13;CPN. . .1:)

14 NEXT PROG NUMBER 8 (14;NPN. . .8:)

NOTE: The Source Program of example 8 assumes that the

part pickup device connected to output line 1 and
is

the part position device is connected to input line 2.

NOTE: Program sequence number 11 recalls position 3 to be
sure that returning from the subroutine places the
arm over the part pickup target.
EXAMPLE 9: Program To Use All Instructions Used In
Examples 1 Through 8
(a) Purpose: To get part at target A and move to target B
when part is "ready". If part is not ready go to target ,
C
and spray target area with short burst. Check for part
ready, if not continue spray.
Note: The program of example 9 assumes:
Part pick-up Device on line 1.

Part Position Sensor on line 2.

Spray gun actuator in line 3.

181
 2

SUBROUTINE SOLID LINE: HOME

POINT DASHED LINE: TARGETS A & B
BROKEN LINE: SUB ROUTINE

TARGET C IS
POSITION 2 OF
THE SUBROUTINE

HOME IS POSITION 1 FOR BOTH THE MAIN PROGRAM AND THE

SUBROUTINE. TARGET A IS POSITION 2 OF THE MAIN PROGRAM
AND TARGET B IS POSITION 3 OF THE MAIN PROGRAM.

Fig. 5-8. Versatran robot's arm motion when waiting for a part (courtesy PRAB
Versatran).

INSTRUCTION DETAIL
Main Program 9

BEGIN ; PGN 9 ESTABLISH PROGRAM NUMBER

1 ; SVL 6: VELOCITY (MED-LOW)
INITIALIZE
2 ; SAD ... 6: RATE (MED-LOW)
INITIALIZE
3 ; SKIP 2: YES CHECK FOR PART
4 ; SRC 14: DO PROGRAM 14
YES 5 ; CPN 2: GO OVER PART
6 ; TDI 5: SET TIME
7 ; ILD . . .100: WAIT TIME
8 CPN
; 3: GO TO PART
9;OCON. . . 1: RETRIEVE PART
10 ; TDL 5: SET TIME
11 ;ILD. . .100: WAIT TIME
12 ; CPN 2: LIFT PART
13 ; TDL 5: SET TIME
14 ; ILD . . .100: WAIT TIME
15; CPN 1: GO HOME
16 CPN ; 4: GO OVER DUMP
17; TDL 5: SET TIME
18 ILD ; . . .100: WAIT TIME
19; CPN 5: SET PART DOWN
20;OCOF. ..1: RELEASE PART
21 TDL ; 5: SET TIME
22 ; ILD . ..100: WAIT TIME
23 ; CPN 4: LIFT ARM AND PASS

182

"I
 INSTRUCTION DETAIL

24 ; CPN 1: GO HOME
25 ; NPN 9: REPEAT

SUB ROUTINE 14
BEGIN ;PGN 14 ESTABLISH PROGRAM NUMBER
1 ; CPN 2: GO OVER SPRAY
IMMED
:D: 2 ; OCON. . . 3: ACTUATE SPRAY
3 ; TDL . . . 20: SET TIME
4 ; ILD . . .100: WAIT TIME
5 ;
OCOF. . . 3: STOP SPRAY
6 ; SKIP 2: YES CHECK FOR PART
7 ; SKIP. .1002: IMMED GO BACK TO ACTUATE SPRAY
YES 8 ; NPN 14: RETURN

List of Instruction Codes

Each instruction code is made up of two (2) parts; the
function command and the function value.
Function Command. The function command is a gen-
eral description of a task to be done, see Table 5-2.
Function Value. The function value is a specific de-
scription of what action should take place. An instruction code
isused by the Control Unit to produce a definite action. The
following is a list of instruction codes and their meaning.

Review Controls
The review controls are used to inspect each program
sequence instruction contained in memory. The SINGLE
STEP FWD and SINGLE STEP REVERSE Controls provide
a means of executing one instruction at a time or beginning
the program from a sequence other than the first instruction.
In this way, the operator can review and inspect the operation
of the program.
Single Step Forward. Once a program number has
been selected and the mode select switch is placed in the
SINGLE STEP position, pressing the SINGLE STEP FWD
Control executes the first instruction in the program se-
quence. At this time, the program teach panel indicators will
display the Program Number, Program Sequence, Function
Command, Function Value, and the Position Number. When a
new position is called, the JOG switch lamp will light. Press-
ing the JOG switch button will allow the robot arm to move

183
 Table 5-2. Function Command Value Meaning.

FUNCTION
COMMAND VALUE MEANING

CPN XXX GO TO POSITION (XXXX)

CSR XX.
GO DO PROGRAM (XX) & RETURN
CSR NXXX SET COUNT LIMIT (XXX) FOR COUNTER (N)
ILD . .XX WAIT FOR LINE (XX) TRUE
ILD . 10X WAIT FOR TIMER (X) TIME OUT
NPN .XX.
DO PROGRAM NUMBER (XX) NEXT
OCOF .XX.
DISENGAGE LINE (XX)
OCOF 10 X
. DISABLE TIMER (X)
OCOF .2 XX CLEAR FLAG (XX)
OCOF .30X DECREMENT COUNTER (X)
OCOF .40X DISABLE COUNTER (X)
OCOF 10 XX IMMEDIATELY DISENGAGE LINE (XX)
OCOF 110X IMMEDIATELY DISABLE TIMER (X)
OCOF 12 XX IMMEDIATELY CLEAR FLAG (XX)
OCOF 130 X IMMEDIATELY DECREMENT COUNTER (X)

OCOF 140 X IMMEDIATELY DISABLE COUNTER (X)

OCON . . XX ENGAGE LINE (XX)
OCON . 10X ENABLE TIMER (X)
OCON .2 XX SET FLAG (XX)
OCON .30X INCREMENT COUNTER (X)
OCON .40X ENABLE COUNTER (X)
OCON . 50 X DISPLAY COUNT FOR COUNTER (X)
OCON .60X DISPLAY COUNT LIMIT FOR COUNTER (X)
OCON 10 XX IMMEDIATELY ENGAGE LINE (XX)
OCON 110X IMMEDIATELY ENABLE TIMER (X)
OCON 12 XX IMMEDIATELY SET FLAG (XX)
OCON 130 X IMMEDIATELY INCREMENT COUNTER (X)
OCON 140 X IMMEDIATELY ENABLE COUNTER (X)
OCON 150 X IMMEDIATELY DISPLAY COUNT FOR
COUNTER (X)
OCON 160 X IMMEDIATELY DISPLAY COUNT LIMIT
FOR COUNTER (X)
ROP XXXX PASS THROUGH POSITION (XXXX)
SAD XX SET ACCELERATION TO VALUE (XX)
. .

SKIP XX SKIP NEXT INST. IF LINE (XX) IS TRUE

. .

SKIP 10X SKIP NEXT INST. IF TIMER (X) TIMED OUT

.

SKIP .2 XX SKIP NEXT INST. IF FLAG (XX) TRUE

SKIP .30X SKIP NEXT INST. IF COUNTER (X) = LIMIT
SKIP .40X SKIP NEXT INST. IF COUNTER (X) ZERO
SKIP 1000 + XXXX JUMP IMMEDIATELY TO SEQUENCE (XXXX)
SVL ..XX SET VELOCITY TO VALUE (XX)
TDL NXXX SET TIMER (N) FOR TIME (XXX)

towards the position being displayed by the position number.

NOTE : recommended that the JOG switch button is
It is

operated for each position when a new program is first en-

tered to the Control Units memory. In this way, the operator
is assured that the robot arm has a free path to travel. If the

operator is sure the robot arm can reach the position being

184

~MM
afaWM "
called for without striking any objects the RUN PROGRAM
switch button can be pressed to move the robot arm to the
new position at program speeds.
CAUTION: Once the RUN PROGRAM switch is pressed in
the single stop mode, the robot arm will move directly to the
position. Releasing the RUN PROGRAM switch button will
not stop the motion of the arm. If under these conditions the
arm is about to strike an object, the EMERGENCY STOP
Control should be engaged.
Single Step Reverse. The Single Step Reverse Con-
trol isused to start a program from an instruction sequence
other than sequence one. This may be desirable in the event
an Emergency Shut down was required or power failure
occurred, while the program was partially through its cycle.
Starting the program from the sequence where the "stop"
occurred to complete the operation that was in process, can
be conducted as outlined in the following procedure.
Procedure:
( i) Place the Mode Select key in the SINGLE STEP posi-
tion.

( Operate the SINGLE STEP FWD Control until the de-

ii)

siredprogram sequence number appears in the Program

Sequence display.
(iii) Press the SINGLE STEP REVERSE Control.
( iv) Press the CONTROLLED STOP (yellow mushroom
switch) on the Operator Panel.
( v) Press and hold the JOG switch until the robot arm is in

the appropriate position.

( iv) Press the RUN PROGRAM Switch on the Operator
Control Panel to execute the program beginning with the
instruction sequence displayed in the Program Sequence In-

dicator.
NOTE: It is recommended that the COMPLETE PROGRAM
THEN STOP Control is activated once the program begins
operating in this mode. Once the program stops, the Mode
Select key should then be placed in the AUTO RUN position
the JOG switch pressed and held until the robot arm is in

position 1; and the RUN PROGRAM switch activated to

execute the program in the normal mode of operation.

185
Editing Controls

to alter or change the program

These controls are used
or instruction sequence when corrections are necessary.
They consist of the INSERT and DELETE Controls.
Insert. The Insert Control is used to place an instruc-
tion in the program sequence. When the instruction is in-

serted at a specified program sequence number, the instruc-

tion originally at that program sequence number becomes the
next instruction following the inserted instruction.
Procedure:
( i) Mode Select key to the TEACH position.
Press PROG SEQ NUMBER and the desired program
( ii)

sequence number on the keyboard: ENTER number,

(iii) Prepare the desired instruction code (function command
and function value) to be inserted.
( iv) Press INSERT.
Delete. The Delete Control is used to take out the

instruction specified by the program sequence number selec-

When an instruction is deleted, all following instructions
tion.

move up one number in the program reference to avoid gaps

in the program. In this way, the next instruction, following the
instruction deleted, will be executed in the program sequence
where the deleted instruction had been originally.
Procedure:
( i) Mode Select key to the TEACH position.
( ii) Press PROG SEQ NUMBER and the desired program
sequence number on the keyboard: ENTER the number,
(iii) Press DELETE.

With the use of Editing Control, the program can be

modified without having to change the sequence number of all
instructions.

Simple Programs/Problems
The following provides three (3) examples of programs
which use many of the instruction codes contained in the
Instruction Code List (Section E). Each program provides a
description of the task and an explanation of the program.
Following the examples are three sample problems
which can be used as an exercise for the reader. A solution to

186
these problems can be found at the end of the section. How-
ever, other solutions are possible and the reader is urged to
use imagination and ingenuity in solving the problem.
EXAMPLE 10.1:
(a) Task: To start at Home and move the robot arm to
location A. At location A, set the horizontal arm into a
stroking motion (back and forth) and repeat the stroke
five times. Then move the robot arm to location B passing
through Home and repeat the stroking motions of the
horizontal arm at location B, return the robot arm to
Home and repeat the process.
(b) This program calls for the same routine to be done at both
locations A and B. The stroking motion of the horizontal
arm can be put into a subroutine motion of the main
program. Since subroutine motion of the robot arm is

relative to the position of the arm at the point of depar-

ture from the main program, the positions A and B will
become position 1 of the subroutine. It is further neces-
sary to keep track of the number of strokes in the sub-
routine, since the task limits the number to five.
(c) Source Program and Detail:

Main Program

BEGIN ;
PGN . . 10: REQUEST PROGRAM NUMBER
TO BE USED.
1; SVL. . .8: SET VELOCITY TO MEDIUM SPEED.
2; SAD. . .8: SET ACCELERATION TO MEDIUM RATE
3; CPN. . .2: MOVE THE ARM TO LOCATION A.
4; CSR. .11: GO DO PROGRAM NUMBER 11.
5; CPN. . .1: GO HOME.
6; CPN. . .3: MOVE TO LOCATION B.
7; CSR. .11: GO DO PROGRAM NUMBER 11.
8; CPN. . . 1: RETURN TO HOME.
9; NPN. .10: REPEAT THE PROCESS
Subroutine
BEGIN ; PGN. .11: REQUEST PROGRAM NUMBER
TO BE USED.
1; CSR 1005: SET COUNTER TO LIMIT 5.
CK: 2; CPN. . .2: MOVE ARM BACK.
3; CPN. . .1: MOVE ARM FORWARD
(RETURN HOME).
4; OCON .INCREMENT COUNTER
301
5; SKIP. 301: YES IS COUNTER AT LIMIT 5?
6; SKIP 1002: BACK JUMP BACK TO PROG SEQ 2.
YES: 7; NPN. .11: RETURN TO MAIN PROGRAM.

187
Program sequence 1 clears the counter (SET TO ZERO) and
establishes a limit of 5 counts. Sequence 2 and 3 provide the
single stroke motion. Sequence 4 adds one to the counter.
Sequence 5 asks if the counter has reached a count of 5. If it

has not, the next instruction (sequence 6) returns to sequence

number 2 where the stroke and count are again executed. If
have been counted program sequence 5 requires
five strokes
that sequence 6 is skipped, consequently sequence 7 in-
structs a return to the main program to the next instruction
following CSR XXXX: instruction,
(departure point)
EXAMPLE 10.2:
(a) Task: Start at Home and go pick up parts at location A and
move them B for a 5 second test. If the part
to location
tests good, move to location C and dump the part, if the
part tests bad, move to location D and dump the part.
Furthermore, if after 10 parts, two or more are bad, stop
If less than two are bad,
the process and sound an alarm.
more parts.
test 10
NOTE: This program will assume the part pick up device is
on line 1. The external TEST source is on line 2. A good parts
sends a TRUE signal on line 2, and the alarm is on line 3.
(b) Source Program: See page 189.
EXAMPLE 10.3:
(a) Task: To get part at location A and move part to location B.
At location b, give part a two minute bath with rotary
motion; after two minutes, move to location C and dump
part. Repeat the process.
NOTE: This process calls for an extended time interval
beyond the 99.9 second limit of a timer. Consequently, set-
ting a timer for one minute and executing the instruction
twice will accomplish the desired task.
The program will assume the part pick up device is on line 1
and the part rotate device is on line 2.
(b) Source Program: See page 190.
Thus we conclude this study of how an industrial robot,
the Prab Versatran may be programmed and controlled and
taught. Other types of industrial robots will have a similar
concept of operation. It is not difficult to program such a robot

188
 Main P rogram

BEGIN PGN. .20: REQUEST PROGRAM NUMBER

TO BE USED.
1 ;
SVL . .8: SET VELOCITY AT MEDIUM
SPEED.
2 ;
SAD. . .8: SET ACCELERATION AT
MEDIUM RATE.
3 : CSR 1010: SET COUNTER 1 to LIMIT 10
(Parts Tested).
4 ;
CSR 2002: SET COUNTER 2 to LIMIT 2
(Bad Parts).
BACK 5 ; CPN. . .2: GO TO LOCATION A TO GET
PART.
6 OCON. .1: PICK UP PART.
7 OCON . 301 INCREMENT COUNTER 1.
8 CPN. . .3: MOVE TO LOCATION B TO TEST
PART.
9 TDL .50: SET TIME 5 SECONDS.
10 ILD . 100: WAIT FOR TEST TO BE
COMPLETED
11 SKIP . . .2: YES PART BAD? YES; SKIP NEXT INST.
12 CST. .22: GO DUMP GOOD PART.
YES 13 SKIP. . .2: YES 1 PART BAD? YES; SKIP NEXT INST.
14 SKIP 1016: JUMP JUMP TO INST. 16.
YES 1 15 CSR. .23: GO DUMP BAD PART.
JUMP 16 RETURN HOME.
CPN. ..1:
17 SKIP. 301YES2 10 PARTS TESTED? YES? SKIP
NEXT INST.
18 SKIP 1005: BACK GO BACK TO 5 and DO AGAIN.
YES 2: 19 SKIP 302: YES 3 2 OR MORE BAD PARTS? YES;
.

SKIP NEXT.
20 NPN. .20: REPEAT FOR 10 MORE PARTS.
YES 3: 21 OCON. .3: SOUND ALARM.
Subrouti ne (Good Pari DUMP)
BEGIN PGN. .22: REQUEST PROGRAM NUMBER
TO BE USED.
CPN. MOVE TO LOCATION C (GOOD
DUMP).
OCOF. RELEASE PART.
CPN. .
RETURN HOME.
NPN. RETURN TO MAIN PROGRAM.
Subroutine (Bad Part Dump)
BEGIN PGN. .23: REQUEST PROGRAM NUMBER
TO BE USED.
1
CPN. . .2: GO TO BAD PART DUMP.
2 OCOF. .1: RELEASTPART.
3 CPN. . . 1: RETURN HOME.
4 OCON . 302: INCREMENT COUNTER 2
(BAD PART).
NPN. .22: RETURN TO MAIN PROGRAM

189
(b) Source Program: DETAIL

BEGIN ; PGN. .40: REQUEST PROGRAM NUMBER 15

1 SVL. . .8: SET VELOCITY MEDIUM SPEED
2 SAD. . .8: SET ACCELERATION MEDIUM RATE
3 CSR 1002: SET COUNTER TO LIMIT 2
1

4 CPN. . .2: GO TO LOCATION A (PART PICK UP)

5 OCON. .1: PICK UP PART
6 CPN. . .3: GO TO LOCATION B(BATH)
7 OCON. .2: ROTATE PART
BACK: 8 TDL 600:
.
SET TIME 1 MINUTE
9 ILD . 100: WAIT TIME
10 OCON .301: INCREMENT COUNTER 1
11 SKIP .301: YES IS THIS TWICE? YES; SKIP NEXT
12 SKIP 1008: BACK JUMP BACK TO SEQUENCE 8
YES: 13 OCOF. .2: STOP ROTATING PART
14 CPN. . .4: GO TO LOCATION C (PART DUMP)
15 OCOF. .1: RELEASE PART
16 CPN. . .1: GO HOME
17, NPN. .40: REPEAT THE PROCESS

and the tasks may be varied a great deal from the illustrations
used herein. Also, it is possible to use one computer to
control many robots on an assembly line, or to integrate the
actions of many robots to accomplish whatever jobs are de-
sired.

190
 ©0
Robot "Hands"
and Arm Kinematics ^fj^
We assume that a robot has at least one arm which can move,
and that the robot can turn to any desired azimuth to perform
the task which we have programmed into it. In the types of
industrial robots we have considered so far, one arm per
machine has seemed to be standard. Of course we are consid-
ering that a second arm, not attached to the robot itself, but
controlled by the same master controller and synchronized
with the movement of the main arm is a distinct possibility.
However, in this chapter, we will deal with the "hand" or
manipulator of just a single arm.

COMPARISON TO THE HUMAN ARM AND HAND

Because humans tend to think in terms of what they can
do with their own appendages, they tend to design robots so
that they duplicate humans. Somehow, in the back of our
minds, we are thinking, "If we can do it, then a robot built like
us can do it." So, we want the robot to be such a machine that
it actually tends to duplicate our own movements with regard

to the upper torso. As far as mobility is concerned, that

doesn't seem to be much of a consideration except for the fact
that the robot must be able to traverse the type and kind of
terrain in which it will operate if movement is required. It is
not necessary that a robot have legs and ankles and feet, nor

191
that have just two of these if it is actually necessary that it
it

duplicate thehumanoid from the waist down, mobility-wise.

In some cases where the terrain is rugged or mountainous
more appendages have been considered and a spider-like
bottom half is what the designers came up with. This, of
course, would be especially necessary if the terrain is such
that one cannot go around obstacles, but has to climb over
them.
The robot must duplicate the human upper torso if the
tasks assigned are such that it is doing work which a human
formerly performed, and thus the rest of the work environ-
ment is geared to humans. Programming becomes easier

because one can plan the movements and operations by com-

paring the robot's movements to those of a human who is very
good Of course, one might take the viewpoint that
at that job.

a robot should be designed so that it is a unique device and

doesn't duplicate the human.
We want to consider some of the similarities and differ-
ences between a robot and the human appendage. First let us
consider the shoulder. In the simplest case the robot's shoul-
der joint would permit an up and down movement of the rest of
the arm. To get the azimuth movement the human enjoys, the
robot's body is turned in a circle. The result is very close to a
human arm when the human is lying on their side. The human
arm can describe a circle using the shoulder joint alone as the
pivotal center.
The robot is capable, without stress on design, of an arm
movement from the shoulder joint, which a human is not
capable of; that is the extension or retraction of the upper arm
elements. This permits the robot's arm to reach further and
work closer than a human might be able to. Where a human
might have to take a few steps to reach something, then step
back to get close to the work area, the robot, by means of the
extension capability, can remain in a fixed position and do the
same task. The elimination of the mobility requirement here
might be a decided plus for the robot in that it cannot get out of
line,has fewer moving parts to worry about, and is simplified
in design and cost. It is more cost-effective, in this manner.

192
 Now we consider the elbow joint. It could be important
have a dual capability, or triple capability. It
that this joint
should permit the forearm to lengthen and contract, it should
permit up and down motion, and it should permit a rotary
motion so that the "up and down" movement can be at any
angle.
The robot, to have maximum manipulator movement,
needs maximum flexibility of arm movement. If a robot is
designed in such a way that it is to accomplish tasks which are
not envisioned at the time of design, then a maximum capabil-
ity of design has a better chance or permitting the robot to do

these unforeseen or unimagined tasks later in time. Of course

one realizes that for a specific task the robot under considera-
tion may not have to have as much arm movement or flexibil-
ity of appendage as we are now considering. Less flexibility

may mean less down time and certainly less cost. Thus one
encounters, again, the concept of cost effectiveness of a robot
doing one or two or a few tasks versus the completely flexible
robot.
The wrist of the robot certainly needs a rotary capability,
and an up and down capability. It probably does not need the
extension capability of the other two arm elements. The wrist
of the robot iswhere the gripper will be attached, and that
device what will enable the robot to do useful work. To do
is

useful work the robot must have the right tool in the right
place at the right time and manipulate that tool in the right
manner for the required time to accomplish the task.
The human wrist has a good movement up and down and
a somewhat limited movement sideways, but it can also be
rotated, when considering the play of bones and muscles from
the elbow joint down to the hand. If you examine your own
hand's movement you'll find that the wrist rotates about 180
degrees only, but the hand can be rotated this much when bent
down or up, or even, to some extent, when it is bent sideways.
It is not the elbow which permits the rotary movement of the

wrist, but the forearm bones and muscles, and the elbow
doesn't cause any arm rotation at all, but we might want this in
a robot. It is easier to design the joint which has both translat-

193
ory movement and angular movement, then to try to exactly
duplicate the bone structure of the human forearm. Re-
member, what we will be looking for in the final design, is
movement of a hand or gripper through those necessary
points in space required for accomplishment of whatever task
we have assigned to that robot.
Finally, we come to the hand or gripper. Now we need to
make some slight distinction. If we call the end appendage a

hand then we want to consider that it has some kind of fingers

or graspers in an amount of three or more, one of which might
be considered a thumb or opposing lever. The gripper on the
other hand might just be considered to be a pincers arrange-
ment of two fingers, which close on an object to a pre-
determined force level, and permit the arm to raise or move
the object so grasped.
The appendage attached to the wrist of an industrial
robot may be some tool such as a drive socket device to fasten
down bolts, or a drill, or a welding torch, or whatever. A good
robot may be able to use one tool on a task, then move its arm
so that that tool can be discarded or disengaged. The arm then
moves to the location of another tool, moves the wrist so that
the second tool is fastened in place on the wrist, and then the
arm moves to perform tasks with the new tool. In this case
there are no fingers or grippers as such. There is just the end
tool which ispositioned by the robot so that it can do the kind
of work it was intended for.
A side note here to those of you who thought that fingers
on a robot would be comparable to fingers on a human.
Although possible, such a thing is probably not very useful.
Take a look at Fig. 6-1. As you see, in this sketch, there are
three finger sections shown which represent the end joint, the
second joint, and the first joint of a finger. If we provide some
small nubs at each joint we can exert a lever force on the
finger element causing that part of the finger tomove up or
down as we would push or pull some flexible push-pull rods as
shown. Such rods are ideally worked by small hydraulic pis-
tons like the model airplane type used for landing gear exten-
sion and retraction. As some force is necessary, and the lever

194
 BEND AXIS
(JOINT) 3
(JOINT) BEND AXIS 2
BEND 1 BASE OF
AXIS 1
\r\ HAND UNIT
^7^7 1
\OTHER FINGERS
: ^Z*J\J /ATTACH HERE
rEEE?
^^.h^^^^^ci
FINGER ^
NVBs^\/ \ A
PULL-PUSH
\\
TO CONNECT B
ROD puLL-PUSH ROD
TO PUSH-RODS
FINGER UNDERSURFACE
ISCOATED WITH NON SLIP
MATERIAL HAVING SOME
"GIVE"

Fig. 6-1. Making a metal finger close and open using push rods.

advantage is relatively small, the hand would not have a

strong grip.
If we imagine such a finger grasping something, we
would imagine that push-rod B is pulled back moving the
second finger element down, then push-rod A is pulled back
causing the finger end element to come down and so we have a
kind of grasping action. The push rods would have to be
flexible enough to withstand the bending, or a two way cable
arrangement might have to be used on each nub to get up and
down movement of the finger element. Mechanical engineers
love a problem like this and delight in imagining just how to
design the mechanism to do the job as shown. But even if such
an appendage is useful, it is doubtful if it is cost effective, so
we leave it to your imagination.

SOME SCHEMATIC SYMBOLISM

When studying mechanical robots which have many mov-
ing parts sometimes useful to diagram those elements
it is

which move in a simplified manner. If you are so inclined, and

talented enough, you can write some equations of motion
which describe the moving elements. We examine this type of
robotic symbolism in Fig. 6-2.

195
 In section A we see a representation of an inward-
outward type of movement such as might be gained from the
use of a hydraulic or pneumatic piston. If we want to show that
a robot's arm extends and contracts, schematically, we might
use this symbol.
In section B we show rotation about a vertical axis. This
movement can be called a one degree of freedom, even though
we can readily see that the axle and pivot arrangement will
permit the mass to rotate in either direction about that verti-
cal axis. Perhaps then, we can define degree of freedom as a
movement about or along a single axis. If we have a robot arm
with five degrees offreedom, we would expect the sections of
the arm to have at least five hinge joints, or thrust joints such
as at A or B.
In C of Fig. 6-2 we see an arrangement which describes
two degrees of freedom. Notice that the mass (M) can move
around a horizontal axis or a vertical axis or both. In D we
show a schematic of a free gyroscope which has three degrees
of freedom. If we want to use our schematic representation to
show this configuration, we do so as at E.
When the kinematic or dynamic situation of a robot's arm
is being considered, it is nice to use such diagrams, adding
one to another so that the entire picture may be obtained. The
mass as shown does not represent the load which the arm may
be moving, it can represent the inertia of the arm itself. That
is a considerable problem in dynamics because the inertia of

the arm changes with each position it assumes, with respect

to most pivotal joints. This makes the equations of motion
difficult to write and to solve!
Most robot arms currently have under six degrees of
freedom. But, as an exercise let us examine an arm with 12
degrees of freedom, in Fig. 6-3. As a sure cure for insomnia
one might imagine writing the equations of this arm, recalling
that each degree of freedom involves a second order differen-
tial equation. Then imagine a method of simultaneously solv-
ing all the equations! If sleep doesn't come soon, consider the
changes mentioned and some types of
in inertia previously
other non-linear relationships which have to exist in such an
arrangement.

196
 E

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CO

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197
 It has been pointed out that the determination of the
required number of degrees of freedom of any robot arm will
be governed by the application of that robot and the conditions
under which it must operate. Recall how the Prab robot
overcame an obstacle in its arm trajectory? If we consider a
robot doing a painting job inside a car body, in order to paint
the interior thoroughly, getting the arm through a body open-
ing and bending the hand around to spray the interior, might
indeed require more than a few degrees of freedom. A Gen-
eral Motors painting robot has sensory capability to detect a
car body entering its world, spray it carefully, and using a
second hand open the door so the painting arm can get through
to spray the interior! Coordination of the arms and hands is, of
course, computer controlled. This robot uses both magnetic
and optical sensors in its operation.
From what we have considered with respect to the arm
of a robot, we now have a clear concept of the two things that
happen. First the arm moves the end device into the required
position in three dimensional space. Then the end device is
actuated by signals from one or more sensors. When it has
completed its task— determined by other sensors— it moves
back to the starting position. Meantime the arm may have
changed its spatial orientation as a function of time or its
program sensing progress detectors, so that an entire job may
be accomplished.
We need to mention two other types of end devices. The
first is the sucker, which can hold onto various parts simply by

creating a suction or vacuum. Normally those parts held

would be rather light weight parts, although lots of suckers
can produce a formidable attractive and holding force. We also
need to mention the magnetic holding power to elec-
tromagnetic elements in hands or grippers. These exert con-
siderable force which can easily be turned off and on by means
of electric switching. They are not useful when handling
non-magnetic type parts or when the parts are apt to have a
high degree of residual magnetism, however.
Limit switches, which can be made an integral part of a
hand are also very useful in that they can provide a feedback
signal when the closing pressure has reached a given mag-

198
 BASE

^ 12
jr 3FINGER
GRIPPER

Fig. 6-3. A robot arm with 12 degrees of freedom.

nitude. These type sensors would be mounted inside the hand

in such a way that when the hand clamps an object, pressure
would cause the switch to close and thus create a signal that a
given force had been exerted by the jaws. The system might
be so programmed that once such a switch has closed, the
controller would automatically cause a continued closing of
some very, very small amount. A sensor tells the computer
there is contact with the object, and the computer, knowing
the flexibility of the object, orders a slightly tighter closing so
that the object might be lifted without falling from the hand or

199
slipping into a disoriented position in the hand. It could be that
several microswitches each requiring a slightly higher force
to close, might be used to sense the gripping forces applied.

EXAMINATION OF A ROBOT'S ARM KINEMATICS

There are many possible orientations of the various
joints in an arm which can permit the end device to reach the
same given spatial coordinate. The selection of any given
version of a kinematic plan for a robot's arm is determined by
many specific conditions and requirements. One considera-
tion is that the arm must have a sufficient degree of movement
to do everything required in its work cycle. Second, from the
engineers viewpoint, the movements must involve the
greatest simplicity of design of the arm and its elements, and
thus keep the unit cost effective. When the end device is so
moved, it must have the proper angular orientation at that
point to do the type job required of it. When these two factors
alone are considered it has been found that, in general, it
requires at least six degrees of freedom of motion. This does
not include those motions of the end device itself which may
have several degrees of motion freedom.
Some robots need only three degrees of freedom to do
the job which they were designed for; i.e., a vertical motion, a
horizontal motion and one rotational motion. In this case
there would not be a translatory motion in and out of the arm.
If the degrees of freedom were increased to 4 then this

translatory movement might be incorporated. If the end de-

vice must have a certain number of degrees of freedom, the
arm must make up the number of degrees of freedom which
the end device does not produce or have in itself.
Since, we know that the number of degrees of freedom
can represent various kinematic plans for the arm. The de-
signer can lay-out the kinematics of the arm to satisfy such
requirements as he may deem necessary for that particular
application of that particular robot. Of course, he may over
design the arm for some installations and realize that the arm
will just meet the requirements for another installation, but
this gives the arm more use in a wider spread of applications,

200
even though it becomes less cost effective for the smaller
application.
When a designer considers the arm itself and its kinema-
tics he want to consider several factors. One of these is
will
that the change in the angular orientation of the end device
when it is at some specified point in its work zone, must not
involve significant movements of the arm elements which are
located some distance away from the end device. One brings
thisdown to an earthy level by saying that when a human
wants to grasp a pencil, he moves his fingers, not his shoulder
muscles. The designer considers the distribution of the
necessary number of degrees of freedom when the total
number of freedom degrees is a constant. If the cost effec-
tiveness requires that you can have only four degrees of
freedom, where should they be located?
So we find that in order to maintain the necessary man-
euverability of a robot's arm seven to nine or more degrees of
freedom might be required on some tasks. You don't have to
play around with mathematic or proofs to show this, just
layout the work area and draw the kinematics required for the
tasks.

POWERING THE ROBOT'S ARMS

General Motors expects to use about 14,000 industrial
robots in their factories by 1990. As many of the parts and
tools used in automobile production are quite heavy, we need
to further examine a robot system with regard to how the arm
is powered.
At each joint, or section of the machine, there must be
powering units to control the movements and position of the
extensions appended thereto. We might even conclude that a
robotic arm consists of many individually controlled ele-
ments, each with its own set of operating signals and sensors,
which become integrated into one unit under the control of a
master computer, or programmed drum, or both. The drive
devices, which we are at the moment interested in, are placed
in various ways to control the motion of the arm. Most
generally they are placed directly at the joints or on the

201
elements of the arm near a joint. But because you don't get
much leverage, this is suitable only when the arm is not
required to heavy loads. We must also consider that type
lift

of drive where the powering units are all located near the
shoulder joint and use other means of transmission of power
from the drive sections to the elements of the arm. In some
applications this may be a good way to power the elements so
that the weight of the drive units are not on the arm itself, and
thus the weight lifting capability vs the weight of the arm ratio
might be increased. Finally, we must consider the third alter-
native, which is that there be a combination of element-drives
and remote-drives for the operating machinery.
The three types of drives used are the electric, the
hydraulic, and the pneumatic. Each has some particular ad-
vantages when used in robotics applications. The pneumatic
and hydraulic systems require pumps at some remote loca-
tion, with only the hoses going to the machine. Control can
only be precise using sensors, however, load capability is
excellent. Electric motors are another matter.
The electric motors are easily powered and may be
designed for low inertia. Thus they are capable of excellent
acceleration, deacceleration, and velocity control, but they
are heavy for the amount of horsepower produced. They have
excellent reliability records. In the past there have been
some machine operations using electric motors working at
constant speeds, using various types of speed reduction units,
which may be controlled electronically, and also using
clutches to transmit the power from the drive unit to the
various elements. Clutches can engage and disengage quickly
and have, in the past, offered quite high reliability in such
applications. It is possible that for certain robotic applications
in the future, some systems or even parts of systems, may use
clutches and electric motors as a part of their powering
system.
Without clutches it is necessary to use stepping motors

in robots.Robot manipulators using these powering devices

are capable of very discrete and tight control and such motors
work easily with digital type input signals. If the stepping
movement is large, then some auxiliary type equipment

202
needs to be used, on the grippers to turn this step movement
into a smooth precise movement of the end device.
Finally, we should not overlook the use of such items as a
powered selsyn type of transmission and powering system for
certain robotic applications. These may have either a physical
or electrical input and can be very precisely controlled even
though their physical power output is very low. They might
be used in conjunction with other types of powering units and
so give the smoothness and precision and power required for
many applications.

THE PLANET ROBOT "ARMAX"

In Fig. 6-4 we see
one arm robot made by the Planet
a
Corp. of Farmington Hills, Michigan. The grippers may be
replaced with other tools as required. This unit uses hy-
draulic power and the source of that hydraulic power is usu-
ally remotely located from the unit. This robot is designed to
be used in welding, material handling, machine loading/
unload, gaging, deburring, flame cutting, surface finishing,
and spray painting operations. Figure 6-5 shows its world. In
this illustration we can see the vertical and horizontal profiles
of its work area.
In Fig. 6-6 we see how the robot is used to manipulate a
wire brush over an automobile body. The brush must come
down on the body at a given point and with a given pressure.
Then it must move precisely over a pre-planned curve, which
might be a welded seam, for example, and then at the end of
its movement, it needs to lift off the body and wait until

another body slips into position. The machine must be taught

just how to move its brush, of course, and a computer will
memorize that information.
Planet Corporation says their robots may come in two
variations; a servo controlled robot or a programmed robot.
The servo-controlled type is operated by a computer which
has one section for each controlled axis of movement. It uses
a high level language and incorporates some adaptive control
so it can adjust to changes in its external environment. This
robot is taught with a hand held unit similar to the ones we
have previously described.

203
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 In Fig. 6-7 the layout of the Armax robot is shown and its
operation is indicated for a parts handling job. This job con-
sists of handling a part which must be deburred and then
placed in a different location. This is a programmed robot.
That means that its actions are controlled by pegs in a drum
which close various switches causing the various operations
to be performed. We look at note 1. The spacer grippers open,
the arm extends the grippers close and the arm retracts with
the item and turns clockwise. In position 2 the arm extends,
the machine opens up, the grippers open and release the part
to the machine. The arm holds still while the de-burring
procedure takes place, then the gripper closes and the arm
retracts again and the robot arm is ready to rotate clockwise.
In 3 the robot arm rotates into the position indicated and some
tooling grips the part and the robot arm is ready to rotate
clockwise. In 4 the robotarm rotates into the position shown,
thearm extends and the tooling ungrips the parts. Now the
arm retracts and the arm rotates counterclockwise to start at
position 1 again. Notice that a gravity feed is used on the
parts,and also that the parts are fed by a mechanical escape-
ment which is operated as the arm rotates. This is necessary
because control is not accurate enough to pick up and pre-
cisely orient small parts with a hydraulic robot.
Figure 6-8 illustrates the positions the arm takes when it
is usedin a machine load/unloading operation. Notice the
legend which uses a letter P for pick-up, and the letter D for
deposit of the part at the point indicated by the numbered
arrow. Now, let us take a look at hydraulic drive and control.

THE HYDRAULIC DRIVE SYSTEM FOR ROBOT ARMS

The basic piston— transfer- valve drive for a hydraulic
system well known and the equations are easily derived
is

when considering the flow rate, dimensions of the piston and

valve, coefficients of friction, orfice flow, and the mass and
load acceleration requirements. The basic unit and equations
in a simplified form are shown in Fig. 6-9. In this diagram we
see that the total force exerted by the piston will be equal to
the differential pressure (pi— p2) and that this pressure will,

in turn be governed by the flow rate of oil through the transfer

207
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valve into the piston. We note that the rate-of-change of the
piston shaft position (y) turns out to be some constant times
the transfer valve shaft displacement (x).

A little more elaborate diagram which shows the control

amplifier with its many inputs, the solenoid, and a load reac-
tion. The expected transfer force minus the load reaction
equals the actual transfer of power. The arm position sensor
feeds information back to the control amp.
Finally, we show in Fig. 6-11 a very simplified diagram
which can be used to develop the second order differential
equation of motion for the hydraulic piston, valve, and load.
We realize that nature tries to balance the forces rep-
resented. The piston force tries to make the load accelerate
and move. The mass of the load and the friction in the load
system or robot arm system or whatever, tend to resist
motion. There must be a force greater than the retarding
forces if the system output is to be moved, and there is to be
an acceleration of the load. The load might be the members of
the robot's arm system, or might be the arm plus whatever
the arm is lifting or moving. In any event we want the arm and
load to move smoothly and accurately without vibration, os-
cillation, overshoot, or other minor problems.
In a hydraulic system the forces can be considerable
since the force exerted on the piston shaft will be a product of
the pressure of the oil times the area of the piston. Assume a
300 and a piston area of 6 square inches.
lbs/sq.in. pressure
The be 1,800 lbs.
shaft pressure can
The favorable aspects of a hydraulic system are low
weight per-unit-power, low inertia of output member, high
speed of operation, and large force development. Some of the
limitations include the requirement for the auxiliary power
system, possible leakage problems, and minimal control.

THE PNEUMATIC POWERING SYSTEM

This system using air as the working fluid is probably the
system possible to obtain. Inertia is low, as with
fastest type
the hydraulic system, and the air may be vented into the
atmosphere, which eliminates the need for a return flow

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213
system. Air is obtained from the atmophere and compressed
into pressurized tanks.
In pneumatic systems one uses air under pressure to
operate pistons, and also one may use the suction. This may
be used to provide power to suckers which might be placed on
grippers to hold certain types of packages or objects, or to
attract them into the gripper jaws.
Although air is light weight and easily available, it poses
some problems in that any contaminants in the system, even
moisture, can cause trouble with system parts such as valves
and tightly sealed pistons. But when its application fits a
particular need, then it is used to quite a large advantage. On

letter sorting machines used by the Post Office an arm moves

to a stack of letters, grips one by its face with suction, moves
it to another position by rotation of the arm, and then releases

it with a short explosion of air.

OTHER METHODS OF POWERING ROBOTIC ARMS

The use of action envelopes with robotic drives has been
studied by some. These are said to be quite sensitive and can
range from low-powering to quite high powering-devices.
They consist of tubes and bellows and follow the traditional
action of these type elements.
You have a tube into which you can force non-com-
pressible liquid such as hydraulic systems use. The tube does
not lengthen, but tends to expand sideways and contract
lengthwise, just as human muscles do. Thus a pulling action is
available just as with a human muscle. When the pressure is
released, the tube lengthens again and the sides return back
to a normal diameter. No moving piston is necessary in this
case. One attaches the load to the end of the tube and can pull
itor, by use of a second tube and proper dynamics, push it to
whatever position one desires.
Regardless of how the arm is powered, robots all use the
same kinds of grippers and in Fig. 6-12 we show some de-
veloped by FIBRO-MANTA. They too are powered by elec-
tric motors, hydraulics, and pneumatics. The grippers may be

caused to operate by proximity detection or by program. The

use of springs gives a snap action which might be necessary

214
 Design

Gripper Module
# hydraulic /

angular gripping motion

Execution

Gripper Module
hydraulic /

parallel gripping motion

Gripper Module
spring-actuated /
parallel gripping motion
(internal)

Gripper Module
spring-actuated /
parallel gripping motion
(external);
fitted with
workpiece-adapted
jaw inserts

Fig. 6-12. FIBRO-MANTA gripper units for robotics (courtesy Fibro-Manta).

215
when high speed of operationis required. For handling cer-

tain typesand shapes of work pieces, special inserts may be

placed inside the jaws which then conform to the required
dimensions to insure a tight grip on the piece of work being
handled.

SOME CONSIDERATIONS OF THE PROGRAMMED ROBOT

There exist in our world a large number of machines
which have been called robots. Many find this terminology
not at all acceptable for these kinds of machines. As stated by
Dr. James S. Albus of the National Bureau of Standards,
"Most of these mechanisms exhibit few of the characteristics
the average person would associate with the term robot; they
are mostly pick-and-place machines that are capable of only
the simplest kinds of motions. They have little or no ability to
sense conditions in their own environment. When they are
switched on, they simply execute a pre-programmed sequ-
ence of operations. The limits of motion for each joint of the
machine are fixed by mechanical stops, and each detail of
movement must be guided by means of an electric or pneuma-
tic impulse originating at a plugboard control panel.
In a typical application, each row of the plugboard repre-
sents one degree of freedom in a specified robot joint, and
each column represents one program step. Connections are
made in appropriate rows and columns to determine which
joints are actuated, and in which direction, at each step.
Whenever a new program is needed, the mechanical stops can
be re-positioned and the programming connections can be
relocated to set up a new series of movements. A more
sophisticated level of control can be achieved by adding ser-
vomechanisms that can command the position of each degree
of freedom to assume any value. The addition of servo-control
requires feedback from sensors such as potentiometers en-
coders and resolvers, which measure the position of each
joint. The measured position is then compared to the com-

manded position, and any differences are corrected by signals

sent to the appropriate joint actuators.
This excerpt is interesting because it tells us how, in
general, a programmed system operates. A robot's arm may

216
be moved by command signals which originate either from a
timing and sequence drum which closes switches at various
times, or from a computer which draws upon its memory for
the movement commands. The difference is that the com-
puter may have solved some equations as part of its own
intelligent operation, it directly commands the movements
and speed of the arm, and it analyzes the feedback to make
adjustments. The program drum— which was set and pat-
terned by us— could only move the arm one way, at one speed
to get to its final position.

THE PATCHBOARD PROGRAMMED ROBOT

It really is a pretty dumb kind of machine. Let us examine
Fig. 6-13. Please realize that this is just an example to illus-
trate our points. You can probably easily imagine a much
better and more complete programming unit for a real-life job.

PATCHBOARD
12 3 4 5

O • O O O I

ARM ROTATE
O O O • O

O O O • O /
ARM EXTEND
O • O O O |

• O O O O \
GRIPPER
O O O O O \

o o o • o \

STOP o o • o o \

2 ROWS FOR EACH JOINT.

1 COLUMN FOR EACH STEP
1 IN EACH DIRECTION

HOPPER 1

FINGER CONTACTS
HOPPER 2

Fig. 6-13. A sketch of an imaginary "patchboard panel" which might program a

robot.

217
 Plugs go into the patchboard where the dark dots are. As
a rotary switch makes contact with the plugs at each step, the
corresponding joints are activated. The actions are stopped
by mechanical stops or sensors attached directly to the arm.
This board will open the grippers, dropping an item into
hopper 1, then pull in its arm as it rotates to the left.

Positioned over the conveyor, it waits to close the gripper

until the sensor is triggered. Notice this is not done by the
patchboard.The sensor could sense light, or color, or, using
magnetism, metal composition. The result is that items not
tripping the sensor go into hopper 2. When the sensor is

triggered, the grippers close and the rotary switch starts

again, proceeding to step 4 where the arm moves out and
right, over the 1st hopper. The START OVER plug indicates
to the rotary switch (not the arm) to disengage and swing
around to position 1, where it all starts again.
In some types of robotic machines a rotating drum is

positioned at a starting point and around its circumference are

such holes as we have shown and switch actuating pegs are
placed in these holes. When the whole unit is placed into
operation the drum starts rotating and closing and opening
switches according to the various peg positions. The speed of
the rotary switch ordrum controls the period of time between
steps, but the speed of movement cannot be controlled.
Although it may seem that this type machine is not
useful, that is not true. It is simple and reliable and will
perform its operations, even rather complex ones, with the
same precision and accuracy time and time again. You know
how useful and reliable the washing machine, dryer, and
dishwasher are in your home? This kind of machine is that
type. For some industrial operations this type machine may
be much more useful and cost-effective than the servo-
controlled machine. We will probably see everything from
pencil sharpeners to lawn mowers called robots in the future
years.

SERVOMECHANISM DEFINITIONS AND CONSIDERATIONS

The world of electro-mechanical control states that
servo-systems fall into two general categories: the open loop

218
system and the closed loop system. It is common to find the
following definitions used with regard to these systems:

open loop system— A system of operation where the

input does not depend on the output.
closed loop system— A system of operation where the
input does depend on the output.

Examine Fig. 6-14. In Fig. 6-14A we see a typical open loop

system which has no feedback. The output is expressed
simply as the product of the various transfer functions of the
various blocks of the system, as illustrated. These functions
are usually expressed in Laplace Transforms.
Systems such as this open loop system can be used for
control purposes assuming that we know where the arm is
currently located, or that the arm is always returned to home
or starting position at the end of each programmed operation
or cycle.The input could be a series of polarized digital pulses
sent from a computer that remembers where the arm is and
where it needs to go next. The polarized pulse would turn a
stepper motor the proper direction and distance. Assume
that we have one such servo-system for each element of the
arm. This means that if we have the shoulder section, the
forearm and the wrist, that we would have three such servos
in operation.
Our three servos might operate in this manner. The first
servo will move the whole arm— it being the shoulder servo.
Once the whole arm has been moved, then movement is
relinquished to the forearm servo for more precise position-
ing of the wrist and gripper, or hand, and finally, the wrist is
positioned so that the torch, paint gun, or whatever is in the
desired position for task performance.
we know the exact end-position that the hand has to
If

reach, we can provide the correct number and type of digital

pulses, as a function of time, to make the robot's arm move to
where we want it to move. This concept of programming
would work with the drum or patchboard too, if the servos
have distances pre-set. Notice that no feedback is required.
The whole machine simply gets an input of pre-arranged and
polarized digital pulses which it amplifies and sends to vari-

219
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ous stepping motors at a proper time so they will operate
correctly and without mutual interference. This machine can
also do useful work, accomplishing jobs suited into this sort of
mindless type operation. The advantages of this type system
are simplicity and low cost, because no feedback is needed,

and a higher degree of accuracy than hydraulics are capable of.

In connection with the programmed movement of the
arm of this type robot, there might be external mechanical
switches operated by the arm as it passes. In this manner,
bins might be opened as the arm swings toward them. Parts
would then be fed into a belt. The combination of operating
pulses of an electronic nature and the genius of mechanical
engineers combine to make a machine do almost wondrous
tasks! It seems there is a place for the open loop type control
system in actual industrial applications.
Why, then, do we want a closed loop system? Using
feedback and some internal computing element, it is capable
of adaptive control. Only a closed system can adapt to varying
situations.
It is interesting to note how the control equations of such
a system are derived. One simply takes the product of all
error detectors and then writes this group of terms as a
fraction. Consider the loop opened at point X in Fig. 6-14. We
can derive the open loop type transfer function to use in the
formulation of the closed loop equation as shown. Realize, of
course, that the KG terms can be very long and complicated
expressions using the Laplace Transforms. Any good text on
Servomechanisms will illustrate how this is done.

SERIES AND PARALLEL SERVOMECHANISMS

A system of series servomechanisms which might be
used to control the arm of a robot is shown in Fig. 6-15.
Assume that there is a command input from some place in the
system. This causes the shoulder servo to activate, moving
its output element physically until it is as close as it can get

and the command is zeroed out. At the same time that it

moves, it causes a command signal to the forearm element so
that it also moves just as soon as the input command signal is
large enough to cause the second servo system to operate. It,

221
222
too, will move until the command signal is reduced below
some operating threshold value— when the error is so small
the servo sees no signal. Finally, the third servo is activated
in a likemanner and it moves until its input command is

reduced below threshold value. In this movement, just to

insure overall stability of the series arrangement, a feedback
is made from the final output element to the primary input
error detector, and this signal may be positive or negative as
required for accuracy and stability.
Notice that we have a feedback around each servo for its
own stability and precise operation, and that there will be an
over-all loop from the output back to the input. Thus we have
loops inside of loops! Techniques for writing the equations of
such a system are well known. Computers can solve such
equations and will permit playing around with variables, so
one might have an interesting time seeing just what would
happen in this situation, with and without load, with varying
amounts of inertia, and if one considers some velocity and
acceleration response situation requirements.
The input command, which may come from a computer,
will govern the actual movement. The inter-relationship and
inter-dependence of one arm element on its preceding ele-
ment means that either the computer will have to do the
calculations, or there will have to be pre-set servos, summing
amps, or some other form of controlled feedback.
Parallel arrangement of servosystems can move the
arm elements either together or sequentially as necessary.
This situation might be diagrammed as shown in Fig. 6-16.
Here we see how a servosystem controls the movement of
the shoulder element. This servo has its normal feedback for
stability and compensation, and it also provides feedback (1)
to the computer driver which generates the input signal (A).
Thus the shoulder element can move such that its end point
(the elbow) will position itself at some coordinate as com-
manded by the input. The computer will know this and be-
cause of the feedback, will know just how the element is
moving in space to get to that point. Meantime the computer
can direct the second servo to move the forearm at the same
time and along some pre-computed trajectory, and it can keep

223
 -( B.F.(S)>4-

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-( B2F2(S) )«-

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-( A?F;(S)

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Fig. 6-16. Using parallel servos to control a robot's arm.

track of what is happening with this second element even as it

programs and commands the first element. The same thing
happens to the hand. Sensors on the hand will tell the comput-
er that the hand is on the object, has grasped it, or that the
hand is now ready for some further signals.
Just one further point concerning servomechanisms of
this type. We have mentioned the threshold signal level. The
smaller the signal which can make the servo operate, the
smaller the actual error in position, velocity, or acceleration
will be, however it is also more susceptible to noise.

ROBOT HANDS AND HUMAN HANDS

A study was made of the technical feasibility of con-
structing a robot hand which would be like a human hand. It

was found that the human hand is just too complex for such

224
duplication in the first place, and in the second place, it really
necessary to exactly and completely duplicate the human
isn't

hand to have that robot perform well enough to replace hu-

mans at some tasks.
Some of the interesting facets of this study were that the
human hand has some fifteen joints which result in some
twenty two individual degrees of freedom. Think about writ-
ing equations to describe such movements! Although this
number of degrees of freedom might be required for playing a
piano, who wants a robot to play such an instrument? If you
can't play it yourself, you can buy a player piano or record
player.
The study showed that of the technically realizable man-
ipulations possible for a hand and fingers, a hand having only
one finger can perform about 5 percent of all the manipula-
tions needed. If two movable finger parts are used (a grip-
per) then the totality of possible manipulations is increased to
If a third freely moving finger is added, with
about 40 percent.
the same number of degrees of freedom as the human hand,
then almost 90 percent of the possible technical manipula-
tions can be performed. Adding a fourth finger increases the
manipulative ability to some 99 percent. There isn't much use
going beyond this capability.
If a two finger hand is our familiar gripper, the three
fingered hand would be one in which fingers would be
mounted on a wrist at 120-degree spacing, as in Fig. 6-1. If
one were to design a hand with an additional rotary joint
incorporated at the base of each finger, so that each finger
could be rotated with respect to the others, and still maintain
their gripping power and capability, then some 75 percent of
all the manipulations of a human hand might be accomplished.
One "ideal" hand has four joints per finger, for three of
the fingers, and the bases of these fingers are separated more
than they are on the human hand. Three of the joints are
controlled in whatever manner is most suitable, the fourth
by the second joint. The wide
joint is automatically controlled
base arrangement permits the "thumb" to fold out of the
working area between the other fingers. With this device
some 89 percent of human hand operations might be achieved.

225
 In a human hand
the joints use sliding surfaces which, in
part, are deformed during the motion of the joint. Also the
human hand has very complicated gliding joints which are
continuously lubricated with the joint fluid and have an excep-
tional safety system which prevents joint damage. The safety
system consists of force and pressure sensors. The man-
ipulating force per finger of the human hand is somewhere
around 3.5 to 5 kg and is about 25 kg for all fingers working as
a unit. It would be difficult to duplicate this variable capability
by machine. With the pincers or gripper type hand one can
design for large forces, up to 10 times the force of the human
hand, and this type design has become very practical. The
mechanical hand can operate at a faster velocity and accelera-
tion than the human hand, and does not tire when moving at a
fast pace. Also the wear on the mechanical parts is very small
even when doing a fast task and exerting considerable forces
in the task.
The mechanical hand may, or may not have environmen-
tal beams of light, generated within the grip
sensors. Infrared
of a mechanical hand could permit the hand to sense the
proximity of objects it is trying to pick up. The human hand

has many more sensors. has a cold and hot sensor, feel
It

sensors, pressure sensors, and force measurement sensors

which are an integral part of the human hand's construction. If
we include heat and cold sensors in a robot's hand, these
might generate alarm signals if things begin to get too hot or
too cold. Force measurement sensors are currently available
in a number of different configurations, from limit switches
and variable magnetic-signal transformers to piezo crystals.
There are several hundred thousand receptors distributed
over the human hand. Considering this, it is immediately
obvious that we can never build an artificial hand that dupli-
cates the human hand precisely! One hand has fingers which
each have 12 degrees of freedom. The hand could give a rough
idea of its surroundings by detecting corners, and determin-
ing structure symmetries, and so on without seeing the ob-
jects. The sensor signals were sufficient for a computer to
build the image.
When humans solve a grasping problem, they are only

226
conscious of the final process which is to feel the object. They
are no longer conscious of the individual motions which lead
to the final result. This is all programmed by means of a
lengthy learning process. Small children learn to grasp ob-
jects with their hands and do from
this at various distances
their bodies. They learn how to manipulate their hands and
arms and wrists for round, thin, long, short, and fat objects.
When this learning phase is over, they have a fixed program in
their nervous systems or in their brains for the control of the
various motion elements which make possible the manipula-
tions required, and in such a manner that certain motion
chains will automatically occur in a fixed sequence or desired
sequence, and in synchronization with other parts of the
human system.
The total robotic manipulation process is first decom-
posed into signals in a first, upper level. These signals deter-
mine which elements should be activated. The individual
motion elements themselves are then activated in a second
logical process. The final manipulation is produced by means
of an additional synchronization control system governed by
the adjustment of the pressure forces and the manipulation of
these forces among the various body elements. The organiza-
tion of such subordinate functions are autonomous, but influ-
ence each other in an adaptive control system manner. This is
called hierarchically organized information processing. Much
of the "feedback" information in robots is accomplished with
analog circuits whose signals are then digitized for computer
processing as we know.

CLOSED-LOOP SERVOSYSTEMS AND FEEDBACK

We have again mentioned feedback in connection with a
We shall see in later pages
closed loop type of servosystem.
how a velocity feedback is important to the overall stability of
one type of industrial robot. Let us examine the concept of
feedback further in preparation for the information yet to
come.
We can diagram a rather complex multiloop servosystem
as shown in Fig. 6-17. There are three feedback loops shown,
two of which have some kind of compensation amplifiers in

227
their lines. The feedback to the input is, of course, the output
shaft or element's position.
We define a transfer function as the ratio between output
and input. The abbreviation for the transfer function is T.F. as
shown in the illustration.
By being able to write a mathematical expression which
tells us what happens to the voltages, currents, or physical

elements controlled by the blocks, using the inputs and feed-

backs as shown, we are able to examine how the output
responds to changes in loading, gain of various blocks, the
addition of various rates of change in voltage or current.
Signals representing the velocity or acceleration of physical
elements will affect the output, whether these signals de-
velop in the feedback loops or in the forward part of the loop
or block input line.
Because the computer will show the effects of these
show whether to increase the torques or
variations and also
power applied, or increase the damping— which prevents
oscillation— one can design a whole industrial robot system
on paper and try it out on a computer before anyone has to
spend a dollar buying expensive motors and gears and such, to
make the thing, and try it out experimentally. Of course the
final proof of design is always the building of a model and

making such adjustments to it and corrections to its control as

are necessary to make it do exactly what it is intended to do
efficiently and precisely, and, hopefully, economically.
If we look at a general second order differential equation

in the form Jp x + Fpx + Kx = C or (Inertia x Acceleration) +

2

(Friction x Velocity) + Power = C, where C is the command

input. Then, if we know that the addition of a type of control
such as velocity feedback will affect the second term or the
damping term of the system, we can predict what will happen
if we add this control to the system. Also, if we use a proper
acceleration type feedback, we can predict whether this will
have the effect of increasing or decreasing the system inertia.
We can vary the value of the system power term (K) and see
what happens. In a general way, we can add anything to the
block diagram, write its transfer function, mathematically
manipulate the equation till we get it in the form shown and

228
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229
then look at it, computer for solution and see
and put it in a

what we have done! Sometimes that is amazing and surpris-

ing!
If our system tends to hunt or oscillate about a final

position then we might have to increase the friction or damp-

ing term of the system to effect a cure. We might do this by as
simple a technique as adjusting a potentiometer. If we find the
robot arm moves too slowly into a final position, so that a part
goes by before the arm grippers can grasp it, then we might
adjust the K term— also by adjusting a potentiometer— and
correct the delay. We might find we have to adjust many
potentiometers or controls same time for a particu-
all at the
lar installation to make the robot work exactly as it should in

that application. There can, and will be, in the normal course
of events, many feedbacks in a robotics system and all these
are necessary.

ELIMINATING THE ERROR

A closed loop servosystem operates on an error signal.
The open loop systems operate on a command input signal.
The closed loop systems always compare the output to the
input and the difference between them is the error signal, it
seems we always must have an error signal for the system to
operate. We have discussed some problems associated with
trying to minimize that error. It is possible to eliminate the
operating error one uses integral control methods!
if

What this kindof control does, in effect, is to average up

the amount of signal developed in an error and then, through
its block of control, develop a voltage proportional to that

error and of the proper polarity to cause the motor controller

of the robotics system to eliminate the error entirely! A very
simplified block diagram of such a system is illustrated in Fig.
6-17.
Here we see the integration amplifier in the forward loop
of the system. It is possible to obtain this effect with a proper
compensation feedback loop also, but we do not obtain
in the
complete elimination of the error so easily. In effect we make
the system very sensitive and so it can easily become unsta-
ble if there is no other compensation used to damp out any

230
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231
oscillatory tendencies. When everything is finely adjusted so
itdoes operate as it should, there will be no error in output
but if there is any slight change to voltages in the system it
might throw the balance off and cause some problems. Inte-
gral control is a delicate type of servomechanism, but it

exists.

DETAILS OF ELECTROHYDRAULIC SERVOSYSTEM

Some robots are constructed with a combination of elec-
tricallyoperated transfer valves and either hydraulic or
pneumatic pistons controlling the arm movements. Examine
a cut-away of an actual hydraulic transfer valve. Notice that
the valve is operated by torque motors. Figure 6-19 shows
the cut-away illustration.
Locate the valve spool. This is the element which is

moved by the torque motor to permit oil to flow to a piston,

not shown here. This valve controls the input to one side of
the piston while at the same time permitting the exhaust of oil
from the opposite side of the piston back to a sump of some
type. In order to have a quick response to the electrical
signals, it is customary to have the spool dither, which simply
means it vibrates in accord with a low amplitude, high fre-
quency signal imposed on the control winding of the torque
motor along with the control signals. Realize that it is easier
to keep something in motion than to start it in motion, so this
action is used to keep the valve spool moving and thus pre-
vent delays due to sticking deadband. Deadband is that region
of no response where a change in the control signal will not
cause a corresponding pressure change of the piston.
Some other terms used to describe phases of operation
of a transfer valve are:
null— the condition where the servovalve supplies zero con-
trol flow at balanced load forces across the piston.
null shift— the condition which results from a change in the
bias current which produces a null. The shift is expressed in
terms of a percent of the rated current of the servovalve.
deadband— that region of no response where a control sig-
nal will not cause a corresponding pressure change in the
piston.

232
 Design Features
TYPICAL ELECTRO-HYDRAULIC SERVOVALVE
SCHEMATIC DIAGRAM

ELECTROMECHANICAL TORQUE MOTOR ASSEMBLY

NULL ADJUSTMENT COVER

-UPPER POLE PIECE

. ARMATURE- RIGIDLY SUPPORTED ON DEFLECTION TUBE

-SUPPORT TUBE

• ELECTRICAL CONNECTOR

9 CYCLES
-DEFLECTION TUBE-DESIGNED FOR A MINIMUM OF 10

- ENO CAP

-LOWER POLE PIECE

"
CONTROL SHAFT ANO TORQUE MOTOR OUTPUT YOKE

FIXED ORIFICE-PROVIDES FLOW TO FIRST STAGE HYDRAULIC

AMPLIFIER

YOKE CAVITY

FEEDBACK SHAFT-CCHL SPRINGS ARE RIGIDLY ATTACHED TO THE

FEEDBACK SHAFT. AND THE SHAFT IS RIGIDLY INSERTED
INTO THE VALVE SPOOL

Design features of DYVAL Servovalves

are protected by patents or patents pendinq

Fig. 6-19. Electrohydraulic servovalve-schematic diagram (courtesy Dynamic

Valve Co.).

linearity— the degree to which the normal flow curve con-

forms to the normal flow gain line with the other operational
variables held constant. It is measured as the maximum de-
viation of the normal flow curve from the normal flow gain line
and is expressed as a percent of rated current.
threshold— the increment required to change from an in-

creasing output to a decreasing output.

Since we have mentioned curves, let us examine the
curve of normal input and output control tolerance for the type
of servovalve under discussion. Look at Fig. 6-19.

233
Notice the tolerance lines, dotted on each side of the solid
reference line. By taking the span between the tolerance
lines, in the vertical direction (y axis), one can obtain the
increment by which a percentage of the load flow may be
calculated. The illustration shows a 10 percent rated flow.
Also a projection on the X axis will give the percent of rated
current. Both English and Metric units can be used to de-
scribe flow and other important dimensions as illustrated.
Finally, we want
examine two actual, commercial
to
servodriver units from Dynamic Valve Co. These are the
electronic parts of a servosystem which operate the ser-
vovalve previously shown. In Fig. 6-21 A we see a schematic
for a velocity servodriver, and we note that it has an integral
control element in the forward gain loop. There is a control
there called the integrator sensitivity control and this can be
adjusted to obtain the desired effect on the servo perfor-
mance.
If we moment the effect of an error in a
consider for a
servosystem in which velocity of movement is important, and
is an input specified quantity, we will realize that an error in

this quantity will cause the wrong velocity, or an oscillation

about some normal desired value. We don't want such an
error in this type of system. We want it to get to the desired
and commanded velocity and hold that velocity. The
integral-control type of servo can make this possible. Notice
in that same system that a tachometer is used for derivative
feedback compensation. This produces the stability required.
Sometimes it is desirable to be able to open the loop of a
closed loop servosystem in order to check signals at various
some cases to locate troubles. In a closed loop
points and in
system, where the system always tries to minimize its error,
one might have a lot of trouble trying to see what kinds of
signals are actually being produced by the various blocks of
the system. When we open the loop we can create a static
condition which permits us to see what these signals are,
since there is no way the system can function to reduce the
error as we have previously defined the error signal. In block
A of Fig. 6-21 we see the switch which opens the loop for
testing or adjustment or whatever.

234
 NORMAL INPUT & OUTPUT
CONTROL TOLERANCE - typical for all valves

Flow Tolerance Chart for all Standard and High Frequency Servovalves

MORMAL FLOW
TOLERANCES
10% RATED FLOW

100 20 40 60 80 100
20 % RATED
CURRENT

Design features of DYVAL Servovalves

are protected by patents or patents pending.

UNITS

Recommended English and Metric ISII units for expressing servovalve pcrfor

English Metric Conversion

fluid flow in3 sec (cist liter /mm (Ipml 98lpm/c.s

gal / mm (gpm) 3 78 Ipm/gpm
fluid pressure Ibs/m2 (ps.l bat 069 bar / ps,
dimensions men Imi millimeters (mml 25 4mm/,n
micrometers uml
( 25400 *jm/,n
mass pounds (Ibl kilogram 454 kg /lb
force pounds Oh) Newtons INI 4 45 N/ lb
torque lb in Newton meteis IN m) 113 N m/lbin
temperature degrees Fahrenheit ( *F| degree Ceisim |
C C 5/9 F-321 1

Fig. 6-20. Servovalve curve showing characteristics of its operation (courtesy

Dynamic Valve Co.).

In block B of Fig. 6-20 we examine a positioning type of

system. There is a control to adjust the value of the gain (K),
and there is compensation, with derivative feedback of an
electronic type. In a way it is like the tachometer feedback,
but doesn't operate from the moving output element as the
tachometer type does. This type operates from the signal and
is able to determine changes in the signal and the rate of

change of the command or error signal. There is also a

velocity feedback to the input and various other controls for
balance and monitoring purposes. In all cases the output of the
servodriver units is sent to the torque motor on the hydraulic
transfer-valve which, in turn, controls the output piston pro-
ducing the power and movement required of the system.

235
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237
 We should not conclude this chapter without mentioning
makes a transfer valve which has a
that Dyval, Inc. also
pneumatic element mounted on the hydraulic valve, and this
pneumatic element controls the hydraulic flow. In systems
where air pressure is used to control fluid flow, the system
has a combination of both power and speed. Recall that a
pneumatic system is said to be the fastest mechanical
system
because the air can be moved faster than oil, however, air is
compressible and so for power, without elasticity, one needs
the non-compressible hydraulic fluid as the power producing
element.

238
 A Computer-
Operated Hobby Robot

The arm described in the following pages, courtesy of

robotic
Microbot and Robotics Age magazine is one which its inven-
tors say can be used for hobby purposes, for research pur-
poses in computer program development, or just for robotics
experimentation. The arm is operated by a computer as illus-
trated in Fig. 7-1.
In the operation shown, thearm is being directed to
pick-up and stack some small wooden blocks in a sequential
order. This is not a professional application, but is fun, as is
the writing of the computer program to accomplish such
You can see the relative size of the arm. You might
tasks.
remember GARCAN and wonder if such an arm might not be
attached to that paraplegic robot. One advantage of this unit's
you can develop various computer languages and
size is that
programs for robotic use, and then check these programs
without having to resort to the expense of procuring a full size
robot.
Many universities and research centers are now de-
veloping the necessary communication languages for robot
control and programming, using computerized programs
which are of great complexity, yet plan their own manipula-
tion strategies, efficiently performing complex coordinate

239
Fig. 7-1 . Computer operation of the hobby-research robot arm is easy (courtesy
Microbot).

transformation mathematics. Studies are being made to use

more and better sensors and get better use from the available
types of sensors, and studies are being constantly made to
gain a better understanding of the robot's kinematics. The
Mini-Mover 5 as this robot arm has been named, was de-
signed to assist this kind of research.

LOOKING AT THE ARM DESIGN AND OPERATION

In Fig. 7-2 we see a close-up of the Mini-Mover 5 with its
gripper and three of its 6 stepping motors. These control the
arm and gripper movement. The motors are; base drive,
shoulder drive, elbow drive, 2 for wrist drive, and the gripper.
In the upper right hand corner of the illustration we can see a
portion of the computer used to control this unit.
Because a coordinate system must be designated for the
arm and the gripper— and this is true for any robot sys-

tem—we show in Fig. 7-3 how this is designated for the

Mini-Mover 5. You system of
will notice that a rectangular
coordinates used which has its origin at that point where
is

the base of the arm pivots on a supporting surface. The

gripper, then, will be displaced from the origin in some X, Y
coordinate direction, and have an altitude position in the Z

240
Fig. 7-2.A close view of the Mini-Mover 5, as the arm is called, and three of the
sixmotors used in its operation. Motors 1,3, and 5 are on the opposite side of the
arm in this view (courtesy Microbot).

direction. One might wonder if using a system of polar coor-

dinates wouldn't identify the gripper position much easier?
Remember that the arm will be responding to a series of
pulses which, in turn, will step the various stepping motors.

Z-AXIS UPPER ARM

SHOULDER JOINT

WRIST JOINT

BASE GRIPPER = HAND

HANO

X-AXIS

Fig. 7-3. The coordinate system for the robotic arm (courtesy Robotics Age).

241
Thus it might be easier to program the unit to move five units
right (X) and two units out (Y) and drop the gripper itself down
two units (Z) to engage some object.
We note that this arm's gripper has five degrees of
freedom because it is driven by a differential gear mechanism
which can rotate the gripper in both pitch and roll. Add this to
the motions of the body, shoulder, elbow, and wrist and you
have a sufficient number of degrees of freedom so that the arm
can be accurately positioned and the gripper positioned in a
partial sphere whose radius is 17.5 inches from the origin.
We have mentioned earlier in this book that in some
cases of robot design, one might use motors which drive
various elements through the use of cables or linkages. That
is the case with this robot arm, as shown in Fig. 7-4.
The drive motor for each joint consists of a stepping
motor, reduction gearing, and a cable drum. From each drum a
tensioned cable goes out over pulleys to the member being
driven and then may or may not return to the drum. Rotation
of this drum causes rotation of each member in proportion to
the diameter of the drive pulley attached to that member and
the drum's diameter. The movement of one joint on this arm
may result, therefore, in the motion of another joint, and this
may not be desirable. Here is how the designers of the
Mini-Mover 5 describe the cabling operation, which must be
understood if you are going to compensate for these unwanted
movements by properly programming the operation of the
arm:
"Base Rotation Qoint 1)— The base drive cable
passes over two idler pulleys, making a 90 degree bend,
to a drive pulley fixed to the base. The base drive motor
causes the entire arm to rotate about the base joint.

"Shoulder Bend Qoint 2)— The shoulder drive

cable passes around the drive pulley on the upper arm
segment to rotate it about the shoulder joint.
"Elbow Bend Qoint 3)— The elbow drive cable
passes around an idler pulley on the shoulder axis to a
drive pulley fixed to the lower arm segment. Joints 2 and
3 interact, so that changing the shoulder angle results in
an equal change in the elbow angle. This interaction has

242
 ELBOW DRIVE
PULLEY
SHOULDER DRIVE
PULLEY
(4),(5)

COMMON
DRIVE
SHAFT

BASE DRIVE
PULLEY

Fig. 7-4. The cable diagram for the Mini-Mover 5 robotic arm (courtesy Robotics
Age).

been designed so that the elbow drive, in effect, controls

the angle of the forearm with respect to the horizontal.
However, the limits of forearm motion are measured
with respect to the upper arm, not the horizontal (x-y)
plane.
"Wrist Qoint 4, left and Joint 5 right)— The fourth
and fifthdrive cables pass around idler pulleys on both
the shoulder and elbow joints and terminate on the drive
pulleys of the left and right wrist differential gears. The
interaction of these joints with joints 2 and 3 has the
effect that the wrist drives control the angle of the hand
with respect to the horizontal (pitch) and the rotation of
the hand around its pointing vector (roll). Through the
action of the differential, the pitch angle P equals the
average of the positions of the and right gears and
left

the roll angle R is their difference. The range of motion

is limited to ±270 degrees at each of the wrist gears due

243
 ±90 degrees in pitch
to limits of the cable length and to
due to interference from the lower arm.
"Hand Qoint 6)— The hand drive cable passes over
idler pulleys located on the shoulder and elbow joints,
through the center of the wrist differential, and finally
terminates at the hand. This drive interacts with joint 3
(elbow) in that elbow bend will cause the hand to open
slightly.This can be compensated for by closing the
hand exactly the same number of steps that the elbow is
raised."

Examine view of the hand and its differential gearing in

a
Fig. 7-5. It is interesting to examine how the grippers have
been made for this robot. Each section is like a two-section
finger, and in the finger tip portion are surfaces which permit
gripping an object so it won't slide away.

SOME NOTES ON THE GRIPPER OPERATION

Another diagram of the cabling arrangement for the grip-
per is shown in Fig. 7-7. Notice the torsion spring which
permits the hand to open when the cable tension slackens.
Also notice the switch which could prevent a too-tight grip
and thus causes cable breakage. This also has a second func-
tion, which is to cause the cable to tighten slightly more after
it first grasps an object. This switch sends a signal to the

computer that an object has been grasped and so, if desired,

one might program the computer so that when it gets this
signal, it can cause another step or so of the tension motor so
that a good tight grip results.

OPERATING THE STEPPING MOTORS

Each of themotors used has two windings which are
center tapped. A
transistor then can operate on each half
winding in such a way that a rotating magnetic field is estab-
lished which then can cause the motor armature to step
around in small steps. These motors require twelve volts
which is supplied through transistors, driven by the control-
ler, as shown in Fig. 7-8. The controlling computer can, with

244
 ihHHHHHHNHHHI
Fig. 7-5. The Mini-Mover 5 hand (courtesy of Microbot).

PITCH ROLL
AXIS AXIS

MOVEMENT
DEFINITION
SIDE VIEW
PITCH
ANGLE

END VIEW

ROLL
ANGLE

Fig. 7-6. Mini-Mover 5 hand gearing and cable arrangement to grippers (cour-
tesy Microbot).

245
 1

S
o
8
I
o
h-
s
z t:
CO o X g
CO h- o
CL
(L CC in ^
OO h- CO

5
-Q
3

Ll

246
 MOTOR
WINDING
/->

+ 12
°^

TO COMPUTER
<

>

M
.MOTOR
WINDING

Fig. 7-8. The transistor drivers for two stepper motors. Since each arm element
has a "forward and reverse" direction,when you step one motor, you must also
step the other to permit movement (courtesy Microbot).

proper software, apply almost any desired arrangement of

currents to these windings.

THE COMPUTER-CONTROL OUTPUT

you note the designation of the motor windings you can
If

see, in Table 7-1, the outputs possible to make the stepper

motor move either forward or backward. The designers tell
us that to step the motor clockwise the patterns are output
sequentially from the top of the table to the bottom of the
table and when the end of this table is reached, it is necessary
to wrap around end of the table and continue the
to the other
outputs sequentially. To reverse
the motor rotation, the op-
eration is reversed. With this table the motor can be made to
step through one full revolution when it has received 96
pulses which makes the increments small enough so that a
smooth operation results.

247
 TO WINDINGS DRIVERS

*1 <f>2 </>3 04
lu
1 1 C/)

LLI
o 1 £ Table 7-1. The Computer Code
C/5 1 1 o to Rotate the Stepper Motors off

£ 1 o
_l Fig. 7-8 (courtesy Microbot).
(J
1 1 o
cc
o
—I
1

o 1 1
z
1 3
o
\
f
o

THE COMPUTER INTERFACE

The computer interface is shown in Fig. 7-9 and it is so
designed that it will operate, by changing some internal
jumpers, with any 8 bit parallel I/O port (TTL levels). The
interface was operated by a Radio Shack TRS 80 Level II
computer by the designers of the robot arm. Notice that there
are seven 4-bit parallel outputs and a single 4-bit input. The
address information is used to channel the four bits of output
data to the particular motor drive circuit selected. This is
done through individual 4-bit latch circuits. After a phase
rotation pattern has been sent to one motor through a given
latch, that latch is held until the next phase pattern is trans-
mitted. These latch circuits actually control the transistor
drivers, and thus the power which is applied to the motor coils
to make the motor step.
As we examine Fig. 7-9 notice several facts. There is

one input to the data bus from the arm at port A. There is one
spare output (port B) since only six of the output ports are
needed for control of the six stepper motors used on the arm.
This output port might be used to control another motor if
desired. Also, notice that only one feedback line is used. This
is to return a signal from the tension or grip-switch of Fig. 7-7.
You could have three more feedbacks incorporated in this
system if desired, without increasing the size of the I/O port.

THE ARMBASIC COMMAND COMPUTER LANGUAGE

The ArmBasic language, developed to control this robot
arm, is an extension of the BASIC language for the TRS-80

248
computer and consists of the five additional commands neces-
sary for complete control of the arm. The commands chosen
are:

• @STEP
• @CLOSE

4-BIT LATCHES (7)

1
1

ADDRESS
DECODER

PORTSTO
CONTROL
OF
MOTORS

DATA 4 SPARE
OUTPUT
>

BUS
h PORT (B)

^ ONE INPUT
DATA 4 •"USED ONLY
FROM
BUS FEEDBACK
SWITCH ON
TRI-STATE ARM PORT(A)

Fig. 7-9. The computer interface to the motor control circuits (courtesy Microbot).

249
 • @SET
•©RESET
•@READ
Each of these commands is used as a BASIC statement, and
interpreted as a Z-80 machine code subroutine. Here is how
the designers explain the computer operation.
"The® STEP command causes each of the 6 stepper
motors to move simultaneously. The syntax of this command
will be:

@ STEP (D), (JD, 02), 03), 04), 05), 06)

in which statement the D is an expression which governs the

delay between steps and the Jl through J6 are the statements
for the number of steps each motor is to be moved. The delay
expression, which is evaluated as an integer, determines the
speed of stepping. If a delay value of zero is indicated the
system is set to wait 1.2 milliseconds between each step
signal. For each additional unit of delay, the driver system
will wait an additional .03 milliseconds between the stepping
pulses. Therefore the delay is expressed as:

Delay = 1.2 + 0.03 times D milliseconds

"To determine which way the motors will step, one uses
a plus or minus sign, and the number of steps; the value of
the integer for each motor, indicates how far it will actually
move, i.e., the more steps the farther it will move the arm."
One interesting concept of this system is that there is an
automatic compensation for the interaction between the el-
bow joint and the hand openings. The compensation permits
the elbow joint to move while not affecting the hand opening.
In systems where the control motors are mounted right at the
joints and are operated by specific signals this may never be a
problem, but in a cable driven system, due to the very nature
of the cabling, interaction is something that has to be consi-
dered and compensated for. The designers point out that the
steps J4 and J5 refer to motors which drive the left and the
right differential gears of the wrist, so that the relation bet-
ween the gear positions and the wrist roll and pitch angles
must be determined by the user's program.

250
 An important function performed by the @ STEP com-
mand is to coordinate unequal motor commands linearly.
Thus if the base control motor is commanded to move X
number of steps and the shoulder motor is commanded to
move Y number of steps where Y<X there should be in such a
system an appropriate number of delays in the Y stepping
signal generation so that the timing of the Y steps will corre-
spond, in time, to the X number of steps. If this is so then the
arm movement is smooth and flowing, just as your arm
movement would be as you reach for a pencil. When the
number of steps for each section are accomplished in the
same time frame, then the end point segments of the arm will
reach their final positions simultaneously.
The @ CLOSE command which is the command which
causes the hand (or grippers) to close until the grip-switch is

activated and sends back a signal to the computer that the

hand has closed with the designed pressure effective. The
syntax for the gripper closing is also very simple:
@ CLOSE (D)
And the letter D again represents the delay-in-closing
time.
We next consider the @ SET command which has a
syntax like this:

@ SET (D)
This is a very simple syntax arrangement indeed. D is actu-

ally the system delay that governs the speed.

The designers state that when one uses the @ SET
command it puts the control system into a manual mode so
that when you depress the various keys on the TRS-80
keyboard (or keyboard of an equivalent computing system)
each joint of the arm can be positioned individually. One
keyboard arrangement for controlling the arm is shown in Fig.
7-10.
When you wish to stop this manual mode of operation,
you simply depress the zero key. Since the driver for the
output is capable of reading all keys at one time, if you hold
down more than one key, the arm will move in accord with the
combination of signals, i.e., the joints commanded will move
at the same time. The motion will continue as long as the keys

251
 WRIST WRIST
BASE SHOULDER ELBOW PITCH ROLL GRIP
CW UP UP UP CW OPEN

\ \ \ \ \ \
1 2 3 4 5 6

Q V\ E R T Y

\\
CCW DOWN
\
DOWN
\
DOWN
\
CCW
\
CLOSE

Fig. 7-10. One keyboard control system for the robotic arm Mini-Mover 5 (cour-
tesy Microbot).

are held down. To stop the motion one simply releases the
keys.
By now you can imagine sitting down at a computer
keyboard and carefully depressing the appropriate keys to
cause a Microbot arm to move in the manner you desire. By
carefully choosing your key and the timing of its depression,
you can make the arm move over a block, extend down and
grip it, move back upward so it can turn with its load and move
it to a new location and carefully stack the blocks as shown in

Fig. 7-1.
It is important to note that as each command is executed,
the number of steps commanded for each motor in the arm are
counted and stored in a set of registers in RAM. On the video
display one can determine the commanded position of the
arm under either manual or computer control. There are two
commands which access these registers. They are the follow-
ing:

•©RESET
•@READ
The @ RESET command zeros the position registers and
stops all current to the motors, thus allowing you to physi-
move the arm to a new position. Any other command
cally
cancels@ RESET, and the position of the arm at that time
becomes the new home position.

252
 The syntax of the @ READ command is:

@READ (VI), (V2), (V3), (V4), (V5), (V6)

Where VI to V6 are any BASIC variables. This command

reads the six position registers and transfers their contents
into the variables. In this way the current position of the
robotic arm is available to the BASIC program at any time.

PROGRAMMING THE MINI-MOVER 5 ROBOTIC ARM

Dr. John Hill, Design Engineer of Microbot, explained
the way to program this robotic arm in the Spring, 1980 issue
of the Robotics Age magazine.
'To illustrate the use of ARMBASIC in manipula-
tion, we will discuss several methods of programming a
pick-and-place task. The task consists of repeatedly
picking objects up at one place and setting them down in
another. This task is common in industry where parts
from a feeder are deposited in another machine or onto a
moving conveyor, for instance. To simplify the example,
we will assume an unending supply of parts at the pick-
up point and continual removal of parts at the destination
point.
The task is defined in Fig. 7-10. Pickup is from A
and placement is at D. The approach and departure
trajectories, AB and CD are usually required for practi-
cal reasons: an object resting on a flat surface normally
must be lifted before it is translated instead of just
sliding it along the surface. In an industrial environment,
such a movement could possibly damage the part, the
manipulator, or some other object in the workspace.
"A simple sequence of ARMBASIC commands for
performing the pick-and-place task is shown in Table
7-2. Movements are performed by the @ STEP com-
mand, including opening the gripper (statement 60),
P=(P1, P2, P3, P4, P5), Q=(Q1, Q2, Q3, Q4, Q5) and
R=(R1, R2, R3, R4, R5) define vectors whose elements
are the number of steps of each joint needed to move the
arm from A to B, B to C and C to D respectively. S is the

253
 END

M START

A • 1 Move Down to A • D

2. Close Grip

3. Move to B

4. Move to C

5. Move to D

6. Open Grip

7. Move to C

8. Move to B

Fig. 7-11. The robot's arm movements in a Pick-and-Place program of Table

7-2 (courtesy Robotics Age).

number specifying the speed and GR is the number of

steps the gripper is to be opened to release the part.
'This simple approach is not very practical, as it

requires that the number of steps on each joint be known

in advance. One practical approach for small tasks is
entering the data manually by moving the arm to each of
the four positions (A, B, C and D of Fig. 7-11) and letting
the computer count and remember the number of steps
each joint moves. This operation is frequently called
"teach mode."
The teach program shown in Table 7-3 illustrates
this principal. Operating interactively with the com-
puter, the operator manually positions the arm to each of
the four positions to specify the pick-and-place task.
Each position is obtained by moving the arm, joint-by-
joint, using the keys in the upper left hand corner of the

254
 keyboard as previously described under the @SET
command. Even the desired grip opening is conveyed by
teach control. Only the speed is entered numerically.
"After the arm is positioned at each of the four
locations, the values of the software position counters
are read by the @ READ command and stored in the
vectors A, B, C and D. The elements of these vectors,
A=(A1, A2, A3, A4, A5), B=(B1, B2, B3, B4, B5),
C=(C1, C2, C3, C4, C5), and D=(D1, D2, D3, D4, D5),
are the values of the position counters of each joint. The
P, Q, and R vectors of the simple program (Table 7-3)
can therefore, be obtained by subtraction as follows:
P=B- A, Q=C-B, R=D-C. The desired grip opening,
GR, measured by reading the grip position counter
is

before and after closing the grip using the® CLOSE

command. (Statements 170-200 in Table 7-2.)
Examine Table 7-4. For this program, the locations
of the four positions of the pick-and-place task (A, B, C,
D) are defined by their Cartesian coordinates (see Fig.
7-3). The x, y, z, coordinates (in inches) and pitch and
roll angles (in degrees) at the fingertips are:
A=(8, 0, 0.5, -90, 0)
B=(8, 0, 1.5, -90, 0)
C=(6, 5, 1.5, -90, 90)
D=(6, 5,0.5,-90, 90)

Table 7-2. Simple Implementation of ARMBASIC

Pick-and-Place Program (Courtesy Robotics Age).

10 ©STEP s, -PI, -P2, -P3, -P4, -P5

20 © CLOSE
30 ©STEP s, P1, P2, P3, P4, P5
40 ©STEP s, Q1, Q2, Q3, Q4, Q5
50 ©STEP s, R1, R2, R3, R4, R5
60 ©STEP s, 0, 0, 0, 0, 0, GR
70 ©STEP s, -R1, -R2, -R3, -R4, -R5
80 ©STEP s, -Q1, -Q2, -Q3, -Q4, -Q5
90 GOTO 10

255
 Note that the object is gripped at a point 0.5 inches
above the table top (z=0) and is raised (or lowered) 1.0
inches for lift off (set down). Its x location is changed
from 8 to 6 inches and its y location changed from to 5
inches. The angular orientation of the gripper is always
straight down (pitch=-90 degrees), but the object is
rotated 90 degrees on its vertical axis between pickup
and set down (roll changes from to 90 degrees).
"Data for the Cartesian coordinate program is lo-

cated after statement 10000. Each data statement

specifies an arm position and orientation in terms of x, y,
z, pitch and roll, and also includes a sixth parameter,
governing the grip opening (if positive) or squeezing
force (if negative) after each move, and a seventh
parameter governing the speed setting during each
move. The actual arm solution, beginning at statement
5000, takes an arm configuration specified by the vari-
ables X, Y, Z, P, and R, and finds the joint angles (in
radians) that would place the arm in that configuration. It
also includes several tests to determine if the position
and orientation requested is within the reach of the arm.
"The first data statement gives the initialization
point, which is used by the initialization phase of
the program, statements 140-260, to tell the computer

where the arm is in the coordinate system. Note that the

arm position registers are not used by the program
(although the ©RESET is necessary). Instead, the
operator is instructed to position the arm at the initiali-
zation point under control of the® SET command. The
joint positionscorresponding to that point are computed
and stored in variables W1-W5. In the main part of the
program, the relative offsets from one point to the next
are computed and used to step the arm. Thus, all arm
movements are made relative to the initialization point.
"Since the computer has no way
measuring the
of
arm's joint angles upon startup, such an initialization
must be made by every program that relies on an exter-
nal coordinate system. Similarly, all arm movements are
made "open loop," or without position feedback. There-

256
 Table 7-3. The Mini-Mover 5 Teaching Program (Courtesy Microbot).

10 REM
20 REM
30 REM
40 REM
50 REM
60 REM
70 REM
80 REM
90 REM
100 ©RESET: REM ZERO COUNTERS
110 PRINT "PICK - AND - PLACE ROUTINE"
120 PRINT " USE MANUAL KEYS TO POSITION ARM"
130 INPUT "SPEED ="; S
140 PRINT "POSITION GRIPPER ON PART, TYPE WHEN DONE"
150 PRINT " ADJUST GRIP OPENING TO CLEAR PART"
160 @SET
170 @READ A1 ,A2,A3,A4,A5,C
180 ©CLOSE: REM CLOSE GRIPPER AND MEASURE PART
190 © READ A1 ,A2,A3,A4,A5,G0
200 G = GO - GC :REM GRIP SIZE OPEN LESS GRIP SIZE CLOSED
210 PRINT "POSITION PART ABOVE PICKUP SITE, TYPE WHEN DONE"
220 ©SET
230 ©READ B1 ,B2,B3,B4,B5
240 PRINT "POSITION PART ABOVE PLACEMENT SITE, TYPE WHEN DONE'
250 ©SET
260 ©READ C1 ,C2,C3,C4,C5
270 PRINT "POSITION PART AT PLACEMENT SITE, TYPE WHEN DONE"
280 ©SET
290 ©READ D1 ,D2,D3,D4,D5
300 REM
310 REM RELEASE PART AND RETURN TO B
320 REM
330 ©STEP S,0,0,0,0,0,G
340 ©STEP S, C1-D1, C2-D2, C3-D3 C4-D4, C5-D5
,

350 ©STEP S, B1-C1, B2-C2 B3-C3 B4-C4, B5-C5

, ,

360 REM
370 REM WAIT UNTIL READY
380 REM
390 INPUT "TYPE G TO GO"; RS
400 IF RS = "G" THEN 410 ELSE 390
410 REM
420 REM RUN THE PICK - AND - PLACE PROGRAM
430 REM
1000 ©STEP S, A1-B1, A2-B2, A3-B3 A4-64, A5-B5
,

1010 ©CLOSE
1020 ©STEP S, B1-A1, B2-A2 B3-A3, B4-A4, B5-A5
1030 ©STEP S C2-B2, C3-B3, C4-B4, C5-B5
1040 ©STEP S D2-C2, D3-C3, D4-C4, D5-C5
1050 @ STEP S, 0,0,0,0,0,6
1060 @STEP S, C1-D1. C2-D2 C3-D3 C4-D4, C5-D5
1070 @STEP S, B1-C1 B2-C2, B3-C3, B4-C4, B5-C5
1080 GOTO 1000
1090 END

257
 Table 7-4. A Cartesian Coordinate Program for Mini-Mover 5 (Courtesy Microbot).

10 REM
20 REM
30 REM MINI MOVER 5
40 REM
50 REr* CARTESIAN COORDINATE CONTROL
60 REM
70 REM PROGRAM
BO REM
90 REM
100 REM DEFINE ARM CONSTANTS
101 H=B.1 :REM SHOULDER HEIGHT ABOVE TABLE
102 L=7.0 :REM SHOULDER TO ELBOW AND ELBOW TO WRIST LENGTH
103 LL=3.5 :REM WRIST TO FINGERTIP LENGTH
104 REM
110 REM DEFINE OTHER CONSTANTS
111 PI=3. 14159
112 C=1 BO/PI :REM DEGREES IN 1 .00 RADIAN
113 R1=1 :REM FLAG FOR WORLD COORDINATES
114 REM
120 REM DEFINE ARM SCALE FACTORS
121 S1=937.B S2=S1 REM STEPS/RADIAN, JOINTS 1 & 2
122 S3=551 .4 REM STEPS/RADIAN, JOINT 3
123 54=203.7 S5=S4 REM STEPS/RADIAN, JOINTS 4 & 5
124 S6=618 REM STEPS/INCH, HAND
125 REM
130 REM INITIALIZATION
131 DIM UUI7.50) :REM ROOM FOR 50 MOVES
132 U=0
133 @RESET
134 REM
140 REM READ IN FIRST DATA LINE FOR INITIALIZATION
141 READ X.Y.Z.P.R GR.S
150 PRINT SET ARM TO THE FOLLOWING POSITION fi, ORIENTATION"
151 PRINT USING KEYBOARD, TYPE WHEN FINISHED"
152 PRINT X •INCHES"
153 PRINT Y 'INCHES"
154 PRINT Z 'INCHES"
155 PRINT PITCH •DEGREES"
156 PRINT ROLL •DEGREES"
157 PRINT HAND GR/S6; "INCHES'
170 @SET
200 GOSUB 5000 REM GET JOINT ANGLES FOR INITIALIZATION
210 REM W IS WHERE WE ARE AT
220 W1=INT(S1*T1 )

230 W2=INT(S2*T2)
240 W3=INT(S3*T3)
250 W4=INT(S4*T4)
260 W5=INT(S5*T5)
270 REM
300 REM READ IN NEXT POINT
308 READ X,Y,Z,P,R,GR,S
309 IF X < -100 GOTO 1000
310 PRINT "MOVE TO X Y ,Z .P ,R ,GR ,S
,

311 PRINT X.Y.Z.P.R.GR.S

320 GOSUB 5000 REM GET JOINT ANGLES FOR NEXT POINT
325 REM C IS THE CHANGE (IN COUNTS)
330 C1=INT(S1*T1)-W1
340 C2=INTIS2*T2)-W2
350 C3=INT(S3*T3)-W3
360 C4=INT(S4»T4)-W4
370 C5=INTIS5*T5)-W5
400 REM UPDATE WHERE WE WILL BE
410 W1=W1+C1 :W2=W2+C2:W3=W3+C3:W4=W4+C4:W5=W5+C5
420 ©STEP S.C1 -C2,C3,-C4,C5
f

425 U=U+1
430 UU(1 ,U)=C1
431 UU(2,U)=-C2

258
432 UU(3,U)=C3
433 UU(4,U)=-C4
434 UU(5,U)=C5
450 UU(6,U)=GR
455 UU(7,U)=S
460 IF GR <0 GOTO 500
461 REM OPEN GRIP IF GR>0
470 @STEP S,0,0,0,0,0,GR
480 GOTO 300
490 REM CLOSE GRIP AND SQUEEZE IF GR <

500 ©CLOSE
520 @STEP 100,0,0,0,0,0,GR
530 GOTO 300
540 REM
1000 PRINT " RUN THE PROGRAM"
1010 FOR 1=2 TO U
1020 ©STEP UU(7,I) ,UU{1 ,1] ,UU(2,I) ,UU(3,I),UU(4,I] ,UU(5,i:
1030 IF UU(6,I)<0 GOTO 1060
1040 @STEP UU(7,I) ,0,0,0,0,0,UU(6,I)
1050 GOTO 1100
1060 @CL0SF
10B0@STEP 100, 0,0,0, 0,0, UU(6, 1)
1100 NEXT I
1110 GOTO 1010
2000 END
2010 REM
5000 REM SUBROUTINE TO CALCULATE JOINT COORDINATES
5010 REM ENTER WITH X,Y ,Z .PITCH .ROLL AND R1
,

5015 REM RETURN WITH JOINT ANGLES T1 TO T5

5020 P=P/C:R=R/C (IN RADIANS)
5030 RR=SQR(X*X+Y*Y)
5040 IF RR<2.25 THEN 6000
5050 IF X^O THEN T1 =SGN( Y »PI/2 ELSE T1=ATN(Y/X)
)

5060 IF X<0 GOTO 6000

5070 T4=P+R+R1*T1
5080 T5=P-R-R1*T1
5090 IF T4<-270/C OR T4>270/C GOTO 6000
5100 IF T5<- 270/C OR T5;270/C GOTO 6000
5110 RO=RR-LL*COS(P)
5120 ZO = Z-LL •SIN[P)-H
5130 IF R0<2 .25 GOTO 6000
5140 IF R0=0 THEN G=SGN(Z0)*PI/2 ELSE G= =ATN(ZO/RO)
5150 A=RO*RO ZO'ZO
5160 A=4*L*L/A-1
5170 IF A<0 30T0 6000
5180 A=ATN[SQR(A))
5190 T2=A+G
5200 T3=G-A
5210 IF T2>144/C OR T2<-127/C GOTO 6000
5220 IF (T2- T3X0 OR (T2-T3)>149/C GOTO 6000
5230 RETURN
6000 PRINT " ****•*•** OUT OF REACH *••' .......
6010 END
6020 REM
9000 REM COORDINATE DATA FOR PICK-AND- -PLACE TASK
9010 REM STATEMENT 10000 IS INITIALIZATION POINT
9020 REM STATEMENT 10010-10070 DEFINE TRAJECTORY
9030 REM STATEMENT 10080 SIGNALS NO MORE DATA
10000 DATA 5, 0, 0, -90, 0, 0, 50
10010 DATA 8 0, 1.5, -90, 0, 0, 50
10020 DATA 8 0, 0.5, -90, 0, -30, 50
10030 DATA 8 0, 1.5, -90, 0, 0, 100
10040 DATA 6 5, 1.5, -90, 90, 0, 50
10050 DATA 6 5, 0.5, -90, 90, 300, 50
10060 DATA 6 5, 1.5, -90, 90, 0, 50
10070 DATA 8 0, 1.5, -90, 0, 0, 50
10080 DATA -999 0, 0, 0, 0, 0,

259
 fore, a reinitialization is necessary if the arm is unable to
successfully perform a movement due to overloading of
collision. The use open loop control by stepper
of
motors eliminates the need for joint position sensors
and associated interface circuitry and is thus an impor-
tant design tradeoff that reduces the cost of the arm
while still providing accurate positioning.
"During the second phase of the program, state-
ments 300-530, the arm is moved from data point to data
point as the solutions are carried out. An arm solution
takes less than one second. The joint angles correspond-
ing to each data point are stored in array UU. After all
the solutions are obtained, control is transferred to the
third phase, beginning at statement 1000, where the
pick-and-place cycle is run repeatedly without coordi-
nate conversions by using the joint angles in UU.
"Those who analyze the Cartesian coordinate pro-
gram carefully will note that it is, in fact, general pur-
pose, capable of generating arbitrary motion trajectories
with up to 50 movements. This is sufficient for many
assembly tasks such as building structures from blocks.
The power of the ARMBASIC approach can be seen by
comparing the simplicity of this program, which is less
than 100 lines of code, with previous approaches which
have required 8K or more of assembly language coding
to do the same type of task."

ROBOTIC-ARM ACCURACIES AND POWER

The Mini-Mover 5 was developed for, and can be used in
learning and teaching, and in an experimental way to verify
computer related concepts economically. From this view-
point,it is an impressive device. From a useful standpoint of

doing work it has some limitations which need examination.

One of these limitations is the power capability of the arm.
There can be no doubt that in advanced robotics applica-
tions a significantamount of power must be generated, pro-
portional to the size of the robot of course, to enable the
machine to do useful work. One may argue that useful work is,
indeed, a good reason for the machine's existence.

260
 Another problem of machines of Mini-Mover 5 design
may be the physical control cabling because it has, by virtue of
its type, some play and elasticity which becomes more pro-

nounced as it attacks jobs which require power and force for

handling. This seems to defeat one much-desired goal of
robot machine development; that of consistent and reproduc-
ible accuracy to an extremely high degree of precision in a
repeatable process requiring movement. Cables give much
flexibility in construction and in many cases simplify such
construction. However, they may not produce the feedback
effect of inertia in an automated system as much as gears do.
Certainly, if one does not have to have motors and gears at
each joint, the system inertia can be reduced for operational
and computational analysis purposes. One might then avoid
the complexities of having a variable moment of inertia to be
concerned with when the robot arm is moved.
Currently the accuracy of robot arm device positioning is
limited tosome .004 inch in a repeatable processing cycle.
While a higher degree of accuracy may be needed in some
types of applications, we must admit that .004 inch is not bad!

COMMUNICATING WITH THE ROBOT

In the example of computer communication using the
operation of Mini-Mover 5, hard-wire signal cabling was
used. We do not have much to worry about as far as getting
extraneous signals into the machine's operation, unless we
are very careless and lay the signal cable in a strong elec-
tromagnetic field, improperly shield it, make the signal cable
too long, or improperly terminate it at either end. Usually,
since the signal cabling is relatively short in length, properly
laid, terminated, and even may be shielded, there is no prob-
lem, and the signals are transmitted strongly and accurately.
If we have a robot located at some distance from the

computer which directs its operations, and if the environment

through which signal cables or lines to the robot must be laid
is harsh, as far as signal transmission is concerned, then we
could have a communications problem. The problem evolves
around two concepts; the loss of signal information, and the
production of spurious signal information.

261
 Loss can be due to actual signal disintegration or to
distortion to such an extent that the robot cannot tell that it is

receiving a command or feedback signal. In an industrial

environment two possibilities exist.
The robot with its drive motors
is the end unit and the

computer, servomechanism amplifiers, and such are all lo-

cated at a remote point away from the robot. Thus the only
signals going to the robot itself will be the voltages necessary
to cause the motors to operate, and since these are high level
signals they are less subject to interference. The second
possibility is that the robot is almost entirely self contained
and thus, with its integral computer and servo system, is
relatively well protected from a harsh communications envi-
ronment. In this latter case, the robot receives signals from
its own world only, be they commands from the computer
program, or feedback from its working sensors.
When the robot is in a fixed location, the wires connect-
ing it remote computing and electronic control mech-
to a
anism panel are usually contained in metallic tubing which
gives physical protection and shielding if such tubing is con-
nected to a common ground. Even then, a shielded cable may
run inside this kind of conduit. In this type of application this
usually takes care of the communications problem. In fact, in
use of hard- ware signal cables might be
industrial plants, the
the most useful way to communicate with the robot, and have
itcommunicate with its control base! But, for a moment, let us
examine the possibilities of having a communication with the
robot by radio signals.
If you are familiar with the antiaircraft missile systems

used by the Department of Defense, then no doubt you will be

concerned if we do not also point out that in these fine
systems, the information concerning the target can be ob-
tained by the ground station, independently of the missile.
The missile is really a controlled robot projectile of the robot
ground station complex.
The point is that two way communication with a robot is

essential. We send commands, we get feedback information

from the robot's sensors. The computing section of the sys-
tem analyzes the data, modifies the commands in accord with

262
that data and sees to it that everything works as it should, for
as long as it should, in the proper sequence, and with the
proper timing. The computer coordinates various machines
and perhaps other robots in doing a job so, the computer must
get feedback from each robot.
Think of the amount of information a complex operation
must have moving over a communications system! This in-
formation must not be distorted or modified or lost in the
process, and it must be very visible to the computer in
whatever noise levels may be present in that communications
system.
We are constantly amazed at the human capability to
distinguish desired information in an environment of unde-
sired information. For example, three persons may talk at the
same time and you want to follow the intelligence of just one
discussion. The human mind, once given the command to
listen to Joe, turns its attention to what Joe is saying, exclud-
ing the other voices as far as interpreting intelligence from
them. The head turns to give Joe's voice the best reception
and to minimize the reception of the other voices. The mind
then instantly develops a pattern of information based on
snatches of words which it recognizes clearly. The mind will
actually fill words and phrases and sentences which are
in
incomplete due to competing noises or distortions. If the
mind gets lost, it commands the tongue to activate and ask
"What? What did you say?"
So it is with robotic communication systems. By using
the binary code and making words out of the infinite number of
patterns of these symbols, sounds, or signals (in which-ever
form they may appear), one might loose some elements and
still not lose the message. That is a required and desired level

of operation for robot machines.

Suppose that a signal comes which has the following
form 110110110100. The zeros underlined for emphasis mean
that no pulse of energy appeared at that time. The question
then is whether a pulse of energy was there and was lost, or
whether a zero was actually intended at that time. If we
suppose that the computer receiving the signal can look at the
word received and calculate that for this word to fit into the

263
intelligence pattern of the phase, the first zero has got to be a
one. It makes a one out of that space and the word has meaning
in its phraseology. Everything continues in a fashion.
With humans, the loss of letters— say with a Morse code
message— can easily be filled to make sense. Suppose you
receive the following; Th an was tall. You supply the
missing letters to get 'The man was tall."

MULTIPLEXING IN COMMUNICATIONS SYSTEMS

Multiplexing means conveying many different items of
information on the same path. If we use a hard wire system we
know that we can send many different types of signals over a
single pair of wires, and each signal, or set of signals, can be
representative of information from a single source. Thus we
can have, with multiple signals, multiple information from
many sources sent over the same pair of wires.
Some elementary means of conveying different items of
information are to use a modulation procedure, or use a time
division of the use of the lines. In the first case, since, usually,
frequencies are involved, we think of this system as fre-
quency multiplexing. The second system, as you would sus-
pect, is called time multiplexing.
Examining frequency multiplexing further we find that
we can send many items of information simultaneously, since
we can modulate a carrier (be it wire, radio signal, light beam,
or whatever) with many different signals simultaneously. An
example is our regular broadcast radio system. We know that
the musical tones of different instruments— say, for example,
the piano, saxophone, clarinet, drums, and a vocal— can all be
sent at the same time and we humans can distinguish each
instrument byits tone. For control purposes it was a practice

some years past— and still is in some systems— to send tones

denoting commands or information and separate them elec-
tronically at the receiving end with audio filters low fre-
quency rf filters. It is understood that a command can be an
off-on or present— absent type of thing. The presence of a
tone can cause a switch to close and some electrical or
electronic function to be performed when this happens. The

264
absence of the tone will mean switch open and a cessation of
that functional operation.
It is also understood that to convey a changing bit of
information, such as we might need in a robotics application,
that we cannot have just an off-on type of signal. The feedback
from sensors must be such that they can be varied in some
way to produce information about slight changes in position,
or values of the object being sensed.
The tone transmission system can vary the pitch of the
tone slightly around some nominal value, and a slight change
can convey the information we desire to be sent to the com-
puter decoding section. The decoder must then change a
variable pitch, or tone, into some kind of machine signal such
as off-on pulses which the computer can then use to do its
assessment and evaluation and computation with.
So, we are now looking at bands in the tone spectrum
over which signals might be varied to convey changing infor-
mation. These bands all might be sent simultaneously and so
we then ask ourselves if there is a limit as to how much
information we might send simultaneously. We can reduce
the band widths by going to higher and higher tone or signal
frequencies. We find that there is a limit to how many tones
we can transmit simultaneously and still recover the desired
information. Scientists who have studied this problem esti-
mate that eight audio channels is about the limit each channel
getting only 12% of the available 100% modulation capability
of the transmitting system.
Think of what this means. If we are dealing with a single
robot, which has many feedback functions, and
self contained
some kind computing and directing system, eight
of internal
feedback channels to some outside and coordinating might be
sufficient. But if that computer is directing many robots, and
needs a lot of information from each to properly effect that
coordination, then eight channels is certainly limiting! So we
look at Time Division Multiplexing.
It seems right away some advantages. One
that this has
particular advantage is that each channel can get the full 100%
modulation since it is singly transmitted. When the informa-

265
tionfrom one channel has been sent, then the second chan-
nel's information is sent, and so on. If we can send the
information fast enough, we can send lots of channels, each
getting the full operational capability of the transmitting sys-
tem, and, as far as the practical operation of the robotics
system is concerned, if the information is sent fast enough, it
won't even know that it is getting its data in spurts.
In a way, a computer already operates with this concept
of time division multiplexing, for it has common busses which
are time allocated to various signals by a timing clock. Thus
we begin to look at robots as just another I/O peripheral. If we
want to go one step further, we can imagine a combination
system, using time division multiplexing and frequency divi-
sion multiplexing over a common carrier which should enable
us to get all the information needed from one point to another
to make remote operation of robots very practical.

SOME EXAMPLES OF PULSE CODE MODULATION

To summarize the previous discussion, we are in-
terested in the feasibility of operating our robots remotely,
without the use of hard wire cables to them, or operating the
robots using a single pair of wires instead of multicables such
as we have learned are used to operate most robot arms.
Examine Fig. 7-12 wherein we see a graphic representation
of some forms of pulse modulation which might be used to
convey intelligence from one point to another. The carrier
might be a wire, a radio transmitter, a light beam of any
frequency, or even sound, which may extend from the audible
range into the supersonic. We see how a signal might be
modulated by extending or shortening the time of existence of
the pulses. This is called pulse width modulation. Notice that
some of the pulses graphed are wide and some are narrow and
realize that a single pulse will be varied about its nominal
width with the signal we desire to convey. If, for example, we
wanted to transmit just ones and zeros, we might set up a
system where a wide pulse represents a one and a narrow
pulse (narrower than the nominal value) represents a zero.
Transmission, then, of computer readible intelligence would
be just long strings of wide pulses and narrow pulses to make

266
up computer words. The diagram does not reflect accurately,
the number of channels being transmitted. If, for example, we
use a five bit word for commands and feedback, we would
have only one channel of communication. We have to define a
channel as being the route to a single operating unit. Thus in
the case being discussed we would have only one channel,
which might mean control of one one robot. We could imag-
ine that we would send many sequential lists of five bit code
groups and thus, using time multiplexing, control many
robots in this manner.
If we restrict ourselves to the width-per-pulse as a
we find that five pulses represent
channel, as illustrated, then
five channels as shown. The width variation might be inter-
preted as ones and zeros as we have stated, or by varying the
width in a sinusoidal manner we could recover tones and tone
variations which could represent variables in the system. The
manner of varying the width of a pulse, such as illustrated, is
left own imagination and requirements, one
entirely to your
might recover saw-tooth or square-wave or exponential
waveforms from the varying tonal modulation. This tone
modulation or variation might be a real variable on a rf carrier,

or it might just be a recoverable value from the varying rf

frequency.
There is a difficulty. If we lose a pulse we have lost a
channel. If the system, somehow, is able to cause pulse
existence shortening or lengthening, we have spurious in-
formation being generated. If rf is used as the carrier, it may
take some bandwidths to accommodate the variation in
pulses. However, on the good side of the situation, this
system has been used successfully in commercial applica-
tions and in hobby applications where it is used to control
radio-controlled model aircraft. It is relatively easy to design
a decoder to separate wide pulses and narrow pulses.
In the second possibility the pulses all have the same
width and are all transmitted sequentially. It is the relative
position of each pulse with respect to a starting time for the
"train" which governs its information carrying content. As
shown, we assume that when no information is being trans-
mitted, each pulse has a definite existence time, following

267
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269
some type of input starting clock signal. Since each pulse can
be varied about this nominal existence time, being either
early or late one can relate these positions to coded data.
Early being one, late being zero. With robots such signals can
also mean up arm, down arm, and neutral arm position.
This is the system of transmitting command and control
signals used with the GARCAN robot discussed previously in
this book. It is a simple and reliable and well understood
method of sending commands. It can be used for both off-on
functions and proportional functions.
The code shown in C can be a direct representation of the
binary words used in computers. One simply has to have
enough pulses to match the computing system used; i.e., an 8
bit system needs 8 pulses, but one might have 12 or 16 or 32
or even 64 pulses if that kind of accuracy is needed. If the
pulses are microsecond or fractional microsecond existence
units, and are separated in time by fractions of a microsecond,
it would not take long to send a 16 or 32 pulse word or train of

pulses. This word could be repeated over and over, just as a

message could be repeated to insure accuracy. There is
probably some probability mathematics which would indicate
just about how many times, on the average, one should repeat
a word to be assured that it would be properly received, but
we won't go into that here.
We find in C a system made to order for transmission of
binary code. We assume that signal presence— or pulse
presence— means a one and absence of the signal means a
zero. Therein lies our difficulty. If we lose a pulse in trans-
mission, the computer on the receiving end might interpret
this to mean that a zero should be written. The computer thus
might be incorrect! But, as we have stated, redundancy might
overcome this problem to some extent, and computer sen-
tence analysis could also be used.
Finally, we glance at D wherein we find the basic radio
teletype system of frequency diversity used to convey ones
and zeros. Two tone frequencies can be transmitted over a
common radio frequency carrier, or other type carrier, such
as previously indicated. One tone means a one, and the sec-
ond tone means a zero, as shown. Since the system must

270
always have one or the other tone being received, any ab-
sence of tone means an error which the computer can recog-
nize. As we know, this system has been found to be highly
accurate and reliable in the transmission of messages. It

would be relatively easy to apply this system to robotics

applications and, using filters, and combination or pairs of
tones, one might control many robots, or robotic functions
over a single wire pair, or rf frequency.

SOME DESIGN CRITERIA OF TELEMETRY SYSTEMS

Measuring the responses system by remote
of a robotics
means is similar to getting information from an experimental
aircraft or rocket in flight using radio systems and sensors at
various critical points in the system. Thus, a few moments
consideration of telemetry design criteria can be helpful in
our study of establishing communications with robots.
We know that radio telemetry systems have been used in
aircraft to measure such things as position, velocity, accelera-
tion, and aircraft attitude with respect to some gyroscopic
coordinates. Also, sensors are used to determine the amount
of vibration or flutter at various points on the body and the
pressure at various points internally and externally. They
also measure temperatures, strain, stress, fuel flow, cosmic
ray counts, ionization, static build-up, and voltages through-
out the aircraft. Of course such measurements can be made on
other vehicles as well. Our space explorers are robots that
send back pictures, and after testing and sampling distant
planets, information on soils, atmosphere, and such is also
sent.
When we consider the return of data, we must also
consider the accuracy of that data and whether it meets the
design and operating criteria or not. Data from such systems
may vary quickly and considerably, or it may vary slowly and
within small excursion limits. If we are looking just for gen-
eral information then, perhaps, accuracies within, say, 15 to
40 percent may be used and acceptable. But if we really want
tight monitoring then we will want accuracies within, say, V2
to 2 percent and in some cases, as in a robotics system where
positioning is being monitored, we may want accuracies from

271
0.1 to 0.001%! Of course we would like absolute accuracy;
zero percent error if possible. But due to system limitations

we just can't reach that optimum.

When we are interested in some sensor value which may
vary at a sinusoidal rate, it has been found necessary to
sample that quantity with at least 3 samples per cycle, and it
has been said that you must have at least six samples per
cycle to reconstruct a varying sine wave with any degree of
accuracy. Of course, if you want to transmit data that is
constantly being measured, as you would if you used a fre-
quency varied by the sensor, then you should have total
information instantly, concerning that measured unit. If you
use a pulse sampling system wherein the pulse voltage
amplitude is then converted into digital (binary) words which
can be used by a computer to reconstruct the wave being
sampled, there is always the possibility that the sampling
system might miss something— some variation— if that sam-
pling is not conducted frequently enough.
In accepted telemetry systems which use tone or low rf
frequencies to modulate a carrier (usually an FM carrier to
reduce noise and distortion), the system is called an
FM— FM system. This means frequency modulation of the
oscillator which, in turn, is frequency modulating a carrier.
The oscillator, of course, is being modulated or varied by the
sensor measurement one wishes to think in terms of
unit. If
computerized handling of data, then one thinks in terms of
receiving pulses which form groups of binary computer words
as we have already mentioned. Analog to digital circuits are
available and can be used in such an application. The accuracy
willbe governed by the number of samples-per-second taken
of themeasured or sensed quantity. A representative tele-
metering system of the FM—
FM type is illustrated in Fig.
7-13.
In the illustration we see some sensors which cause the
frequency of the oscillators to change according to the move-
ment, strain, velocity, or whatever is being sensed. This
signal is then used to FM modulate the transmitter. It is sent
to the receiver, there separatedby band-pass filter sections
converted into varying levels of plus or minus dc voltages

272
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273
which are proportional to the instantaneous position, strain,
or velocity of the sensed unit, and then sent to analog-to-
digital converters and thence to computers. Of course these
signals might be used in their analog form to control a remote
robot or whatever.

COMMUNICATIONS SIGNALS NEEDED

It is essential that regardless of the type of carrier which

conveys information to the robot, this carrier must also be

capable of returning signals from the robot to its control
station. We think of a simple, proven example. If one has a
guided missile whose control station and computing station
are on the ground, and the mission of this missile is to destroy
enemy aircraft in flight, then the missile should, under some
circumstances, be able to inform the ground station how close
it is to the aircraft it seeks as prey. When it is close enough,
the ground computer will determine an exact time to detonate
a warhead for destruction of the enemy aircraft. The signals
might also be used to drive pen recorders, printers, or illumi-
nate video displays, as desired, in the operation being con-
ducted.
It is some 18 frequency bands,
interesting that there are
made up of frequencies from roughly 350 Hertz to some
70,000 Hertz which can be used in FM telemetry. One must
make sure that he does not use two bands which are harmoni-
cally related, as that plays havoc with the system's ability to
give out good data. Variations in frequency are relatively
small, usually about 7.5%, and of course, the higher the band
frequency, the higher the frequency response capability of
that particular sensing section can be.
Thus, when we consider the use of robots which are not
fixed in a given location, we think in terms of systems of
control which can radiate a roomful of signals which can be
received any place in the area or room, and getting back
at
responses from the robot in the same manner.
The reference system in which all movements are de-
termined is the instantaneous position which they might have
at that moment, probably with respect to the four walls and
floor and ceiling of the room, and with respect to whatever

274
objects may be within the room, even to a consideration of
other people who also may be moving! The feedback sensor
system must give you (or your computer) this data. In an
automated robotic system with free wheeling robots in ac-
tion, some computer somewhere must know everything
about everything and keep this knowledge accurate and cur-
rent!

CURRENT SOCIOLOGICAL THINKING ABOUT ROBOTS

To many people, not well enough informed about auto-
mation and robotic technology, or incapable of completely
understanding just how these machines work, the existence
of robots present them with a threat. To some it is a job-loss
threat, to some it is a much more serious threat such as; "Will
robots take over and rule the world making us slaves?" We
may grin about this, but, be assured, such thinking exists in no
small dimension. The Robotics International Organization
defines a robot as "A reprogrammable, multifunction man-
ipulator designed to move material, parts, tools, or
specialized devices through variable programmed motions
for the performance of a variety of tasks." One can see, in this
definition, a description of a machine and that may be a big
help to industry when they plan the utilization of these de-
vices. It may help out with the psychological problems of
people.
There are many fantasies concerning robots and these
become more prevalent when we consider the robot in some
kind of human form. For some reason, that seems to be what
the average person would like for his robot to have. One of the
leading Science Fiction writers, Isaac Asimov has written of a
situation where a mother becomes jealous of a robot who was
assigned a baby-sitting task over her daughter, in the story
ROBBIE. In another story he described the relationship
between a wife and a robotic butler. Movies have been made
which show humans falling in love with robots. Why people
would be attracted to robots that are, to all appearances,
duplicates of themselves, or of "beautiful people" can be the
subject of another study. We just pose the idea here for
consideration.

275
 In all pseudo-science stories concerning robots we find
that sooner or later, the "Laws of Robotics" are derived or
stated. These laws are supposed to be the statements which
govern the limits of robotic action. Isaac Asimov formulated
and first wrote the Laws. One of these is paraphrased "The
robot shall not harm his maker." Designers were supposed to
insure, in the circuitry associated with the robot, that this
Law was embedded and used as a control on the robot's
operations. Now we find that there is an effort to state some
Laws for industrial robots, and since these, in a way, reflect
thinking concerning the use of industrial robots, we should
examine them. As stated by Neale W. Clapp of Block Petrella
Associates, one set of such Laws are:

(a). Organizations may not install robots to the economic,

social, or physical detriment of workers or management.
(b). Organizations may not install robots through devious
or closed strategies which reflect distrust or disregard for the
work force, for surely they will fulfill their own prophecy.
(c). Organizations may only install robots on those tasks
which, while currently performed by men, are tasks where
the man is like a robot, not the robot like a man!
This decade is the beginning of the age of robotics, cjid
thus, while we how to make them operate, and
are learning
what they can do, and how to make them better from a design
and operational standpoint, perhaps the sociological aspects
of robotics showed also be a prime area of consideration. This
could also influence the design, installation, development,
and operation of these types of machines.

HOW SOME EXECUTIVES DETERMINE THE NEED FOR ROBOTS

W.R. Tanner of Tanner Associates has stated some rules
of thumb by which an executive might determine if he is on a
correct course when he installs robots in his installation.

(a). Avoid extremes of complexity

(b). Operations must be orderly and systematic
(c). Remember, robots are generally no faster than people
(d). For short runs use people, for very long runs use fixed
automation

276
 (e). If it doesn't make dollars it doesn't make sense
(f). One is not better than none
(g). If people don't want it, they won't make it.

Refer to the Spring, 1980, issue of Robotics Today magazine

forMr. Tanner's discussion.
Some of the ideas expressed in the rules seem suitable,
and others are open to question. We would question f as it

seems that a detailed consideration of the application might

be in order before making a judgment such as stated here. If a
robot can be operated 24 hours a day (not considering down
time) and if it requires no breaks or rest periods, and if it can
,

be adjusted to perform new tasks with relative ease, then

perhaps just one robot in an installation can add up. You will
determine, from your own experience and knowledge, which
of the other rules might be appropriate, but we would venture
to suggest that some debate might be worthwhile on some of
these rules. We have included some of the previous rules and
definitions to illustrate that industry, as well as users of other
types of robotic equipment, seem somewhat frustrated when
they really begin to consider such machines in the hierarchy
of human-machine relationships. When we think of an au-
tomobile, we simply think of transportation. It can be with or
without comfort and conveniences, and it can be cost effective
or not. It can be status making or demonstrating. But we know
where and how to think of that kind of machine, both in a
pleasure sense, and in a profit producing capacity. We also
know how to relate the human element to the machine, even if
it is a variation of the automobile, such as the truck, tractor,
tank, or whatever.
Perhaps we must come to the same type of thinking with
robots? Is it possible that one status symbol of the future will
be the number of domesticated robots one has around the
house? It is possible that the industrial profit margin will be
controlled by the number, type, and efficiency of robot work-
ers. It is possible that one might find a completely new type
world which the human must be re-programmed to be
in
compatible with the robotic machines which he previously
programmed?

277
 As I write this book I wonder what the future of writers
will be. Will a robot typewriter investigate the many areas of
research by simply sending signals over the telephone lines
to libraries and other repositories of knowledge; analyzing
and assembling and developing material and then spewing out
pages of text? Perhaps it would write novels, based on tried
and true plots, or screen scripts? Man may tend to forget, and
a computer can memorize almost forever. Man may be emo-
tional in rendering judgments, a machine will just consider

facts. Man may be unable to render perfect decisions, due to

his inability to retain or consider all facts needed to get the
absolute picture of background, trends, or whatever. A com-
puter, with the new technology making possible a larger and
larger memory capability, and with the computer ability to
solve equations relating to the decision making process that
baffled man in years past, we, even currently, note how many
humans are turning to these machines for the answers to their
problem.
In any event, we need to know as much as we can about
these robotic computer-controlled things and to this end we
now continue into the next chapter where we consider first

another industrial robot, and then some aspects of giving

robots eyes. You might even begin to think about the situation
we have now, where most robots are blind. What will the
see mean to these machines?
ability to

278
 0©
The ASEA
8
Robot System

One unique feature of this robot is that it is an all electric

system. As illustrated in Fig. 8-1, you can see the large,
specially designed electric motors on each side of the arm at
the shoulder position, and one to the rear of the arm section.
Also visible in the illustration is the control panel which
governs its operation. At the right end of the arm itself is an
attachment disc which permits use of a multitude of tools or
devices to do the various tasks for which it is designed.
Notice that while the arm itself is not directly extendable,
reach can be obtained by use of the electric motors at the
shoulder position, or by causing the arm to bend at the elbow
rotary joint. This is very similar to the human arm.
When we examine such an arm and realize its strength
and capability, it brings to mind a vision of a sleeping giant and
helpers as illustrated in Fig. 8-2. In this illustration we at-
tempt to show that only a portion of a robotic capability,
perhaps, is being used to assemble or adjust some objects
brought to it by, in this illustration, elves, who position and
hold the workpieces while the arm performs its operation on
them. Then they move on to the next robotic station. This, of
course could be some type conveyor system, but one which
has a positioning capability at the end where it meshes with
the arm operation.

279
Fig. 8-1. The ASEA robot for industrial applications (courtesy ASEA).

As to the giant itself, note that only a small portion of the

possible computer brain has been used, and that a second arm
remains motionless. In some applications there is a need for a
second arm, or even a second pair of arms and some robots
have been designed to have these appendages. Underwater
repair of cables or oil lines use such robots to perform work-
ing tasks. Our giant gets his orders by telephone or more
accurately, by electronic-electrical signals. Maybe it's a little

fanciful but it is intended to illustrate a point. The ASEA robot

280
281
is made by the Electronics Division of ASEA, Vasteras,
Sweden. More than 600 of these type robots are being used in
various types of industrial applications in more than 20 coun-
tries. The tasks which it performs range from moving a

stainless steel sink around a polishing brush, to delicately

applying liquid adhesive glue to a car top, to applying a multi
torch welding unit to car bodies. This robotic arm has six
degrees of freedom to do the tasks assigned. Notice in Fig.
8-1 how well sealed the whole unit is, and that makes it

possible for it to operate for long periods of time in dirty

environments where grime and other contaminants may
exist. In one de-burring application a vicious stream of tiny
metallic particles is generated during the working process.
The arm must not be affected by them. Each electric drive
unit includes a complete servosystem with a dc motor, resol-
ver, for positioning indication, and a tachometer for control-
ling its speed. It is said to have a quiet operation.
What we gain by examining this unit is a further under-
standing of just what an industrial robot consists of, how it is

programmed, how it operates, and what it can do. Since this

arm is electrically driven, it also can provide a giant example
for the hobbyist or experimenter as to how electric motors
are,and can be, used in such an applications, and how they are
controlled and regulated. Smaller motors, of course, would be
used in smaller arms.
In the description which follows we must realize that the
robot arm is described as having a lower arm section which is
that section connected to the base pedestal, and an upper arm
section which is the horizontal member attached to the lower
arm section. The robot can rotate about its base pedestal and
the motions of the arm segments will be angular about their
pivot points, but this angular motion can result in an in-out
motion of the end wrist to which various tools and devices can
be attached. The wrist is the small circular section at the right
end of the horizontal upper arm in Fig. 8-1. Its rotation is
perpendicular to the rotational up and down movement of the
upper arm. In this robot the designers have used an ingenious
system of linkages to accomplish wrist rotation. Now let us
learn some details of this robotic arm.

282
DESCRIPTION
The ASEA industrial robot system is made up of three
main parts:

Control system
Measuring and servosystem
Mechanical system
The control system consists of the computer, memories,
inputs and outputs to control the robot and interlocks from
peripheral equipment, and functions to control the servo-
system of the robot.
The measuring and servosystems include servo
amplifiers and dc motors with tachogenerator feedback. Posi-
tion regulation is by means of a cyclic resolver system con-
sisting of a resolver with associated supply and decoding
circuits, and a position regulator.
The mechanical system includes the robot and the
transmission which converts the rotation of the motors into
the required motion. The following motions are available:
Rotation (</>) entire robot rotates
about its pedestal
Out/in motion (0) lower arm moves
Up/down motion (a) upper arm moves
Wrist bend (r) the wrist bends up or down
Wrist turn (v) the "cuff' of the wrist
rotates

Various additional units (options) can be connected to

the control system of the robot:
A programming unit, which is used to program robot
motions
A tape recorder unit, used to store programs on magne-
tic tape cassettes
Standby battery supply, ensures that the contents of the
program memory are maintained up to 45 minutes after loss of
supply
Memory module to increase the size of the program
memory
Test panel for servicing and troubleshooting

283
 Solenoid valves for gripper operation
Gripper
The control system
based on a computer, as shown in
is

Fig. 8-3, which illustrates the main communication paths in

the system.
A control program is stored in the memory. This pro-
gram, which is fixed, tells the computer how the various robot
instructions and control functions are to be performed. The
operator and control system communicate via the control
panel and programming unit. The computer regularly scans
the state of the controls and reads out acknowledgement

g) OPERATOR
DISPLAY

§^
TAPE
RECORDER I
CONTROL PROGRAM-
PANEL MING UNIT

> I f
I 1

TEST l#» COMPUTER MEMORY

I

|
PANEL p
I I

l^-£
l
AXIS UNIT
POS. LOOP DRIVE UNIT
SPEED LOOP
*
INPUT /OUTPUT
SIGNALS r>
CAN BE
EXTENDED TO

stm +
ROBOT
6 AXES

AXIS

Fig. 8-3. The block diagram of the robot system of ASEA (courtesy ASEA).

284
Fig. 8-4. Dimensions of the smaller industrial robot arm with a 6 kg capacity
(courtesy ASEA).

orders by switching lamps on or off.The computer monitors

and controls input/output signals between the process and
the control system, and reads out orders to the axis units if

travel is required on any axis.

The operator programs the robot with a particular pat-
tern of motions by means of the programming unit. Each move
is commanded by the operator using jog buttons and the

position and speed are stored in the computer memory. The

conditions for process signals (e.g., for gripping tools and
external acknowedgements or interlocks) can also be pro-
grammed and stored in the memory. When the program is
complete the operator can operate a control on the control
panel to order the computer to store the program on magnetic
tape. The program can then subsequently be read in from the
magnetic tape and stored in thememory of the computer. A
robot program stored in the memory can then be started and
continuously repeated or stopped from the control panel on
the order of the operator.
We have mentioned that a robotic arm should be capable
of doing work, and thus it requires power. ASEA makes two
robotic arms seen in Figs. 8-4 and 8-5. One is much smaller
than the other (IRb-6vs IRb-60). It is now of interest to use to

285
see what some technical specifications are with respect to
weight handling capability, degrees of freedom, and gripper
capabilities. In many applications the speed of arm movement
can be very important. Thus we also examine this capability.
Remember that as the size, and thus the inertia, of an arm
increases, more power is required to make it move quickly,
and also much more attention must be given in the servo-
system to the damping function to insure that the arm will not
overshoot its required positions, and that it will not hunt or
oscillate about an end-point position.

Power
Robot IRb-60 IRb-6
Permitted handling weight 6 kg 60 kg
including gripper:

Maximum gripper length at 200 mm 400 mi

above handling weight:
In order to calculate the permissible handling weight when
the gripper length exceeds 200 mm or 400 mm as the case
may be, the following mechanical data apply:

Maximum moment of inertia 2.5 Nm 2

100 Nm 2

Maximum static load 12 Nm 240 Nm

The robot is available with the following degrees of freedom:

Arm motion: rotation 340° 330°

Arm motion: radial ± 40° +50° to -20°
Arm motion: vertical +25° to -40° +10° to -55°
Wrist motion: bend ± 90° +75 to - 120°
Wrist motion: turn ± 180° ± 180°

Gripper functions:
Two independent solenoid valves housed in the upper arm,
which can be operated from the keyboard of the programming
unit, are available as an option. There is also a four-pole
electrical outlet in the upper arm; among the intended appli-
cations of this is the supply ofmore advanced grippers with
search functions.

286
 Weight of robot: 125 kg 750 kg
Repeat accuracy at wrist: ±0.20 mm ±0.40 mm
Speeds:
Arm motion: rotation 95°/s 90°/s
Arm motion: radial 0.75 m/s 1.0 m/s
Arm motion: vertical 1.1 m/s 1.35 m/s
Wrist motion: bend 115°/s 90%
Wrist motion: turn 195% 150%
Every robot arm has a working envelope or area through
and which the arm can be programmed to move. We show
in
the profile of the IRb-60 in Fig. 8-6. Again notice that the
dimensions are stated in metric units.

Description of Motions

The basic version of the robot has three degrees of

freedom for positioning the hand in space. The three main

1150 200

UPPER ARM

£33 *
WRIST

LOWER
ARM
1600

800
*e
j BASE

130

Fig. 8-5. Dimensions of the larger industrial robot arm with a 60 kg capacity
(courtesy ASEA).

287
coordinates are a rotary motion (</>) and two arm motions in
the vertical plane, performed by a lower arm (0) and an upper
arm (a). All three main motions are position-controlled by
means of dc motors. A further two degrees of freedom are
available as options, a wrist turn and a wrist tilt version.
These motions are available either with dc drive or with
pneumatic rotary cylinders with mechanical limit position
stops. In the basic version these motions are mechanically
blocked.
The drive unit for the rotary motion is rigidly mounted in
the pedestal and drives the body around the pedestal column
through a reduction gearbox with a very low ratio. See Fig.
8-7.
The drive unit for all coordinates except the rotary
motion (</>) mounted on the rotating body. The arm mo-
are
tions are provided by ballscrews which actuate the arms via
links and levers. The lower arm (0) moves the wrist horizon-
tally in and out. The motion remains completely horizontal
since the a-motion compensates for the 0-motion by means of
the control system. In the same way, the motion of the upper
arm (a) is compensated so that its motion moves the wrist
vertically up and down.
The wrist motions are driven via a system of linkages
which is designed so that the wrist coordinates will assume
the set angle to the horizontal plane regardless of whether the
0- or a-coordinate changes. The drive units for the wrist
motions are mounted on the frame at the lower bearing point
of the lower arm.
The wrist is also designed in such a way that tilting
always takes place in the vertical plane.
The driving system for this arm consists of dc electric
motors. It is easier to design a driving system to produce
variable speeds and torques using dc motors than it is using ac
motors. When using ac one must have modulators, and de-
modulators and phase comparers and such. With dc motors
one simply uses high powered transistors or similar solid
state drivers. Since signals from computers are dc this also
makes the whole system more compatible, electrically. In
Fig. 8-7 we show the drive unit locations and some defini-

288
 F A B C

o O
c

:o

IRb-60
A- 990
B - 1 ,720
C- 1,890
D - 1,400
E - 930
F - 900

a- 1,750
b - 1 ,655

c - 1,215
d - 370
e- 645
- f 1,065

(MILLIMETERS)

Fig. 8-6. The working profile of the IRb-60 robotic arm (courtesy ASEA).

289
tions.A unit as stated here is an electric motor. Inspect the
wrist motions and notice that both turn and tilt are ac-
complished.

Drive Unit Analysis

The drive units consist of:

Motor unit
Mechanical transmission
Servoamplifier

The motor unit of the basic version is made up of the

following components:
Dc motor
Resolver for position indication
Tachogenerator for speed regulation
The motor unit for the wrist turn or tilt motions can be
replaced by a pneumatic turning cylinder, two versions of
which are available, one for 90° turn and the other for 180°
turn.
The transmission is of two types, the harmonic-drive
gearbox or the ballscrew unit. Each motion is described in the
following pages, which also deal with the transmission, that is
the way in which the motions are achieved.
The servoamplifier is installed in the control cabinet
together with the rest of the electrical equipment.
Pedestal:
The pedestal is in the form of a baseplate with a cylindri-
cal top; it is an aluminum casting. The cylindrical part houses
the motor unit and a harmonic drive gearbox for the rotary
motion (</>). See Fig. 8-8.
Body:
The body is coupled to the output shaft of the ^-motion
drive unit. It is alsomounted on a bearing in the pedestal and
rotates on this (the </>-motion). Mounted on the body are the
drive units for lower arm motion (0-motion) and upper arm
motion (a-motion).
The from the control cabinet is con-
electrical wiring
nected in the pedestal by means
of connectors and passes
from the pedestal to the body through coiled flexible leads
between the pedestal column and the body.

290
 TILT (BEND), t

TURN, d

b <5 BODY

PEDESTAL
SCREW
UNIT

SCREW UNIT

TURN DRIVE UNIT, tf

TILT DRIVE UNIT, t

8 DRIVE UNIT
a DRIVE UNIT

4=f DRIVE UNIT

Fig. 8-7. The drive units of the IRb-60 and some definitions (courtesy ASEA).

291
 {-
GEARBOX

BODY

— D.C. MOTOR (POWER UNIT)

TACHOGENERATOR (GIVES VELOCITY
FEEDBACK)

RESOLVER (GIVES POSITION

FEEDBACK)

PEDESTAL

Fig. 8-8. A cut-away view of the robot's pedestal (courtesy ASEA).

In this illustration we see that the left hand side is the

enclosed part which shows how the body and pedestal appear
as you view them, such as in Fig. 8-1. On the right half of the
illustration the internal location of parts and devices is shown.
Notice that the tachogenerator which we call a tachometer
which is really a small generator which produces a voltage
output exactly proportional to speed and which is used in
its

the damping of the system, is an integral part of the motor

unit. The resolver (we sometimes call them selsyns or syn-
chros) will give a signal (ac) the phase of which is directly
proportional to the instantaneous angular position of the body
with respect to the pedestal. This used for position feed-
is

back in a servosystem. A dc resolver is a potentiometer and it

is sometimes used in servosystems.

Next we begin an examination of the moving sections of

the robotic arm and the gripper unit. Notice that small lever
arm sections are located near some rotating joints so that a
motor driven screw can exert the force necessary to move the

292
arm section. The manner in which this driving force is
exerted is easier than using the motors directly connected to
the joint through a complex gear train as necessary in a
direct-driving system. (In many cases direct-drive is used,
and very successfully.) The screw-type lever-action motion
shown in Fig. 8-9, approximates a hydraulic type piston mo-
But the reserve oil tank, the valves, and the pressure
tion.
pump and use of oil are eliminated which may be a cost factor.
Speed of motion is reduced over that of a hydraulic system,
and perhaps some power capability is lost when using electric
motors in this arrangement. Look at Fig. 8-9.
Mounted on the body is a bearing bracket to which the
lower arm is fixed and in which it pivots. The motion of the
lower arm (0-motion) is obtained by means of a drive unit
consisting of a motor unit and ballscrew transmission; these
are rigidlymounted on the body. The motion of the ballscrew
is transmitted to the lower arm via a lever pivoting at the

ballscrew and attached to the lower arm. The drive units for

UPPER ARM

SCREW DRIVE

D.C. MOTOR DRIVE

Fig. 8-9. The lower arm motion system of the ASEA Robot arm (courtesy ASEA).

293
Fig. 8-10. The upper arm motion system and drive assembly for ASEA robotic
arm (courtesy ASEA).

the turn and tilt motion of the wrist are mounted on the lower
arm around its lower turning centre, see Fig. 8-11.
The upper arm description and operation are as follows:
The upper arm is fixed to, and pivots on, the upper end of the
lower arm. Movement of the upper arm is achieved as fol-
lows.
The drive unit, consisting of the motor unit and the
ballscrew transmission, transmits a motion to two link rods
articulated on a shaft extending from the ballscrew nut as-
sembly.One of the link rods is attached to a shaft fixed to the
upper arm and the other end is attached at the center of
rotation of the lower arm. Together with the upper and lower
arms, these two link rods form a parallelogram. As Fig. 8-11
shows, movement of the nut assembly and one corner of the
parallelogram will move the wrist up and down.

294
 Electrical and compressed-air lines to control the grip-
pers run through the upper arm. At the rear of the arm there is
a connection for the supply of compressed air. Outlets for the
gripper, two individually controllable pneumatic outputs and
an electrical contact with four wires are mounted on the
underside at the front of the arm.
The wrist is rigidly mounted on the upper arm. Two
motions are available at the wrist, a turning motion and a
tilting motion. These motions are achieved as follows. The
drive unit for each motion can either be a dc motor equipped
with a resolver and a transmission consisting of a gearbox, or
apneumatic rotary cylinder for turning at right angles or 180°.
With pneumatic power, only one motion can be driven and the
other must always be locked. The motion of the drive unit is
transmitted to the wrist via a linkage system.
The linkage system operates as follows, Fig. 8-11. A
linkage disc is coupled to the drive unit, which is mounted on
the lower joint of the lower arm.Mounted on this linkage disc
are two arms displaced tt/2 rad (90°) on the linkage disc.
link
The other end of the link arms is mounted on a linkage disc
pivoting in the upper arm. From here the motion is transmit-

WRIST
TURN GEAR UNIT
^vTILTS
UPPER ARM A ^ A TURN
fi
W ROTARY
ROT/s

LINKAGE RODS
TURN MOTION
LOWER
ARM LINKAGE DISCS

^Wr^ BASE
TURN

Fig. 8-11. A schematic diagram of the wrist linkage system for ASEA Robot
(courtesy ASEA).

295
ted to a linkage disc in the wrist via two more link rods. The
turn and motions have separate linkage systems on either
tilt

side of the arm system. Wrist tilt is achieved because the

linkage disc at the wrist is moving part of the
fixed to the
wrist. Wrist turn is achievedby means of an angled gear unit
which transfers the motion from the linkage disc to a turning
disc, free to rotate in the wrist. The angled gear unit is

adjustable so that subsequent adjustments can be made in

cases requiring very little backlash.

Figure 8-11 shows the linkage system in the lower arm
and upper arm. In the basic version the disc for the tilt motion
at the lower joint of the lower arm is mechanically locked, so
that the wrist keeps a given angle relative to the horizontal
plane regardless of arm motions. The turn motion is mechani-
cally locked at the wrist itself.
Mechanical stops are rubber composition. There are
mechanical limit position dampers for all motions, to prevent
damage to the mechanical components of the robot if, because
of faults in the control system, the robot motions should
exceed the working range. The dampers are of rubber and are
designed to damp the full motion speed without deformation

of the mechanical components.

A SIMPLIFIED DESCRIPTION OF THE LINKAGE MOTION

While ASEA uses two linkages from one disc to another
in the actual machine, the drawing (Fig. 8-11) is difficult to
analyze to see just exactly how the discs rotate to cause a
movement of the wrist. In Fig. 8-12 is a simplified look at how
this can be accomplished. If you follow the arrows and con-
sider that the motor output rotation through the gearing will
be limited to somewhat less than 90 degrees each way from
the neutral position shown, then you can see how the output
disc to which the wrist is attached will move up and down as
the motor driven disc is turned. Of course, the motor might

just have a small lever output to move the linkage up and down
(A) and not need a disc (B) at all in this first position.
It is essential that the discs and motor shaft be fixed to

the robot's body so that no movement up or down, left or right

will occur. If they move physically, then they cannot transmit

296
297
the rotational movement which we need at the wrist. Also,
you can consider another set of such discs and another motor
and some additional linkages which can be so positioned that
when this second motor is rotated each way somewhat less
than 90 degrees, it can cause the wrist to turn sideways, back
and forth.Thus we have the movements needed for back and
forth and up and down. The rotation or turning of the wrist
about its own axis can be accomplished with an integrally
installed motor at the wrist position, said motor to be turned
and tilted when necessary, and when activated, it can, through
its own gearing, provide a rotational movement 90 degrees

one way and 90 degrees the other way, of the wrist, or

whatever is attached to the wrist. It would be advisable, of
course, to provide electrical limit switches on the wrist so
that the motor cannot overdrive it past the 90 degrees posi-
tions. Examine Fig. 8-12.
We recommend that if you are deeply interested in this
linkage situation, you might contact some mechanical en-
gineering student, or friendly professor, at a nearby univer-
sity and question them about Fig. 8-11. A second source of
information on linkages of various types, pantographs, etc.,
can be found in your local library under mechanical devices or
mechanical engineering mechanisms. Ask the librarian to
help you locate a good reference work if you need it.

No one has said that a robotic arm is a simple device, it

just looks that way! Actually there is quite a bit of mechanical,

electrical, and computational equipment installed in such a
unit. Examine a block diagram of the ASEA robot system in
Fig. 8-13. The legends are in English and Swedish so a brief
explanation of the operation will help tie all the various blocks
together.
The control electronics consist of circuit boards which
make up a computer with a memory. There are also interface
boards for data communication with the various input and
output units, i.e. tape recorder, control panel, programming
unit and axis units. The signals between the function modules
of the control electronics appear at the rear plane of the
electronics rack and are in the form of a data bus, memory
address bus, address pointers for the various input and output

298
units and a small number
of clock pulses and control signals.
The and output signals for the control panel,
digital input
programming unit and external process go to the input/output
unit via the terminal unit. An analog reference signal, the
polarity and value of
which indicate the direction and speed of
movement of the robot axis,
is generated in the axis unit. The

analog reference (command) signal is amplified in the drive

unit so that it can control the dc motor.
The computer included in the control electronics can be
divided up into five main sections.

•Input for reading-in data from the process (feedback)

•Arithmetic unit for arithmetical and logical data pro-
cessing
•Memory to store both data read in from the process
(feedback plus command signals) and the robot system con-
trol program
•Control functions to check what is to be executed
•Output for the supply of data to the process

The arithmetic and control sections consist of the func-

tion modules known as the central unit (A) and the interrup-
tion and power failure detection unit (B). These units contain
a clock pulse generator to generate clock pulses to the control
section and other electronic sections, a microprocessor and
circuits to control a general 8-bit data bus for data transmis-
sion between the microprocessor, memories and input and
output units. The microprocessor contains, among other
things, an arithmetical-logical unit, an instruction decoder
and a program counter. The instruction decoder interprets
the instruction read from the control program of the memory
and establishes the conditions for the execution of the re-
quired operation. The program counter keeps track of the
order in which the computer instructions in the control pro-
gram are to be carried out.
The memory, which may be either of the write/read type
or of the read type only, consists of various combinable
function modules, depending on its size and type. The mem-
ory is organized in memory words of eight bits each. A total of
16 k (16,384) words can be addressed.

299
 There are two electronics modules for the computer
memory: the memory unit and the PROM-unit.
The memory unit contains a 4 K (4,096) word write/read
memory. The write/read memory is a semiconductor mem-
ory which stores the robot programs programmed by the
operator. It defines the patterns of motion of the robot, that is,
data for position coordinates and speeds, and the control of
digital inputs and outputs. The second variant of the memory
with write/read memory only, is used to increase the
unit,
memory space for the storage of robot programs.
The PROM-unit, which contains a 7 K (7,168) word read
memory, stores the control programs of the systems. The
memory content of the PROM-unit does not change in normal
service, but it can be re-programmed with a special pro-
gramming unit.
Finally there are the input and output units: these are the
tape recorder interfacing, axis control circuits and input/
output unit. The tape recorder interface controls data trans-
mission between magnetic tape and the memory. The "axis
control circuit" function unit receives datawords which state
by how many increments the relevant robot axis must move.
The purpose of the input/output unit is to match words on the
bus system of the computer to signals for controlling and
checking panel controls and external relay and contact func-
tions.For reference voltage supply of the measuring trans-
ducers on the robot, the reference counter and resolver
amplifier function unit will be required. A test panel for
servicing is also available, as shown in Fig. 8-13.

OPERATION
As Fig. 8-14 shows, the basic program for controlling the
robot system is divided up into a number of subprograms. The

start-up routine is always activated after switching. Among

other things, this clears the registers and program counter.
The clock pulse routine synchronises the computer with the
10 ms sampling period used in the robot system. Whenever
the clock pulse arrives, a jump to the clock pulse routine takes
place, and at the same time the conditions of a group of
controls are read in. While automatic running is in progress, a

300
jump back to the automatic routine always takes place, so that
new movement data are read out during the next sampling
period or at the beginning of execution of the next robot
instructions. In other cases a jump takes place to the mode
selection routine. This routine investigates which load is

required and whether any related operator actions have been

taken. If so, a jump takes place to the routine for the selected
mode: if not, the system jumps back to the clock pulse routine
to await the next clock pulse.
The manual routine deals with all operator actions relat-
ing to the manual mode and required for robot programming,
program corrections, synchronising the robot and step-by-
step running during program testing. For example, when the
routine is complete, the system jumps to the clock pulse
routine, except in step-by-step running, when it jumps to the
automatic routine in order to execute the robot instruction.
The automatic routine selects which robot instruction is,

in turn, to be executed. After this, each robot instruction has

its own sub-routine; in other words the automatic routine
includes a total of 16 sub-routines.
Finally there are the routines "read cassette" and "write
cassette", which carry out reading of robot programs to, and
transfer of robot programs from, the magnetic tape cassette.
After reading or writing is complete, the system jumps to the
start-up routine.

Feedback and Servosystems

Each robot axis is fitted with a feedback resolver for axis
position measurement. The resolver has two fixed stator
windings and one rotating rotor winding. The resolver stator
windings must be supplied with two reference voltages with
the same peak-to-peak value and 90° out of phase. The fre-
quency is 2 kHz. The voltage induced in each rotor winding is
filtered in the appropriate "axis control circuit" function unit.
The phasing of the basic frequency of the resolver response is
a measure of the position of the axis. The resolver is coupled
to the drive motor shaft, and one motor revolution corre-
sponds to 200 increments.

301
 I/O-ADORBUS
DATA BUS '

^EM-ADDR BUS i.

CLOCK-PULSES CONTROL SIGNALS

i
i

? JL 1

I i
'
I \>
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INTERRUPT AND
TEST PANEL CENTRAL UNfT POWER FAILURE MEMORY 16k x 8 BIT TAPE RECORDER
DETECTION R/W. ROM. PROM INTERFACE

(A)
(B)

TAPE RECORDER

MAIN POWER
FUSES AND MAGNETICS UNIT

POWER SUPPLY FOR

ELECTRONICS
RECTIFIER UNIT
ONLYIRB-6

Fig. 8-13. The block diagram of the ASEA robotic arm (courtesy ASEA).

302
 REF SIGNALS

REFERENCE
COUNTER AND CONTROL CIRCUIT CONTROL CIRCUIT INPUT /OUTPUT
RESOLVER EXITERS FOR -AXIS FOR 6th AXIS UNIT

TERMINAL UNIT

PLINTENHET

,
J 1 T
UNITFOR -AXIS DRIVE UNIT FOR 6th CONTROL PANEL PROGRAMMING
AXIS UNIT

I I I I

INTERFACE UNIT

CONTROL UNIT
§a

303
 SWITCHING ON

START-UP
ROUTINE
CLOCK PULSE

CLOCK PULSE
^ ROUTINE

t
MODE SELECTION
ROUTINE
1

'f
>\
i
MANUAL —- AUTO READ
CASSETTE
WRITE
CASSETTE

>

Fig. 8-14. The flow chart of the ASEA robotic system (courtesy ASEA).

A desired value signal with a frequency of 2 kHz is

generated electronically in the "axis control circuit" function

unit. The measuring system operates on a phase-analog prin-
ciple, meaning that the phase difference between the actual
value signal from the transducer and the desired value signal
is directly proportional to the position error. The function
unit contains a converterwhich converts the phase difference
to an analog error signal which controls the servosystem.
During axis motion, the computer regularly reads out
orders which result in phase-shifting of the desired value
signal. A phase difference between the desired and actual
value signals will cause the robot axis to move and therefore
the resolver to rotate in order to reduce the phase difference.
During motion at constant speed, the axis lags behind the
commanded value with a particular lag which increases with

304
speed. On starting and stopping, the acceleration or retarda-
tion is controlled automatically in such a way as to prevent
overshoot.
The "axis control circuit" function unit contains two
circuits which monitor the value of the lag. The condition of
these circuits is scanned regularly and read into the com-
puter. If the lag exceeds a certain maximum permitted value,
emergency stop takes place and the robot stops. The second
circuit detects whether the lag is within a few robot incre-
ments, the zero zone. During fine positioning with the robot,
the next robot instruction does not begin until the axis has
taken up position, that is, the lag is less than the zero zone.

Servoamplifier
The servoamplifier is part of the position control sys-
tem. In IRb-6 it consists of a transistorized chopper and in
IRb-60 a thyristor converter is used.
The drive units of all axes in IRb-6 are supplied by a
common power supply rectifier; see Fig. 8-15. The positive
or negative supply voltage is supplied to the drive unit motor
circuit at a frequency of about 1 kHz. The motor voltage is

controlled by varying the pulse length. Figure 8-15 shows the

block diagram.
In IRb-60 the ac voltage is fed directly to the drive units
after reduction by transformer as shown in Fig. 8-16. The
drive unit is a conventional thyristor converter with a circula-
tion current reactor. The current and speed are controlled in
the same way as IRb-6, but in this case by controlling the
firing angle of the thyristors.
In both versions there is an inductor connected in series
with the motor; the purpose of this is to reduce current
pulsations due to the pulsating nature of the motor drive
voltage.
An analog error signal which serves as the speed refer-
ence for the drive motor is obtained from the "axis control
circuit" function unit. The actual speed is measured by a
tachogenerator coupled to the drive motor. The speed refer-
ence is compared with the tachogenerator voltage in the
speed regulator of the drive unit. The difference is amplified

305
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307
and used as a reference for the motor current. A pulse shaper
then controls the transistor switches to give the required
direction of motor rotation and the required speed.
In IRb-6 the smaller robot system, the motor current is
monitored by a circuit in the drive unit and if the current
exceeds its critical value for more than 5 sec, this circuit
ensures that the current is reduced to a safe value. This
function is used to protect the system, when for any reason,
the robot arm comes up against a mechanical limit position.
The motor circuits of both IRb-6 and IRb-60 are fitted
with a thermal release which causes an emergency stop when
the motor temperature goes too high.

GIVING THE ROBOT A SENSE OF ITS WORLD

There used to be a saying that "mobile object knew
where it was because it knew where it had been." It's true!
Everything is relative. If a robot arm does not know where it
has been, how can it know where to move next?
To give the robot a sense of its working world, that is, to
give it some base coordinates from which to measure its
movements, and then to give it well defined programs in its
coordinate system results in a fine state of robotic well being.
It will then be able to make moves in coordinate system you

have selected. We now examine how a world is defined for the

ASEA robotic arm.

THE ASEA ROBOT'S WORLD

In order to enable the patterns of motion of a robot
program to be defined relative to the rest of the peripheral
equipment the robot must be set to a well-defined position
before the program starts. This takes place on synchronizing
to the reference zero point of the robot. When an order for
synchronizing is given, the robot axes begin to move at a fixed
speed in a positive direction. The axes move until a syn-
chronizing switch— one for each axis— is actuated; when the
switch closes, the axis continues to the nearest resolver zero,
or electrical reference zero point. On synchronizing to a
reference zero point, the position registers of the axes are
updated so that none of the robot axes can be run up against a

308
mechanical limit position. These position registers are stored
in the memory. The working range of the axes is stored in the
control program, and any axis attempts to exceed the value,
if

the motion is interrupted and a warning lamp lights up.

The robot can also be synchronized to its actual position.
This means clearing the position error for a brief instant on
the "axis control circuit" function unit. This takes place when
the robot switched on, to prevent the robot jerking when
is

the drive motors engage, and on emergency stop, for rapid

stopping of the robot.

LOSS OF MEMORY POSSIBILITY WITH MICROCOMPUTERS

It is a constantly possible horror story. Somehow the
electrical supply system to the plant or robot was interrupted
and the inevitable result was that the memory lost all of its
information! It is not necessary that the supply voltage be lost
entirely, sometimes this might happen if the supply voltage
drops below a critical level. Of course there are other pos-
sibilities which might affect the robot's computer brain such
as temperature extremes, static, and in case of discs, dust and
dirt. In the case of a good robotic system an alternative supply

is incorporated into the system. This is how the ASEA robot

system handles the problem:
Since the program memory is made up of semiconductor
circuits, the stored information will be lost if the +5 V supply
falls below a critical value. To eliminate the necessity for
reading the program from the cassette after brief supply
voltage failures, the control equipment is available with
standby battery supply for the program memory. The blank-
ing plate on the control panel is then replaced by a
maintenance-free battery unit. A standby supply unit must
also be fitted to the control equipment. The program memory
receives its +5 V supply from the battery. If the mains
voltage is available, the battery is continuously charged from
the standby supply unit. These are the technical data of the
battery package:

•Life expectancy at least 3 years

•Capacity with maximum program memory equivalent
to a mains voltage failure of at least 45 minutes

309
 • Charging time for discharged battery, approximately 6
hours.
A red indicator lamp on the battery unit lights up if the
battery is discharging. There is also a switch to disconnect

the standby battery function for expected long disappear-

ances of the mains supply voltage if, for example, the main
switch is off.

If the voltages for the electronics section of the control

equipment disappear or if their value becomes incorrect,
either too high or too low, this is detected by a monitoring
circuit, and the mains voltage to the control equipment is

switched Only the standby power supply unit (where

off.

fitted) continues to receive mains voltage in order to maintain

the battery charge.
The system includes a circuitwhich monitors the
voltage supply of the program memory. If at any time this
voltage below its critical value, a flip-flop is set and a
falls

warning lamp indicating loss of program lights up on the

control panel when the mains voltage is restored. The pro-
gram must then be re-written into the memory.

SIGNAL TRANSFERENCE IN THE ASEA ROBOTIC SYSTEM

There are tapes and recorders used to store programs
and other types of data and these are conventional so we won't
spend time on this aspect of the system except to note that
they are used and have the normal advantages and disadvan-
tages. We also realize that from the control rack of any robot
system, a multitude of signals must pass to and from the robot
and its brain section. We have discussed this to some extent
in theprevious chapters. Here is an actual working example
system for us to examine with respect to this important area.
Signals pass between the control cabinet and the ASEA
robot for the following:
Dc motors
Resolvers From three to six
Tachogenerators electrically-controlled
Synchronizing switches axes

310
Solenoid valve For pneumatic control of
Limit switches or turn and 6th axis
tilt

(replaces electrical
control)

Grippers 1 and 2, which are controlled by solenoid valves

Ac-operated grippers or alternatively, search devices with an
acknowledgement signal
Connection leads to connect the programming unit to the
robot
Protective earthing of robot
In order to match the control equipment for various
applications it may be necessary to duplicate a number of
important control functions and to control external units or
detect various acknowledgements. The available signals with
maximum voltage and current data are listed below. All input
and output signals are filtered to suppress electrical interfer-
ence. Shielded cables must be used for the input and output
signals, and the leads must be connected to terminals in the
cabinet. The cabinet wall has a sealed entry for the external
cable. Following is a description of the external connections
of this system.

Output signals, 4 contact functions

•Contact closed if control equipment is operating (220
V, 1A)
•Contact closed when the OPERATION pushbutton is

pressed (24 V, 200 mA)

•Contact open on emergency stop (220 V, 1 A)
•Contact open when the EMERGENCY STOP pushbut-
ton is pressed (24 V, 200 mA)

Input signals, 3 contact functions

•Open contact gives emergency stop (24 V, 1 A)
•Contact closure gives "program start" (24 V, 10 mA)
•Contact closure gives "program stop" (24 V, 10 mA)
The contact closure function for "program stop" has priority
over the "program start" function.
Output signal to drive relays
•14 outputs numbered 1 to 14

311
 The relay driver stages, which are current-sinking, are
designed for +24 V and 150 mA maximum. The total current
in the output stages must not exceed 2 A.
The programmed outputs are used in automatic running.
Interlocking inputs for the robot program
• 16 inputs numbered 1 to 16.
The input stages convert the contact functions or signals
from current-sinking driver stages into logical signals suit-
able for the control equipment. A contact or current-sinking
driver stage must be capable of connecting 10 mA to V and
must be dimensioned for +24 V. A 2.5 ms filter circuit is
provided to eliminate the effect of contact bounce and high-
frequency interference.
The programmed inputs are used in automatic running.
Gripping tools and search devices signals and connec-
tions
The standard version of the ASEA robot is supplied with
electrical wiring to a socket on the robot arm for the connec-
tion of search devices or other types of grippers. Different
connections must be made in the control cabinet depending on
the function for which the socket is to be used. The following

signals are available, depending on the application.

a. Connection of search devices
• ± 15 V to supply search device electronics (max 0.5 A)
•Input to control system for the "search-stop" function.
The search-stop contact or transistor must be dimensioned
for + 24 V and be capable of connecting 10 mA to V.
b. Connection of valves to control grippers
•2 make contacts (220 V, 2 A)
•An option unit must be added to the control cabinet.
Two solenoid valves to operate two pneumatically con-
trolled grippers are also available as extra equipment. The
valves are controlled by signals from the control unit.
Compressed-air lines inside the upper arm are fitted to the
robot as standard.
The procedures in checking cables for proper signals and
to check these cables for broken wires and/or bad connec-
tions in sockets is the same as for any large piece of electronic
equipment. There are many relays used in this unit and these

312
must be maintained so that they provide proper connections
between their moving points and the fixed points. Cleanli-
ness, spark prevention, reduction of pitting, and heating are
some areas which must be considered. Sealed relays or solid
state relays tend to reduce problems in relay maintenance and
in the switching of large voltages and small signal voltages in
any robotics system.

CONTROLLING THE ASEA ROBOT

On the control equipment there is a control panel with
controls to start the industrial robot system and to select
various operating modes. For normal operation of the robot
system, that is, when programmed, only these
the robot is

controls are required. If the equipment has standby battery

supply of the program memory, the battery package is
mounted in a module on the control panel.

What the Control Switches Control

Switch Function
MAIN SWITCH To switch the power supply on
and off

a. I Power supply connected to

robot system if MAINS ON is

alight.
b. Power supply switched on.
Content of program memory
will be lost unless standby bat-
tery supply is provided.
PROGRAM SELEC- The control system can store 4
TION programs in its memory. The
1-4 switches are used to select the
programs in automatic running
and when programming a new
program, or when using the tape
recorder. A yellow indicator
lamp lights up for the selected
robot program(s).
a. OFF This program is not used.
b. ON This program is connected

313
BATTERY The switch is on the battery unit
and is used to switch the
standby battery supply function
on or off.

a. OFF Standby supply of program

memory from battery is
switched off.

b. ON The battery is switched on and

supplies the program memory
in the event of power supply
failure, to prevent the content
being lost.

OPERATION Power supply connected to

robot motors. Yellow indicator
lamp lights up. Control system
is in the operation condition.

STANDBY Starts the control system after

power supply has been
switched on or after disconnec-
tion of the supply voltage for the
robot motors. Yellow indicator
lamp lights up. The control sys-
tem is in the standby condition.

SYNCHRONIZING A red indicator lamp lights up

after the power supply has been
switched on or after emergency
stop.
Ifthe button is held pressed the
robot axes go to their syn-
chronizing position.

314
EMERGENCY STOP Immediately stops all robot mo-
tions and sets the system in
the standby condition. The
EMERGENCY STOP lamp
lights up.

RESET EMERGENCY This pushbutton resets the

STOP emergency stop circuit if the
contact circuit which caused the
emergency stop has been
closed again.

OPERATING MODE There are four pushbuttons

with yellow indicator lamps for
operating mode selection.

a. AUTO Automatic operation with one

or several programs to be exe-
cuted consecutively in order.
Yellow indicator lamp lights up.

b. MANUAL Manual mode. The robot can be

synchronized, or operated and
programmed by means of the
controls on the programming
unit. Programs can be tested
step-by-step. Yellow indicator
lamp lights up.

c. READ CASSETTE A robot program can be read in

from the magnetic tape cas-
sette.

d. WRITE CASSETTE Transfer of a robot program

from the program memory to a
cassette tape. Yellow indicator
lamp lights up.

315
PROGRAM START In the automatic mode, the
robot program starts. In the
manual mode an instruction
isexecuted whenever PRO-
GRAM START is pressed. The
pushbutton is also used to start
reading from, and transfer to,
tape cassette in the "read cas-
sette" and "write cassette"
modes. A green indicator lamp
lights up during activity.

PROGRAM STOP In automatic mode, stops the

robot program in progress; in
manual mode stops the instruc-
tion which is being executed.
The PROGRAM START indi-
cator lamp goes out. In the
"read cassette" and "write cas-
sette" modes the tape recorder
is stopped.

POWER ON Yellow lamp lights up if main

switch is closed and power sup-
ply voltage is available.

PROGRAM LOST Red lamp up to indicate

lights
program
that the content of the
memory has been destroyed.

EXCESS Red lamp lights up to indicate

TEMPERATURE excessively high temperature
in control cabinet.

OPERATOR ERROR Red lamp lights up for incorrect

operation of controls, e.g. if a
switch is set to the wrong posi-
tion or if an incorrect mode is

set.

316
EMERGENCY STOP Red lamp lights up after an
emergency stop has taken place
or after internal emergency
stop initiation from the control
system.

BATTERY OPERA- This lamp is situated on the bat-

TION tery unit and gives a red light
when the battery is discharging.

TEACHING THE ASEA ROBOT

In an earlier chapter we learned how a hand-held unit can
be used to make the robot arm go through the desired motions
to accomplish a task. As the arm gets into various positions
we press a learning button which causes that information to
be placed in the computer's memory bank. In essence the arm
is jogged or wiggled into the various positions it must have to
do the tasks as you teach it what to do. You jog or wiggle the
arm by depressing various buttons on the hand held unit. It
follows your every command and the process has a fascination
all its own. In a way it is like steering a radio-controlled model
airplane or car or boat by slight movements of the joystick or
the steering wheel. But this is a big and powerful unit which,
once it has learned its job, will then, when put into automatic
operation, perform that job for you almost endlessly! And do it
with a constant precision and speed that always makes those
concerned with budgets smile broadly! So be it. Let us see
what happens when we program the ASEA robot.

PROGRAMMING THE ASEA ROBOTIC ARM

The portable programming unit which can be plugged in
used to re-program
at the control cabinet or at the robot, is
the robot for new applications. When the robot is working in
the normal operating mode the program unit can be used in
conjunction with other robot systems. The robot is program-
med by using the pushbuttons on the programming unit to run
it to the positions it is required to take up in automatic
operation. Each position is stored in the program memory

317
when an instruction key on the programming unit is pressed.
In addition to positioning instructions, it is possible, for
example, to store in the program memory instructions for the
operation of grippers, opening and closing of a number of
number of interlock inputs, time-lag and
outputs, testing of a
repeating. The programmed instructions are then executed in
sequence in automatic mode. The programming unit is shown
in Fig. 8-17.
In order to avoid tedious reprogramming after long
periods of power supply disconnection, or when more than
four programs are to be used with the robot, programs can be
stored on cassette tapes.
Some interesting aspects of the remote control panel are
section D, which controls the arm, and E which has the
control buttons for the wrist. Notice how the movements are
designated on this panel. Numbers have been added to the
button faces to make it easier to discuss their individual
operation. Look at section D first.

Buttons one and two control a rotary movement of the

arm assembly by rotating the base structure. Refer to Fig. 8-7
where the Greek symbols for the angles are shown. The
control of the lower pivot of the arm is accomplished by
buttons 3 and 4, and the control of the upper segment of the
arm is with buttons 5 and 6. For the wrist section (E) buttons
1 and 2 control the tilting of the wrist, while the buttons 3 and
4 control the rotation of the wrist clockwise or coun-
terclockwise.
Since the angles in Fig. 8-7 are expressed in Greek
letters it might be of help to review this symbology. The
following short table shows the letters used.

Greek Name Capitol Letter Lowercase Letter

Alpha A a =
Theta e
Phi <D z = p = <p

Upsilon Y v
Tau T r(r)

318
 1 2 3 4
PTPF PTPC PTPL GR*>PER UMfT ACKNL OP ERROR

5
-
J

output on output off

JU 6
y
7
n*•

WATT PROGRAM END

8
j

'
> ' \
9 10 11 12 "
TESTWAI T TEST OUT TESTJU*V JUMP

13 14 15 16
REPEAT END REPEAT PATTERN MOO

V=

DELETE SIMULATE INSTR NO »CTR TYPE

J SI r
L S

AUTO SPEED MANUAL SPEED

&Ogra»!

WRIST

GRIP 1

•!
;1
r> r+ rl RELEASE 1

J k 1. J 1 nrt — U 4.

Fig. 8-17. The remote programming unit for the ASEA robotic arm (courtesy
ASEA).

Now, having identified each of the pivoting joints and the

directions of motion of the arm segments and the wrist itself.
Let us examine what the other buttons do in the following
table.Notice that you must sometimes push two or even more
buttons, and set a dial switch to a proper setting in order to
get the arm ready for whatever kind of commands you want to
give it. It can be instructive, if you want to get a feel for

programming of a robot arm such as this, to imagine that you

have the remote panel before you— look at Fig. 8-17— then
look at the robot arm in Fig. 8-6 and see if you can write down
which buttons had to be pushed and in what sequence in order

319
tomake the arm move through each of the positions shown. Of
course you might also imagine some positions of your own
choosing and write down the button pushing program to get
the end point of the arm to those positions. You can also
imagine that grippers are attached and include in your pro-
gram the steps necessary to grasp and move something from
one place to another. Try it! In the following table you will find
what everything does on the control panel. Some statements
will require some thinking and analysis on your part, but it
will be worth the effort.

THE CONTROL PANEL

Switch Function
AUTO SPEED Selection of speed to be pro-
grammed for positioning in au-
tomatic mode. In automatic
running of program, the highest
speed is limited to the speed to
which this switch is set. In
step-by-step operation the
speed is limited to not more
than speed 6. Position 8 gives
maximum speed
Posn 7 gives 75% of max speed
Posn 6 gives 50% of max speed
Posn 5 gives 31% of max speed
Posn 4 gives 13% of max speed
Posn 3 gives 5% of max speed
Posn 2 gives 2.5% of max speed
Posn 1 gives 1.3% of max speed

MANUAL SPEED Speed selection for manual op-

The motion
eration of the robot.
is executed by means of the
ARM and WRIST pushbuttons.

320
a. INCR The relevant robot axis moves
one increment

b. LOW The relevant robot axis moves

at 1.3% of maximum speed

c. MEDIUM The relevant robot axis moves

at 15% of maximum speed

d. HIGH The relevant robot axis moves

at 50% of maximum speed

INSTRUCTIONS INSTRUCTIONS is a group of

pushbuttons used to program
the instructions to be executed
when the robot is operating au-
tomatically. On programming
each instruction in the program
is given a serial number. The
instructions themselves are
designated by a type number
from 1 to 16.

a. 1 PTP F Point-to-point operation with

maximum accuracy. With argu-
ments (special numerical val-
ues) search and vertical/hori-
zontal running can be program-
med.

b. 2 PTP C Point-to-point operation with

coarse positioning. With argu-
ments (special numerical val-
ues) search and vertical/hori-
zontal running can be program-
med.

321
c. 3 PTP L Straight-line operation such
that positioning is concluded
simultaneously for all axes. The
travel time is stated in the form
of an argument.

d. 4 GRIPPERS The states of the grippers, .e.,

"on" or "off' are stored.

e. 5 OUTPUT ON The digital output (1-14)

selected on the keyboard must
be "on."

f. 6 OUTPUT OFF The digital output (1-14)

selected on the keyboard must
be "off."

g. 7 WAIT Waiting time as set on the

keyboard (0.1 - 9.9 s).

h. 8 PROGRAM End of robot program. Restart

END from first instruction or jump to
next program.

i. 9 TEST WAIT Wait until the interlock input

(1-16) selected on the keyboard
is on .

j. 10 TEST OUT Jump to next program if the in-

terlock input (1-16) selected on
the keyboard is "on"; otherwise
continue with next instruction.

k. 11 TEST JUMP Jump over next instruction if the

interlock input (1-16) selected
on the keyboard is "on"; other-
wise continue with next instruc-
tion.

322
 1. 12 JUMP Jump to the instruction number
selected on the keyboard.

m. 13 REPEAT Repeat the sequence the num-

ber of times keyed in on the
keyboard. This instruction also
marks the beginning of the
sequence.

n. 14 END REPEAT Marks the end of a repeat se-

quence. The system jumps to
the next instruction when the
sequence has been repeated the
programmed number of times.

o. 15 PATTERN Marks the beginning of a pat-

tern and defines the common
part of a number of different pat-
tern procedures.

p. 16 MOD Marks the beginning of each

part of a pattern to be modified.

q. DELETE For deletion of the program in-

struction with the number dis-
played.

r. SIMULATE Used when program testing to

simulate that the selected inter-
lock input is "on."

s. INSTR NO To modify a program instruc-

tion or start within a program.
The relevant number is keyed
in on the keyboard.

t. INSTR TYPE Used to display on the keyboard

the type of instruction stored at
the selected program instruc-
tion.

323
GRIP1 l-r.;;t: 1 lists

RELEASE 1 Gripper 1 opens.

GRIP 2 ~sT.ZZ±Z - I SrS

ARM Used for manual operation of

the <*-. d- and a-axes of the
robot. The travel speed is
selected with the MANUAL
SPEED switch. Several axes

ly-

When only one of a and are

operated, the control system
compensates to give a purely
vertical or horizontal motion.

6-axis rotates clockwise

6-axis rotates anticlockwise

c 0-axis

a-axis
moves forward

moves up
a-axis moves down

WRIST rd for manual operation of

•_-.r :;:;: •--'. r z:.y\:. a- :±-
scribed for the ARM pushbut-
:;r.s

The tilt compensated

motion is

with the turn motion to give

pure bending.

22-
 Tilt-axis moves up
Tilt-axis moves down
Turn-axis rotates clockwise
Turn-axis rotates anticlockwise

PROGRAM START This pushbutton, which is du-

plicated on the control panel, is
used in automatic operation to
start the robot program. In
manual operation, new pro-
grams can be tested step-by-
step, since one instruction is

performed every time the

pushbutton is pressed. A green
indicator lamp lights up in the
pushbutton while a program or
instruction is in progress.

PROGRAM STOP This pushbutton, which is du-

plicated on the control panel is
used to stop programs or in-
structions in progress; the
PROGRAM START indicator
lamp goes out.

Digital Keyboard Function

0, 1, 2, 3, 4, 5, Used to key in numerical values

6, 7, 8, 9 and arguments belonging to the
relevant instruction and to
select the instruction for indica-
tion or deletion, (argument =
angle)

Clearing before input; the nu-

merical display panel is also
cleared.

325
Indicator Lamps Function

LIMIT A red lamp lights up if, in man-

ual mode, an attempt is made to
move any axis outside its work-
ing range.

ACKNL A green lamp lights up when a

new instruction has been regis-
tered in a robot program.

OP ERROR This red lamp lights up if any of

the controls on the program-
ming unit or control panel is
wrongly operated. An error
code appears on the numerical
display panel.

Numerical Display Function

ERROR CODE Four-digit readout to indicate

INSTR TYPE instruction number, instruction
INSTR NO type or error code.
The format is explained by the
text above the display panel.

Notice that the designers of this robotic system have

used indicator lights to help prevent errors. This is especially
true in the area of operator error. Notice that not only does a
red warning light light up, but also an error code showing
what is wrong with the command or sequence appears on the
numerical display panel. When one sets in all the necessary
commands correctly, the whole panel is lighted up with green
(go ahead) lights.

THE GRIPPERS
We need to spend some time examining the gripper
operation as it applies to this robot and the others which we

have discussed. We already have some knowledge of how the

326
grippers appear and function from previous illustrations, but
here we will look at these units in more detail.
The end units are those that are affixed to
first types of
the robot's wrist by bolts or other type locking mechanisms.
Some of these types of end units are the welding torch, the
paint atomizer or spraying unit, drilling mechanisms, and
perhaps even nut tightening units that can tighten to the
correct torque, precisely. There are many other end units
which fit into this category as you can imagine.
The second type which may have a
of gripper is that
pincers arrangement or claw using two or more fingers that
can grip and hold various objects while the arm either moves
to new positions, or adjusts the object held to another
mechanism which may polish, sand, de-burr, paint, or what-
ever. We have noticed that many arrangements of the claw or
pincers type end-unit are possible, one of which is illustrated

in Fig. 8-18.
One interesting aspect of this gripper is the lever ar-
rangement which makes the jaws open and close as the drive
mechanism pulls or pushes the levers at point A. A second
item of interest in this unit is that the jaws have a soft face
which permits some compliance in the grasping action. What
this means is that the jaw faces can conform to the shapes of
some objects to grasp them better, and are not rigid as would
be the case if the jaw faces were solid metal. Also, when you
have this compliance capability, it is an easy step to incorpo-
rate some pressure activated switches in the complying
material such that when the object is grasped a switch is
closed that lets the computer know that the object is being
held. The computer can then order, perhaps, a slightly in-
creased tightening of the jaws. Not enough to damage any-
thing, but enough to insure that the object won't slide out of
the gripper when the robot arm moves it. In systems where
the jaws simply close to a certain dimension and are stopped,
if the size of the object changes or its physical shape changes,
then the object may not be properly grasped at all. One has to
re-program the closing dimension in order for the gripper to
close satisfactorily on the new object's shape or configura-
tion. Compliance is a good thing and we can think of only one

327
 PNEUMATIC PISTON OR
ELECTRIC MOTOR FINGERS

Fig. 8-18. A pneumatic type gripper may also be electrically operated. In the
case the pneumatic piston is replaced with an electric motor. Here we see a
latter
diagram which shows the mechanics of operation of one type gripper. Notice that
the "fingers" open in a rotary movement, not a parallel, translatory movement.

possible disadvantage. The material may wear out and have to

be replaced.
Examine Fig. 8-19 where two types of gripper arrange-
ments are shown. Manca, Inc. manufactures various types of
grippers for robot machines. Notice that in A two fingers
which are pivoted can be caused to move through an angular
rotation if they are connected by a suitable screw and nut-type
linkage to a motor's gear train shaft. As the motor rotates the
shaft screw it will pull or push the linkages to cause them to
open or close, as shown in B where the position is closed. The
illustration in B of Fig. 8-19 also shows the disadvantage of
this type gripper action. Because the motion is angular the
tips of the fingers tend to come together while the body of the
finger has a rather wide gap or spacing. Of course, as shown
by the dotted lines in B, one might use a compliant material
which can compress and this helps to overcome this difficulty.
If we examine further in Fig. 8-19 we notice that part C

will overcome this disadvantage of angular motion because

here the electric motor will cause the fingers to come to-
gether in a parallel motion instead of the angular motion just
described. In part D of the illustration we see how nicely the
fingers close together. This may be an ideal method for
palletizing, or similar type work for the robot.

328
329
 Only two fingers have been shown. Please realize that in
some cases it may be necessary to use three or more fingers

and these can be made a part of a somewhat elaborate mechan-

ical system which can be activated by a motor arrangement

without undue difficulty. The principles of operation may be

the same as we have herein illustrated. In the pictorial we
show two such units courtesy of Manca, Inc. In some applica-
tions where a slight opening and closing of the fingers is all

that is necessary to grip the object the rotary or angular

system might be very satisfactory. Since it closes only
slightly, you would not have the finger-tip condition we have
shown at B or Fig. 8-19.
When one has fingers which can move in a parallel
manner, it is mandatory that guide rods be used to hold the
fingers in line while the motorized section opens or closes
them. We have called this part of the gripper a stabilizer bar in
Fig. 8-19.
Now we turn our attention to the fingers portion of the
grippers. We use Fig. 8-20 as an aid to our thinking. The
fingers may be just bar-like metal units or they may be flat
surfaces of metal. They may have some compliance or sticky
material attached to the flat metallic surface as shown in B, or
they may have an indent of some particular shape as shown in
C. The grippers fingers will be designed and shaped accord-
ing to the type objects they are to handle and may include
even pneumatic suction cups on the inside edges which will
afford a tighter grip or better holding capability on fragile or
light weight objects which must be moved. In such a case a
very delicate closing of the gripper can be accommodated so
that it doesn't close tightly at all. The grippers fingers will
close enough to bring the suction cups against the object and
then they will stop moving. The suction of the cups then will
hold the object while it is being moved by the robot arm.

Figure 8-21 is a typical commercial, angular type gripper

for an industrial robot. This unit can be operated by a hy-
draulic system, a pneumatic system, or a spring system.
Notice the limit switch labeled here as a proximity switch.
Realize that with hydraulic or pneumatic systems the
backpressure in these systems can cause the proximity

330
331
switch to activate, sending a signal to the control computer
that the jaws have gripped something with a pre-determined
force.
In Fig. 8-22 the specifications are shown for the parallel
motion jaws of the Fibro-Manta gripper module. Also shown
are the diagram of the hydraulic system and the diagram for
the proximity switch installation.
We normally do not think of a gripper as being some unit
which must operate within a given time limit, but it is such a
unit, especially in industrial applications. If the robot is to be a
part of a large automated chain, then it will receive the units it

handles in some pre-planned time sequence. In order to do

this precisely, the jaws of the gripper must open at a particu-
lar instant of time, close in some fraction of time, and open
again on schedule. Note the time specification of the unit in
Fig. 8-22. If the unit is operated by hydraulics or pneumatics
the time is 0.2 seconds, which is very fast. If the unit is spring
activated then the time is longer by 50% to 0.3 seconds. If

these jaws were operated by an electric motor the time will

vary depending on how they were operated. Using a clutch,
gears, or a direct drive motor could vary the time to substan-
tially more than the fraction of a second stated for the hy-
draulic or pneumatic units.

A COMPARISON OF GRIPPER POWERING UNITS

We can make some comparisons among the three or four
types of activation units used to power robot grippers. First
let us list four types. Hydraulic uses a noncompressible oil or
similar working fluid. Pneumatic uses dry air or similar type
gas for operation. exhausted into the atmosphere
If the gas is

it must not be uses electric currents and

toxic. Electric
magnetic fields to produce the required forces. Spring is a
reactionary device responding to a compressing or expanding
force produced by some other means. Like the hammer
mechanism of a pistol, the spring can be cocked at a slow rate
and then released by some trigger mechanism. When it is
released it responds violently, and in a very short span of time
it returns to its rest state. A spring may or may not have

vibratory tendencies. A spring may come in many shapes and

332
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forms and sizes from the commonly visualized circular unit to
a simple bar-lever type arrangement. However, it is reac-
tionary, and must be driven to energy storage by
its state of
some other means. This requirement may or may not be a
disadvantage.

HYDRAULIC-ACTIVATED GRIPPERS
The hydraulic system works with a non-compressible
fluid. This means that there is no give in the system. It

consists of a storage tank apump or compressed air system to

apply pressure to this oil. The piston converts the pressure
into mechanical motion. The flow of oil to this piston is
regulated by the transfer valve, which means by which
is the
the robot brain can control the movement of the arm seg-
ments. The transfer valve is electrically operated. It consists
of a spindle which has large and small sections machined into
it. When the large sections cover the oil-flow ports, the oil is
shut off. When the small sections are in line with the oil-flow
ports, the oil can get by the spindle. The spindle thus must be
centered when a neutral signal is applied to the magnetic coil
which encompasses the spindle. The centering is usually
accomplished with a spring which is factory adjusted. From
the description we can assume that the speed of operation of
the piston will be governed by the speed of oil flow, and its
pressure.
The transfer valve is subject to two forces which can
cause some delay in operation. They are stiction and friction,
the friction being of a viscous type, while the stiction is a
molecular attraction which tends to cause a kind of binding
when two metal parts are very closely machined and put
together. In other words, a larger force would be required and
there would be some delay if the spindle were at rest when
move the spindle energized the magnetic field.
the signal to
To overcome this problem, it is customary to apply a low
frequency ac current to the magnetic winding and this causes
the spindle to vibrate at a high frequency with low amplitude.
Since it is thus in constant motion around its neutral position,
the stiction force is minimized, and a faster response is

obtained. But we must also remember that the working fluid,

336
oil,has a high density, and thus, even though it is light-
weight, (low SAE number) it also adds delay in motion. Thus,
while a hydraulic system is very fast in operation, it does have
some delay forces acting on its elements.
We can summarize the hydraulic type gripper, then, by
saying that it is very powerful and very fast. It requires some
ancillary equipment and it requires high pressure secure
lines, fittings, and seals.

THE PNEUMATIC SYSTEM

The air or pneumatic system is operated with com-
pressed air or a gas of similar type. Air is compressible, thus
under large back forces the system must apply more pressure
to adjust or the system will "give" a little. If the additional
pressure is applied and the back force
reduced suddenly, is

the system must accommodate andand so we have

adjust,
some tendency toward an oscillatory motion of the output
member of the system under these conditions. But air is much
less dense than oil and thus can move faster and so the
pneumatic system is probably the fastest system possible.
Valves, seals, and the working gas itself must be kept clean
and dry which means filters and other ancillary equipment to
do this task. The air, or inert gas, may be exhausted into the
atmosphere and the storage tank may be supplied from the
atmosphere using a pump, so, unless the system works in a
vacuum or under water it can get its working fluid from the
atmosphere and put it back into the atmosphere after using it!
The pneumatic system is fast and has the happy advantage of
being usable in reverse, or in a suction capacity. It can hold
items and can attract them and be otherwise of value in a
robotic system.
Because the air is compressible, it can be stored in tanks
where it can be drawn in low amounts for a long time to
activate some pistons through a transfer valve system similar
to that used in the hydraulic applications. Compressed air can
be used to pressurize a hydraulic system, and if the air is
contained in tanks, then the hydraulic system can be operated
without a pump or storage tank separate from the air-oil
supply cylinder. Of course in this arrangement the oil is not

337
returned to the cylinder after use, it must be expended out of
the system in some way.
The seals in an air operated system must be tight be-
cause the density of air is less than oil. A transfer valve used
in the airsystem must also overcome stiction and viscous
even though the viscosity of the air is very low. Then,
friction
as we have stated, the air must be dry (inert gas is often used
because of this), and the air must be clean, requiring filters
with micron size holes in them.

THE ELECTRICALLY OPERATED GRIPPER

Perhaps the most versatile powering system is electric-
ity. It is easily controlled through well known means, and as
we have seen, motors can be mounted directly at the point of
usage and screw drives or clutches or cables can be used to
transmit the mechanical power. Electric motors are reliable,
have long life, can be well sealed, have no leakage problems,
require no tight seals and so on.
The motor also has a disadvantage or two. First, in order
to get lots ofpower one must have a powerful motor which
means bulk in size, and they are heavy. If one uses a gear train
to develop the required power, delays in movement must be
expected unless the motor turns at a fantastic speed. The
armature is heavy so there is always the inertial overshoot
problem to content with, snap-close clutches tend to wear
and have to be replaced and cable drive systems can become
loose if they do not receive constant attention. All of these
problems can be overcome, however, and the advantages
make it worth it.
Some advantages of additional importance are that the
electric motors can be controlled with either ac or dc electric-
ity. They can develop, through their own back emf, voltages

and currents proportional to their speed and these can be read

directly for control purposes. This prevents or helps to pre-
vent overshoot and subsequent oscillation or hunting. Elec-
tric stepper motors can be moved precisely with electronic

pulses, and a computer can keep track of exactly how much

the motor has moved. Solenoid-type magnetic units can cock

338
spring loaded units, which then can be released by another
magnetic trigger creating very fast operation.

SUMMARY ON GRIPPER POWERING METHODS

To summarize on the powering system for grippers we
might list the pneumatic system as fastest, using compress-
ible gas, requiring excellent filtering and tight seals, and
producing a good powering level. It can be used on delicate
operations.
The hydraulic system is the most powerful, requires
ancillary equipment to pressurize the oil, needs good tight
seals and is slightly slower than the pneumatic system.
The electric system is versatile and comes in many
forms, is easy to control, but can be bulky and heavy if lots of
power is required. It can also be used on delicate operations.

GRIPPER SENSORS
We must not leave this discussion concerning grippers
without mentioning the feedback units which can be used with
such end-devices. We know that many countries are experi-
menting with fibre-optic systems built into the gripper to give
the control computer some knowledge of the proximity of
objects, the shape of objects, and when the gripper has such
items in its grasp.
Examine Fig. 8-23 where the angular type gripper might
not be most suitable because the light beams might not
constantly impinge on the receptor units in the fingers. In A
we see the static condition of a gripper and the light beams
from the generators going directly across the open space to
the receptors where they cause
signals to be sent to the
computer. If you
imagine the top finger and bottom finger
will
pivoting as they open to grasp something, you will see how
moved toward the end of the finger and
the light beams will be
no longer impinge perpendicularly on the lower finger recep-
tors. See part B of Fig. 8-23. You might consider this to be a
valuable effect if you let the beams activate the receptors, say

2, 3, 4, and then 3, 4 and then finally, just 4 and let the signals

339
thereby generated inform the computer controller just how
far the jaws have opened. Then if the beam is interrupted
completely, the computer knows an object has come between
the fingers and can initiate closing of them.
If we consider a parallel gripper finger movement such
as previously described, then we note that all beams stay
positioned on their respective receptors from wide open to
close position of the fingers. This fact can be used to let the
computer know how far inside the jaws an object has been
positioned as well as the fact that it has been positioned
therein. This could be of value in some applications.
Some system
applications might use a gripper-finger
wherein would be emitted from each finger outward and
light

a receptor near the emitter would then receive a reflection

when an object was encountered. This idea could be used to
help the gripper find an object on a belt, or help it be re-
positioned by the computer brain of the robot when items
come along some feeder system with some discrepancies in
their position. There are many ways in which this type of
sensor might be used in a robotic system gripper.
Another sensor which has been used is the proximity
switch system or the back pressure switch system which
enables the robot's brain to apply just the right pressure to the
fingers to firmly grasp an object once it has found it and has it

within its fingers or jaws. We have had some examples of this

type switch system in the Mini-Mover- 5 system. The back
pressure switch outlet is shown on the Fibro-Manta specifica-
tion drawings, Figs. 8-21 and 8-22. We know it is relatively
easy to incorporate such a switch in the fingers themselves. It
can be closed when a given pressure is applied. These switch
sensors are very reliable and very commonly used.
If the objects being handled are metal of a ferro-magnetic
type, then one might imagine a gripper made of some non-
metallic substance and inside this gripper a sensor which can
generate a magnetic which will be routed with more
field
intensity through its windings when ferrous material comes
into its field. The closer the object is to the generated mag-
netic field the stronger the sensor signal would be, thus we
have a proximity sensing device with no moving parts. It can

340
341
be very sensitive and very reliable. There are many ways a
magnetic field might be used as a sensor system in a robot's
grippers.

POSITION SENSORS FOR GRIPPERS

The type sensors we have discussed have been of a
proximity type. They can inform the computer that an object
is present, where
it is with respect to the grippers jaws, and

so on. Now we
want to consider some simple type sensors
which can inform the computer of the actual physical position
of the grippers jaws. Refer to Fig. 8-24.
At A on the figure we can see a linear potentiometer
which has been connected mechanically to the bolt-screw
arrangment which translates back and forth to open and close
the gripper fingers. At this particular point of the mechanism
the motion is a translation and so a linear translatory poten-
tiometer can be used. The translatory potentiometer can be
calibrated so that a fraction of a volt represents a fraction of an
inch. It will give a signal amplitude directly proportional to
the position of the fingers since they move together and in the
same opening or closing direction. Notice that only one need
be used because of the simultaneous and twin action, of the
fingers. If the linear potentiometer is used in a bridge as
shown to the right, then opening the fingers will (or can)
produce a negative signal with respect to ground, and a
closing of the fingers will produce a positive voltage. Now we
have both amount of motion and direction specified by an
analog voltage.
At B on that same section of Fig. 8-24 we show how a
regular circular or semicircular potentiometer might be used
in the same manner. The arm of the potentiometer must be
fastened to the finger at the pivot point so when the finger
rotates about this point it will turn the wiper. The body of the
potentiometer must be fixed in place as had to be done for the
linear potentiometer. The housing shell or frame on which the
fingers are mounted can be used for this purpose. It would
work in the same manner as the linear pot.
At C on the figure we see how a resolver might be used
to give amplitude and direction information to a computer. It

342
343
has to be mounted in a similar manner to the circular poten-
tiometer. It has an armature which must rotate with the
movement of the finger. The stator part of this unit has to be
fixed. When the rotor or armature is turned, an ac signal is

produced from this unit which has a phase relationship di-

rectly proportional to the displacement. The amplitude of the
signal is proportional to the amount the armature has been
turned. This an ac system which is quite commonly used in
is

servo mechanisms for position feedback information. Again,

note that only one unit is required to give information on the
fingers because they move simultaneously, and always in the
same direction.
Finally,examine Fig. 8-24 D which is simply a parallel
type gripper equipped with a linear translatory potentiometer
to measure and generate signals proportional to the finger and
direction. It works the same way A did.
It is possible that one might ask why we need position

information on the fingers of a gripper. First because the

gripper fingers want to be opened to receive or grasp some-
thing and the robot's brain will want to know that the fingers
have opened to the proper degree. Second, the fingers will
want to be closed only a specified amount in some cases to
receive specially constructed items. Again the robot's brain
wants to know that when it initiates a signal for the fingers to
close, they have done so, and to the amount specified. It is

much the same as our human requirements to know our hands

have our fingers open to pick up something, or that our fingers
are pre-positioned tomake grasping of special objects easier.
We also like to know when our fingers have opened to release
the object, although we are not really conscious that we have
obtained this feedback information. Our eyes simply tell us
we have put a book on a shelf, replaced a mechanics tool, or
laid down a pencil or whatever.
So we have proximity sensors and position sensors. Do
we need any others? You might well answer yes without fear
of contradiction. If the robot is working in an environment
where temperature is a factor on the parts it handles, then,
perhaps, it needs a temperature sensor to tell it when it can
handle a part and when it cannot handle that part. If a grinding

344
operation is being done then the robotic brain might like to
know when the part is reaching a too-high temperature due to
the abrasion, and thus pull it away from the grinding wheel.
Temperature sensors in the form of thermocouples are com-
monly used in automobiles and in our homes on water-heaters
and perhaps in other places. They can generate a voltage
which can cause a switch to open or close and thus produce
the high temperature warning signal. It is possible, also, that
the thermocouple can generate voltages proportional to the
temperature so one could have gradual control over a heat-
application process if this was necessary.
What else might we use? How about a vibration sensor?
This might let know when some object being
the robotic brain
handled was not going through its process smoothly for some
reason. If the mating of a part is not a good smooth operation
then excessive vibration could occur which would be felt. The
vibration sensor, in turn, would sense this and send the signal
alarm. Here, again, it is an item which is commonly used in
the market place. This type sensor used on large window is

glass to signal breakage, thus security systems have them,

and instructions as to their use, and security people have
experience in their use. You wouldn't want such a sensor to be
too sensitive as there is always some vibratory action in a
mechanical robot.
If you are an engineer or experienced experimenter then

perhaps you desire some kind of speed-of-operation or

speed-of- motion signal. This signal can be obtained using
derivative electronic circuits, into which a part of the position
signal is fed. One could also use some kind of small tachome-
ter attached, to moving elements to produce a signal propor-
tional to the speed of movement. Remember that the rate-of-
change of position is velocity, and so a first derivative circuit
whose input is the feedback position signal should produce a
signal which is proportional to the velocity of movement.

SUMMARY ON GRIPPER SENSORS

There no doubt but what a robot's gripper must have
is

some kind of sensing devices built-in,

if it is to do expanded

and complex tasks. It must also have some kind of compliance

345
so that the gripper can adjust to the shape of the object it

handles, especially if the object changes in size and/or shape

in various batch units. Grippers must be matched to the task
they are involved with, such as high temperatures or very
tight gripping.
You may be thinking ahead and wondering just how
optics, or the fact that robots can be equipped with eyes,
might affect the gripper sensor concept. Giving the robot
eyes will assist it, but gripper sensors still may be required.

346
 Robotic Eyes

In Chapter 4 we looked at the Cincinnati Milacron T 3

robot.
Now we want to consider this robot again with respect to
some features which are pertinent to what we have been
discussing. As a stepping off point for this chapter, let us
examine Fig. 9-1 which is another view of this modern robotic
arm for industrial type applications.
We should be pretty knowledgeable about what we are
looking at. There is a base section, lower arm section, its

rotary electrohydraulic driving motor, the upper arm section

which is operated by a piston type linear hydraulic system,
and finally out to the wrist and gripper which are also oper-
ated by electrohydraulic units. Notice that in the illustration
the gripper s are of the parallel movement type, that the jaws
are shaped to accommodate round or similar shaped objects,
and that the grippers have a small thin compliance sheet built
into them.
In an industrial application, of course, there can be a lot
of dirt from the products, or processing of the products. In
these locations and situations, of course, you would want the
robot to be adequately protected by sealing, and with covers
on the moving mechanisms so it won't acquire any debris
which might cause premature wear, inaccurate operation, or

347
 fc&h

Fig. 9-1 .The Cincinnati Milacron T robotic arm (courtesy Cincinnati Milacron)

excessive down time of the system. As you notice, the T3 is so

protected. It is also of interest to see the complexity of the
wrist giving the equivalent of a human's wrist movements.
it

In the specifications for this robot, we find that the

servomechanisms use both the position feedback we have
discussed and also a velocity feedback. The position feedback
is through the use of resolvers which operate on ac, and a
tachometer-generator which produces a voltage proportional
to the speed of movement. These two feedback signals enable
the servocomputer to adjust the movement and operation of
every axis of the robotic arm to a smooth and fast operation.
You might want to go back and review Chapter 4 for the
operation and teaching method employed with this robot.
We have mentioned the velocity-of-movement feedback,
but perhaps we have not specified just how fast such a robotic

348
arm moves when it does a task for us. This Milacron robotic
arm can move from one inch-per-second to as fast as 127.5
inches-per-second and this velocity range can be adjusted in
increments of 0.5 inch-per-second units. Its precision-in-
location ability means that it can return to the same over and
over with an accuracy of plus-minus .025 inch. A way of
visualizing this accuracy is to know that it represents 1/40 of
an inch. You know what a 32nd of an inch is, so tighten up a
little on this distance and you'll have the l/40th of an inch

distance.
There are some types of applications where tolerances
must be even more precise. In fitting a bolt or a shaft into a
tight tolerance hole, an accuracy of 1/64 th inch or even better
might be desired! Even then some wobble may be incorpo-
rated into the robot's wrist movement to cause the tight
fitting object to go into the hole as it is supposed to. Figure 9-2

ANGL LAR POSITIONING ERROR

A
j$r

BOLT
^U— WONT MATE AT THIS
i

ANGLE
3f

PLATE )

) 1

Fig. 9-2. A tight tolerance fit requires precision positioning.

349
illustrates how just a small off-set can make it difficult if not
impossible, to get a bolt or shaft into a closely machined hole.
Perhaps the problem of getting a servomechanism to have
even greater than usual position accuracy on a repeatable
basis will be solved, and the limit of such accuracy may
astonish all of us!
When we consider an industrial robot as shown in Fig.
9-1 we also want to be aware that this type unit can be
programmed to perform a series of operations with one tool
as its end unit and then change to another tool to do some
other operation. The wrist connection must be such that a
quick disconnect and quick connection can be accommodated,
and with all power connections necessary to make the
the
new tool operate in whatever manner it is designed to oper-
ate. When we think about this for a moment we realize that
there is more to a tool changing operation that is first
apparent.
One other item of information which we now should be
aware of and which we have not mentioned prior to this is the
concept of a rotary hydraulic actuator. They exist and they are
rather common. They are much used in marine operations.
They can be precisely controlled to rotate small or large
amounts and they have considerable power. If you are in-
terested in going into this subject deeper, I suggest a good
text on hydraulic engineering from your local library.
It is always interesting to see a robot arm in action. If you

examine Fig. 9-3 you can get one idea of how this Milacron
robot appears on location and in action. One other view of this
robot in action can be seen in Fig. 9-4. What is interesting
about this picture is that this is just one station of a two station
operation. Shown is a refrigerator liner which is made of thin
gauge plastic and due to its large size is difficult to handle.
One robot arm removes the from a moving conveyor and
liner
places it in a removed from this trimming
trim press, then it is

press by a second robot which again hangs it on the moving

conveyor overhead. The two robots must work together in
coordination and must know all about the orientation of the
linear to insure it will be properly trimmed and will not be fed
to the next station up-side-down!

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352
THE QUEST FOR IMPROVEMENT OF INDUSTRIAL ROBOTS
Time marches on and improvements and breakthroughs
in technology make possible concepts, ideas, and things
which are almost incredulous. Improving an industrial robot
may not be anincredulous feat, but it is worth some time and
attention. And, like our mini and micro computers, robotic
systems do improve as time advances. We will examine one
such development.
Turn to Fig. 9-5 where the newest of the Cincinnati
Milacron robots is shown. The immediate focus of our atten-
tion is on the new wrist development shown. This is a three-
roll wrist and if we look back to Fig. 9-1 we can see how the

wrist complexity has been reduced in this later version. The

upper arm and wrist are more slender and the powering units
for the wrist and gripper are now mounted at the elbow joint of
the upper arm. Physical linkages are contained inside the
upper arm so that it is very clean in appearance.
It is of some importance to discuss the use of such a robot

on an automobile assembly line such as at the General Motors

Lakewood, Georgia plant. The robots are used to spot weld
about 9600 welds per hour on as many as 48 car bodies which

3
Fig. 9-5. The "F^R Milacron robotic arm has a three-roll wrist. Compare this arm
construction to that of Figure 9-1 (courtesy Cincinnati Milacron).

353
pass its station each hour. 200 welds per body are ac-
complished, and that means the robotic arm must operate
quickly and precisely to do this job. Four such robotic arms
arm can
are used. With a capability called tracking the robotic
move as the car body moves so that the welding takes place in
a continuous fashion, and the conveyor line never has to be
stopped. It is makes no difference whether the line
said that it

speeds up or slows down, the ability of the arm to operate

faster or slower, going to the precise positions where the
welds are to be made, is accomplished by position sensors

which are attached to the conveyor belt and electrically inter-

faced with the robot's computer control center. Thus we learn
even more about how such a robot is used and how it operates
in the industrial application. With these position sensors on
the conveyor belt, a continuous signal is sent to the robot's
brain telling it the exact position at all times of the car bodies.
Inside the robot's computer brain is a section which can take
this feedback signal and use it to the previously taught weld-
ing program and the arm's position so that it moves to new
locations at the proper speeds to compensate for the car's
movement.

THE MILACRON THREE -ROLL WRIST

The new wrist design which we examined in Fig. 9-5,
and which is called the three-roll wrist, is shaped like a
sphere about 8 inches in diameter and has built into it three
roll axes. Two of these axes work together to give the robot
arm 230 degrees of pitch (up and down) and 230 degrees of
yaw (side to side) motion. The third roll axis is aligned so that
it permits continuous rotation of the wrist with whatever tool
may be affixed thereto.
Once again, with remote drives to make the wrist func-
tion, resolver position feedbacks and tachometer feedbacks
on each axis, and each axis controlled independently by its

own servomechanism, the arm functions with a high degree of

precision. Its positional accuracy is within .020 inches. It is

quite an accomplishment to move

mighty arm around so
that
quickly and yet to within that small of an error of a defined
point in three dimensional space. Please note that many of the

354
industrial robots achieve this accuracy, or better accuracies
than this. The discussion of accuracy is in connection with the
generic robotic generation of our time, not any single system,
although we are examining the Milacron as one example of a
fine robotic arm.

THE ROBOTIC EYE OR OPTICS CONTROL

was delighted when I first saw the small robot mounted
I

on wheeled cart that was like a child's wagon. It was self

a four
propelled and steerable, and carryed the robot (shaped some-
thing like the upper half of ahuman torso) along with astonish-
ing speed. The head turning to look at various scenes around
this robot. I was told that this was an inspection robot which
was patrolling the yard of an industrial complex. It moved fast
and saw everything and then relayed, through a special mi-
crowave or ultra high frequency channel, the information
about what it was seeing back to a central control station
where the guiding mechanism— a human being— was in-
volved with steering, stopping, starting, and evaluating the
picture received from this remotely controlled robot. Figure
9-6 illustrates the general concept of this unit.
The robot has no hands or arms. Its purpose is simply to
run around the area's complex looking at everything and
relaying the information back to control-central. It worked
much faster on patrol than a human might, and in case there
was danger from penetrators, its metal armor could shield it
while it informed its master what was going on. It never tired,
and aside from a pit stop now and then for a new batten-
supply, it could patrol constantly and for indefinitely long
periods of time. Its eye protruding from the front of the round
head actually is the snout of a TV camera and on its head
protrude two antenna, one for transmission and the other for
reception of the required TV and guidance signals. Some
plaything!
But it has its purpose and can do a job for its owner. It
never tries to fight back if it runs into culprits, so it doesn't
need guns and it may not even need a voice although it would
be an easy task to incorporate a speaker which would relay its

owners voice if questioning or demanding were in order.

355
 Let us now proceed to investigate some hard facts about
just what robotic eyes are, how they work, and what their
capabilities and limitations are.
There is no way at present to provide a robot with all the
visual capabilities that a human has developed. To elaborate
on this idea, think of all the various scenes that you can
immediately identify. Think also how the human brain can
identify size and shape and coloring and structure and com-
position and distances. Can a robot's eyes do this? Can it do it
for all the countless pictures which the human brain has in its
storage bins?
What we are saying is that perhaps the hobbyist's dream
of having a robot, with eyes roll down the street and say good
morning to Mrs. Smith and Mrs. Jones and Candy and Jim as
the robot seesthem and identifies them, seems unlikely. Of
course, if we provide the robot's brain with pictures of these
people and it can then compare the picture it sees with what
we have given it, it might. Polaroid and Bell Labs have both
been working on computer recognition.
In the industrial situation we find it very desirable to
give a robot some eyes. If it can identify a particular part
amongst many parts passing by on a conveyor belt, that can be
most useful. If it can watch and follow and adjust for parts
misorientation and placement and such, that also can be most
advantageous. So there are many prominent companies en-
gaged in developing robotic eyes for use in the industrial
scene as we shall see. For the hobby scene, it may be some
time before the use of eyes on a robot becomes worthwhile to
incorporate. The basic question is what advantage is there to
giving the robotsome vision?
The remote-controlled robot might be clad in asbestos
armor for going into a flaming floor of a home or office or
warehouse and seeing what is there, and perhaps accomplish-
ing a rescue attempt. For underwater robots, one must cer-
tainly have some vision transmitted to the control center so
that a human might send commands to make the robot fix or
adjust things underwater. The seeing robot can be very useful
if it extends our own vision capabilities. Visual feedback may
also help to eliminate the stringent accuracy requirements in

356
 ANTENNA

Fig. 9-6. A remote-controlled "seeing eye" robot.

the workplace. If the robot can see what it is doing, the arm
can adjust the manipulator so that the task is accomplished.
Seeing as we use the word here, may not be precisely the
same as seeing related to the human optic operation.
Let us examine what is meant by seeing in an industrial
application. A robot is going to be able to reproduce what it
sees in a digitized form so it can compare it to a previously
saved picture and make adjustments in the arm. Examine Fig.
9-7.
The camera is pointed where the object is to appear and
instructed to follow, or keep track of it. When a picture is
obtained, must be analyzed by the microcomputer and
it

identified. If the part is misorientated a match does not occur.

The camera may be moved slightly to see if it is the camera
angle which is responsible. If this is not the case, then the
system must order the robot's hand to move the object around
to see if the proper orientation can be obtained. If the proper
orientation cannot be obtained, the microcomputer decides
that this object has no business being there and will instruct
the gripper to separate it for human inspection.

357
 LIGHT CAMERA
REFLECTIONS =^> -Tl|
I SCANNER

ELECT SIGNAL
V
MICRO
COMPUTER
ANALYSIS

X
CAMERA
MOVED TO NO y YES ROBOT ARM
SEARCH SELECTS &
LIMITED GRASPS-MOVES
SPACE
IDENTIFICATIC MSI
& RECOGNITIC )N

Fig. 9-7. A basic block diagram of a vision system for a robot.

Assume that a robot is using visual feedback to insert a

guidepin in a hole. To provide position information, the sys-
tem will track four features of the scene; the hole, the tip of
the pin and both sides of the pin. These are three totally
different features. A dark blob is the hole. A complex curved
bottom edge, and the sides are straight vertical
line is the pin
lines. The computer knows there must be a certain specific
relationship between the curve and the blob, and the straight
lines and the blob, and these must occur simultaneously. It
then steers the robot's hand to try to accomplish this.
We are now confronted with getting some dimensional
coordinates of the object which the hand is to take hold of.

Notice that the Z coordinate in Fig. 9-8 is the distance

from the camera to the object. The X coordinate is the left-
right position, and the Y coordinate would be the forward-
back position. Imagine an object coming along a conveyor
belt. If the camera were exactly aligned, the object would
move from -X direction, through zero, and on out to the +X
direction. The Y coordinate might be zero all this time. The Z
coordinate (the distance) will change as the object moves
directly under the camera and then away from it.
Imagine the picture that might be seen by the camera. If
we have a monitor screen to look at, we might see the dark
shape appear at one side of the screen and vanish off the other

358
Fig. 9-8. The camera coordinates of a system for robotic vision.

end unless the gripper appears to grasp it. A pictorial rep-

resentation of the situation is given in Fig. 9-9. The computer,
which is directing the operation of the robotic arm, will have
been informed where the objects are to appear, the shape they
should have and of course their existence as denoted by a
darker blob of light reflected from the object than from its
conveyor. If the object is not in the position it should be in,

GRIPPER

Fig. 9-9. An imaginary monitor screen shows the "object" and the gripper, and
the motions of each.

359
then this might be a signal to put it in the proper position. If it
does not have the shape the computer thinks it should have
then the computer might stop the conveyor and have the robot
re-position it. If this cannot be accomplished the computer
will decide that the part is not useful and discard it.

THE VISION WINDOW

The computer cannot look at the whole screen all the
time, so it finds it convenient to establish windows to get
useful information concerning the object it is looking at. We
might illustrate this as shown in Fig. 9-10.
The computer finds the hole blob where it should be, in
window 2, and moving in a straight line toward window 5. It
finds the bolt blob occupying window 1, window 4, and win-
dow 2. If the bolt were positioned properly, it could not be
seen in window 4 at the same time that it is seen in window 1.
So the computer has something to go on to adjust the bolt's
orientation. If necessary the computer can shrink or expand
the size of the windows.

NOTE
BOLT-ONLY SECTIONS IN
WINDOWS ARE VISIBLE
WE SHOW ALL OF BOLT END FOR CLARITY

\ ^
\

1 \ ^4 7 10

BOLT HOLE
\ N BLOB
^

2 5 8 11

3 6 9 12
I
Fig. 9-10. Robot-Vision "windows" depicted on an imaginary display monitor.

360
 PREDICT
FEATURE
LOCATION
&
SIZE

V
EXTRACT
WINDOW

V
DETERMINE
Fig. 9-11. A robot-vision tracking
FEATURE
system block diagram. TYPE

v
LOCATE
FEATURE

V
UPDATE
TRACKER

Many robotic eyes are light-sensitive cells arranged in a

matrix. Each cell produces a signal whose intensity or polar-
ity is a function of the amount of light falling on it. The
light-gathering unit is the lens system in front of the matrix.
Figure 9-11 shows what the seeing robot has to do in a
situation where it is required to follow an object or track its
position. The computer identifies a feature of the blob that it
sees. This feature may be the round segment of the hole. It
could be the straight parallel lines which tell the computer it
is It could be the shaped curve of the bolt
looking at the bolt.
tip,which is a different curve from that of the hole. The
system tracks the feature by causing movement of the robotic
arm, hand, or camera.
Scanning a matrix window and producing a voltage ac-
cording to the various shades of color from white, then digitiz-
ing this voltage and giving that information to the microcom-
puter is how it needs
the computer can get the information
from the robotic-eye system. The computer can then compare
this digitized signal with memorized signals in its memory
bank, and do something as a result of this comparison. Figure

361
9-12 may be helpful. Each window may be scanned separately
in a high resolution system. The scanning process is just like

standard TV technology.

USING THE MATRIX EYE

Scanning a light sensitive surface with a beam is one
method of converting light into voltages. A better way is to
have a grid which is composed of an incredible number of
small wires running vertically and horizontally and then tap-
ping into this matrix by means of a computer like system and
reading the voltages produced at each cross-wire junction.
General Electric has such an eye and we show it in Fig. 9-13.
General Electric calls their new camera the TN 2200 and
ituses a charge injection device, (CID) to convert the light
energy into an electrical signal. The system resolution can be
enhanced by use of an appropriate system of lenses.
With the grid system the X and Y coordinates of the
object will be defined by the electrical charge at the junctions
in the grid field. The Z coordinate can be determined by the
intensity of that charge.

SOME BASICS OF
ROBOTIC-VISION COORDINATE DETERMINATION
Figure 9-4 shows the military problem of trying to hit an
airplane with an artillery shell. The first task in that problem
is trying to define the position of the airplane in a three
dimensional world. That is, its altitude, its azimuth, and its

distance. Here we assume that the observer's position is the

origin of the coordinate system. The airplane is flying along a
path which is directly on the X axis, and it is approaching the
observer at a constant altitude Z. As shown we could say the
plane has at this moment an X coordinate of 18 units, a Z
coordinate of 14 units and zero Y coordinate. The TV camera
can certainly provide information on two dimensions of that
space, but what about the third measurement. How can a TV
camera give us range information?
The human eye is able to perceive distance because two
eyes are used. There is some distance between them, and the
brain can perform the necessary calculations (and we aren't

362
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Z DISTANCE

OBSERVER
IS COORDINATE
ORIGIN POINT

Fig. 9-14. A three-dimensional airplane position situation.

even aware it is doing so) to tell us the distance of an object.

This system is called triangulation and, the answer, of course,
yes, it can be used in robotic applications. Let us examine
Figs. 9-15 and 9-16. Figure 9-15 uses a laser and one camera;
Fig. 9-16 uses two TV cameras. They examine a given point
The base distance between
or object through identical angles.
the cameras known. A side and two angles are known. The
is

other two sides can be determined. The range is then calcu-

lated. The angle is how far the head is turned. Polar coordi-
nates are converted to Cartesian (X,Y) and then the elevation
(Z) is found.
You will recall that we have to track the recognizable
edge or curve of a particular shape. Our range finding system
must be able to differentiate, in perhaps fractions of a millime-
ter, the distances to various sides of, say, a hexigon shaped
nut. Whereas a camera might not be capable of this as Radar
and Sonar are.

THE RECOGNIZER, THE

COMPUTER, AND THE CONTROL SYSTEM
The recognizer is that part of the system which identifies
some characteristic of the object. It may be the outline,
reflectivity, position, or something of that nature. Figure 9-17
is a block diagram. If the recognition is satisfactory the com-

365
 4 i

TARGET
-X2 o X2 +X2

X1
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(AX)

-X1 o /J ( +x

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AZ Z2- Zi OS-
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LASER

fl
LIGHT
SOURCE
TV CAMERA

Fig. 9-15. One concept of distance measurement using a TV type camera

imaging system.

puter orders the control system to do something to the object.

If the recognition is not satisfactory then a new look is or-

dered. The system tries to identify the object as something

which should be there, even though it doesn't have exactly the
right position or orientation.

THE SYSTEM CONCEPT OF G.E. 0PT0MATI0N

We have mentioned the G.E. CID video camera.
Examine it in Fig. 9-18. It is not very large and it differs in

366
configuration from the camera we have examined in Fig. 9-13,
but the operation is the same. The basic concepts underlying
the Optomation video system are three.
The first is visual observation with the CID camera.
Because it has a very stable coordinate, system, it can effec-
tively super-impose a stable and repeatable measurement
grid over the object under observation.
The second is the recognition of the object by the extrac-
tion of some of its key features.
Finally, based on observation and recognition, some kind
of decision is arrived at by the computer controller.

X- — — ax J Tax,az is area of
[uncertain position)

DESIRED
DISTANCE
MEASUREMENT
I

Z3

t GRIPPER

BASE DISTANCE
EFERENCE PLANE

Fig. 9-16. Triangulation measurement of range using two TV cameras.

367
 CAMERA L
CONTROL CAM
(ADJUST) r-
WINDOW "
—
iI

1 >

WINDOW INPUT
DATA

\t

ANALYSIS
&
COMPARISON

/ANALYSIS^
NEW
WINDOW *
/ COMPLETE'\ INFORM
SITUATION NO v (IDENTIFI- / YES COMPUTER
REQUIRED

i t

CONTROL
SYSTEM
OPERATION

Fig. 9-17. Robotic-vision recognition system, block diagram.

system development a strategy has been em-

In the
ployed which says that there will be two levels of viewing. In
the Level I system operation the objects are placed in the
camera's field of vision in a carefully pre-determined orienta-
tion. The system then obtains such information as length,
height, area, and relative or absolute location. The relative
location may be the position of the object with respect to the
robotic gripper. The may be the object's
absolute location
location with respect to camera. In this system simple shape
recognition can be accomplished by comparison of the viewed
object with a feature set which has been memorized from a
previous image. If desired a multitude of electronic windows
can be used all at the same time, to make many measurements
simultaneously. The Level II system operates on all the
things the Level I does and also can examine randomly
oriented objects.

THE CAMERA ROBOT INTERFACE

The interfacing unit feeds the robotic control system
signals from the camera. The G.E. interfacing unit requires

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only that a cycle control pulse be sent to it. This pulse informs
the interfacing unit that the camera data is ready to be ac-
cepted by the computing section. It also causes a new frame of
video to be put into the feature extraction section. This, in
turn, causes a new set of measurements to be taken.
There are 8 separate decision outputs available to the
computer and control system from the interface unit. These
may be in either one of two forms. They may be in TTL
positive true logic levels or a one amp, 60 Hz control signal of
either 110 or 220 volts, present when the output is true. A
strobe interface is provided in this system to synchronize a
stroboscopic lighting system with the input cycle.

DECISION GENERATION IN THE 0PT0MATI0N SYSTEM

The contents of the decision state registers provide
input data for the decision generation function. These regis-
ters are updated each time a measurement cycle is per-
formed. Notice how the camera is used in this robotic applica-
tion. It is providing both measurements of position and recog-
nition of objects in its field of view.
Going to the decision registers we note that a variety of
output decisions can be generated from the input decision
states. A part may be rejected, or selected, on the basis of
only height measurement. It can be rejected if the height is

too large or too small. A part may be rejected because its

width and total area are not within specifications.

A delay function is also available and output decisions
may be delayed by as 255 measurement cycles. The
as much
delay interval determined by an 8-bit binary number which
is

can be set by the human programmer using another system of

multipole switches on the programming panel.
In Fig. 9-20 we examine the system's control panel. At
the top are the multipole switches and the top section is
labeled "Control Panel". On the second broad row the first

unit is the decision logic panel and next to it is a data readout

panel. This panel shows the decision outputs, the binary
values, the channel routing and a section to compare results
and the decimal value of the binary readout. In the third row
down, on the left, is shown the feature control section and the

371
Channel 1 and the Channel 2 blocks. On the right of this
section is the sequence step constants section. On the bottom
row we find the section for window control.

0PT0MATI0N SYSTEM OPERATION

The PN 2303 system has seven primary modules as you
can see from an inspection of Fig. 9-19. These can be desig-
nated as; the camera unit, the input data conditioning unit, the
feature extraction unit, the data analysis unit, the decision
generation unit, the machine interface unit, and the monitor
and control unit.

Fig. 9-20. The G.E. Optomation system control panel.

372
 The camera unit is a logical starting point. It has a CID
eye which means that it is composed of a mosaic of solid state
light sensitive elements called pixels. The TN 2200 of Fig.
9-13 has 16,384 pixels, and the TN 2201 has 14,364 pixels.
Pixel time is the time required to scan a single pixel or light
sensitive point. Pixel time for the G.E. TN-2200 camera is 10
clock periods.
Frame time is the time required to scan a full array of
CID elements and it includes the blanking time. The TN-2200
frame time equals 17,688 pixel times and the TN-2201 frame
time is equal to 16,608 pixel times. The line time is that time
required to scan a single line of pixels and it includes the
blanking time. For the TN-2200 it is 134 pixel times and for
the TN-2201 it is 48 pixel times.
As used in the schematic diagram the X,Y, and Z axes are
the same as an oscilloscope's axes. X is left-right, Y is up-
down, Z is bright-dim.
As we develop this subject we will be seeing some
abbreviations, and so definitions of them will also be useful
here. TTL is transistor-transistor-logic. LRR is line re-read.
Inhibit Input is abbreviated II. EOL is end-of-line and refers

to a CMOS output of the camera that goes negative when the

last element EOF stands for end-of-frame
in a line is selected.
and this is similar to the EOL except that it refers to the last
pixel of the frame. EOL and EOF are used to designate
retrace. STROBE is flash lighting.

In the TN-2200 unit the pixels are located just 0.0018

inches apart from center to center. The camera will accept
standard C mount lenses which have a fixed back mounting
flange length of 0.69 inches. The camera uses plus and minus
15 volts dc at under 50 milliamperes, and there is a 12
conductor cable used to attach the camera to its ancillary

equipment.
There is a relationship between a lens picture size and
the actual size of an object. The camera under study at the
moment has a chart relationship which defines the size of the
object as seen by the camera in terms of a ratio of object size
to distance. The focal length of the lens is the factor which
governs this ratio, as follows:

373
 Focal Length Object Size/Object Distance
mm inches
4.5 0.18 1.3
6.5 0.26 0.89
9 0.35 0.65
12.5 0.50 0.46
16 0.63 0.37
17 0.67 0.34
25 1.0 0.23
35 1.4 0.17
50 2.0 0.12
75 3.0 0.08
100 4.0 0.06

To view a 6-inch object at a 4-foot distance, the object

size/distance ratio is 0.5/4 = 0.125. Therefore, a 50 mm lens
is appropriate for this application.
The video output signal of the camera can be converted
to a TTL level signal with a threshold anywhere in the gray
scale required. A simple conversion is shown in Fig. 9-21.

THE INDUSTRIAL VIDEO-INSPECTION SYSTEM

Figure 9-22 is a block diagram of the industrial video
inspection system which shows us in a very simple arrange-
ment how the robotic eye can be used gainfully. The signal
processor shown is the computer. When it defines a part as

+5V

100K

PIN M 10K
VIDEO 100 n TTL
TO
^w^- SIGNAL
CAMERA 10K
PIN N 301
VIDEO
RETURN- i
THRESHOLD
OP AMP

SETTING /

R" CHOSEN TO MATCH VIDEO CABLE

Fig. 9-21. A Video to TTL (transistor-transistor logic) signal conversion circuit.

374
 POWER

^ J?
'/l\
LIGHT
SUPPLY

®Q TN2200
i

— *,

- Z
- X

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SWEEP kiOMlTOQ
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A /D
YEOLDE SIGNAL
ROBOTIC EYE! PROCESSOR

EOL- EOF 1 1
VIDEO STROBE
BAD GOOD
PART PART

OUTPUT TO
SORTING MECHANISM

Fig. 9-22. An industrial

inspection system using a G.E. robotic eye. The speed of
scan is chosen match the signal processor requirements, and is controlled by
to
setting the clock frequency. The decision as to whether or not the part is good or
bad is made by the signal processor which may be a mini-or micro-computer
based system. An analog to digital conversion will be required for the video
signal if it is to be processed digitally. In many systems a monitor view of the
object is useful. A view may be presented by amplifying the video to modulate the
Z axis of an X,Y monitor. The Z axis is the light intensity on the monitor tube
presentation.

bad, the robotic arm and gripper are signaled to reach out,
grab that part, and convey it to the re-cycling area. If the part
is good, the robotic arm may pick it up and send it along
on another belt.

THE CID CAMERA CONSTRUCTION AND OPERATION

The signal readout is accomplished by a half-address
scheme which is similar in concept to the core memory
readout. The row scanner applies an address signal to a given
row, resulting in a half-address condition on all the row pads
in that row. (See Fig. 9-23.) The column scanner then sequen-

375
tially applies the appropriate address signals to each of the
columns, one at a time. This establishes a half-address condi-
tion on all the column pads in each column in turn. When all

the columns in a given row have been scanned the row

scanner increments to the next row and the process is re-
peated.
The result is a video signal in a television-like format.
This read-out is fast— usually 30 frames per second. Of
course this output is analog in nature and so to use it in a
microcomputer you have to feed it into an analog-to-digital
converter. There are many types described in the current
literature. If the signal is to be used directly by a robotic
control system, the converter in Fig. 9-21 can be used to
digitize it. The use of a video system for measurement of
parts size and shape can produce really good accuracy. In the
system described, it is claimed that an accuracy of up to 4 mils
(0.004) inch can be obtained using microscope-optics sys-
tems.

FOLLOWING THE VIDEO SIGNAL

If we again refer to Fig. 9-19 we see that the video is

immediately converted into a one-bit binary, black and white

signal. The threshold level is adjusted electronically, but
compensation for light variations can be made by adjusting the
camera lens setting or the aperture opening. The balance of
the equipment shown diagram uses the binary
in the block
TV monitor, which uses the raw
signal as input except for the
video. The system has a video mixer which permits the
processed video to be superimposed on the normal image as
an aid to setting up the system.
After the signals go into the feature and select switch
where information from the window generators unit may be
selected, the signals go the feature extraction section consist-
ing of the accumulators. Let us examine thewindow feature in
more detail.
The windows may be of any size or at any position within
the field of view. They may overlap if this is desired. The
position of each window is programmed by means of a set of 8
switches which set up binary numbers equivalent to the

376
Fig. 9-23. The robotic camera eye's CID (charge injection device) row-column
matrix system (courtesy G.E.).

column counts at the left and right edges of the window

desired. They also set up the line counts at which the top and
bottom of the window are to be located. The person looking at
the monitor can superimpose a white level signal on the
picture to show where the window is located. The output of
the window generator is sent to the input of the feature
extraction unit by means of a replaceable wire-interconnect
header. Any of the five window generators can be assigned to
any or all one
of the eight feature data accumulators, but only
window can be assigned to any one feature. As an example,
window 1 may be assigned to both feature A and B, but
windows 1 and 2 may not be assigned into feature A at the
same time.

WHAT IS FEATURE EXTRACTION?

We can gain some idea of what feature extraction is by
examination of Fig. 9-24. What the feature extraction function
does is to count the black and white pixels within the bound-
aries establishedby the window generators. The specific data
to be stored in the eight accumulators is determined by the
user. The type information which needs to be stored is
selected by setting the switches on the control panel. Each of
the small square blocks contains eight single pole switches.
we note that there are two
In the block diagram of Fig. 9-20
accumulator channels which can be used to store information.

377
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378
The reason for this is so that you can arrange for the storage of
the absolute values intwo sections and then you can get sums
and differences by comparing these values if this is desired or
necessary.
The feature control unit with all of its switches does
permit a great deal of flexibility. For example, you can obtain
your choice of video polarity which can be important depend-
ing on the background of the object under inspection. You can
also select either smoothed video data or raw video data.
To find the position of the object in the space viewed you
can check either the position of the object in the window
section or the edge of the object in the window.
To measure size the count direction will determine
whether measurement will be made along the X axis or the Y
axis. You can choose whether you want a linear count or a
cumulative count. The difference is a linear count will give a
width of the object along a single line within the window. If

you choose a cumulative count, then you'll get the total area in
the window. Total black and white pixels are in the two data
accumulation units, one in each channel.
The contents of the feature data accumulators are
time-multiplexed into the channel 1 and channel 2 output
buses under the control of the 12 channel step program
sequencer. This performs the total basic steering function of
data for the entire system. Each feature data accumulator can
be assigned as many as three program steps and any unas-
signed data effectively becomes zero.

THE DATA ANALYSIS SECTION

The data analysis function is accomplished by comparing
the present data with the stored data. The contents of
selected feature data accumulators are multiplexed by giving
each a time slot into the output bus at each of the 12 program
steps.An eight-bit bus conveys measurement values for each
sequence step. These values are then sent to the data com-
parator in a sequence. At the same time another set of values
which define the acceptance or rejection thresholds are sent
from the twelve sequence step constants switches to the data
comparator. The output signal is used to drive the mechanism
which accepts or rejects the part.

379
 More on Robotic
Vision and Speech

In the previous chapter we found that in the G.E. system the

eye was a special camera which used a special matrix of light
sensitive cells. In the system we are about to investigate, we
find that a standard vidicon camera tube or an optional
silicon-diode type tube is used. The system digitizes the
video output of the camera so the information can be used by a
microcomputer and its associated control system.

THE SPATIAL DATA SYSTEMS EYECOM II

This is a picture digitizer and display system. Its general

operation and assembly are shown in Fig. 10-1. Notice in the
diagram that the reflected light from the object goes through
an optical system and impinges directly on the face of the
vidicon camera tube. There, a beam of very small diameter
scans the face of the tube and generates the video signal,
which is analog in nature. The output goes to a display picture
tube for a person's inspection and also goes to a digitizer and
from there the information goes, via control, data, and timing
buses, to the computer section. Most of the electronics are
used to enhance, expand, or update the picture as seen on the
monitor. The joystick can place a marker on the video monitor
screen, and move it as desired. I call your attention to a block

381
 MASTER CLOCK HI-RES DIGITIZER REAL-TIME
AND SYNC 8 BITS » 640 DIGITIZER
GENERATOR x480 6 BITS x 640

X COUNTER I Y COUNTER Z REGISTER

*

CONTROL BUS

MICROPROCESSOR COMMAND-STATUS
DATA BUS ALPHANUMERIC MEMORY REFRESH

<=> INTERFACE
CONTROLLER
AND
CHARACTER
MEMORY
6 BITS x 640 x 512
& 1 BfT \MHfTE GRAPHICS
GENERATOR

Fig. 10-1. A Block diagram of the Eyecom robotic-eye system (courtesy Spatial
Data Systems, Inc.).

near the camera tube, the shading correction block. The

circuits contained in this block provide the color enhance-
ment and correction which can be accomplished in the
EyeCom System.The system uses a scanning system which is
compatible with standard television.
A light image of the object is produced on the photosensi-
camera tube by an optical system containing an
tive face of the
ordinary camera lens.The system uses a standard C mount-
ing which accepts television lenses, however, a universal
screw type mounting for 35 mm camera lenses can be pro-

382
vided. In normal operation the image is stationary and the
brightness at any point of the image is a function of the X and Y
coordinate position on the tube face. The image brightness at
each point is then defined as a third dimension or Z coordi-
nate. This is converted into the video signal by repeatedly
scanning the image with an exploring spot formed by the
electron beam of the camera gun. Notice the EyeCom camera
in Fig. 10-2. It may look familiar to you. It is relatively small
and easy to mount in a number of either fixed or moving base
positions.

383
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384
THE INTERFACE CONTROLLER
All of the EyeCom functions are controlled through the
control bus. This bidirectional bus transmits control signals
to the displays, digitizers, and registers from the interface
controller. It also sends status signals from the EyeCom
internal units to the interface controller. Data is transmitted
throughout the system on the data bus. The interface control-
ler connects the microprocessor bus to the EyeCom bus. The
keyboard used with the microprocessor connects indepen-
dently to the interface controller. Figure 10-3 depicts the
monitor screen unit and the microprocessor keyboard unit.

USING THE EYECOM SYSTEM

IN AN INSPECT-REJECT-ACCEPTANCE MODE

With proper lenses system can inspect with toler-

this
ances as fine as 0.0001 inch! Using a Macro lens this unit is
said to be able to check hole dimensions and locations in
machined parts to a resolution of 0.0005 inch. The use of the
EyeCom in this application is called the automated parts
measurement application. Ultra small integrated circuits can
be checked for accuracy, completeness, and tolerances in the
PMS mode. One physical set-up for such inspections is shown
in Fig. 10-4.
The smallest of circuits can be inspected for missing
connections, for short circuits, for cracks in the base struc-
ture and so on. Since the data can be fed into the microproces-
sor, its computer can make a line by line comparison with
referenced information gained from a perfect unit previously
examined and stored.
In some visual inspection systems the table top upon
which the part is mounted is caused to move by servo control
commanded by the computer. The table top— and thus the
part— can be moved.
The main requirement is good contrast between the
table or mounting base and the part, and between the part
mass and the hole. An automated operation is illustrated in
Fig. 10-5.

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387
 ARM ARM
k ROBOT
MACHINES *
MEMORY
&
SOFTWARE
CAMERAS
/ROBOTIC\
TEACHING Ieyes I
UNIT
4-
COMPUTER
EXECUTIVE
RECOGNITION
UNIT
DATA BUS
4—

I DIGITAL TO
ANALOG
ANALOG TO
SPEECH DIGITAL
CONVERTER
UNIT

+ + +

SERVO SENSORS
SYSTEMS ON SERVO
UNITS

Fig. 10-5. A general concept of a robotic control system using microcomputers

and robotic eye.

388
THE EYECOM DIGITIZER FLOW OPERATION
The X-register and the Y-register are loaded from the
data bus with the location of the pixel to be sampled and
digitized. The X and Y registers are continuously compared
with the spot position as provided by the sync generator
counters on the timing bus. When the scanning spot reaches
the stored X, Y address the address comparator issued a
sample pulse to the high resolution digitizer. The command to
sample and digitize a pixel is received by the digitizer control
from the interface controller through the control bus. The
sampled video is digitized into an 8-bit binary Z-value and
then stored in the Z-register where it can be accessed through
the controller by the computer.
The physical electronics of the system are shown in Fig.
10-7. Notice that the circuit cards are so arranged that they
are easily removed for inspection, replacement, or whatever.
Finally we examine a block diagram of the EyeCom color
digitizer system in Fig. 10-8. If one wants to make a color
display of something which isn't colored then the data from
the picture display is converted to color by the optional color
look-up table. Each of the 64 gray levels in the most signifi-
cant 6 bits of the picture display memory is assigned a color.
Colors are stored in the table by the digital computer. Colors
are defined as proportions of the primary red, green, and blue
values using 8-bits per primary. As pixel values are read from
the refresh memory, they address the color look-up table.
Color values are then converted to video signals.
In the block diagram we find four solid state random
access memories in the refresh memory section. One of these
is used for display of graphics and the other three are used for
color pictures. Color pictures are produced by superimposing
three separations in red, green, and blue on the color display
picture tube. Each separation contains tonal variations rep-
resented by an array of pixels stored in the red, green, and
blue refresh memories.

INVESTIGATIONS OF ROBOTIC EYES ATTACHED TO GRIPPERS

The idea of mounting a camera on the wrist of a gripper so it
can see what the gripper is trying to grasp obtained results

389
 DIGITIZER ELECTRONI CS

START
COMPUTER PROGRAM
r- ( )

START
( ) /^ SMPL CMD ^\ NO
<
\. RCVD? S

LOAD YES
X REGISTER

SET BUSY

LOAD
Y REGISTER
^

>^ X Y ^"s NO
OUTPUT
SMPL DMD
V. CMPR /
|YES

DIGIT ^fcH SMPL

\

SEQU ENCE AND

1 DIGITIZE

Z VALUE TO
Z REGISTER

RESET BUSY

SET READY

END
( )

Fig. 10-6. Computer programming and digitizer flow diagram (courtesy Spatial
Data Systems).

390
 START
c }

OUTPUT COMMAND 1 18
INITIALIZE SCROLL
ENABLE X. Y
PROGRAMMING OUTPUT COMMAND
(200508)
RUN DIGITIZE
INCREMENT

LOAD Y1 =511
AY =2
YO =

YES
LOADX1 639
AX =80
X0 =
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I

OUTPUT COMMAND
(200506)
RUN DIGITIZE
+ INCREMENT

end
C )

391
which indicate that this may be something which we can use
to advantage if it is refined and improved. The future of this
kind of system titilates the imagination. Smaller cameras,
better lighting methods, ruggedization of the equipment, and
good accurate algorithms might well bring about a whole new
world of usefulness for the robotic arm and robotic eye
systems.
More on this research is in the 1979 winter issue of
Robotics Today.

A NOTE ON ONE INDUSTRIAL

DEVELOPMENT TREND USING ROBOTIC VISION
In Japan, where there is great effort being made toward
development of the automated factory, the development of
the two-handed robot using three dimensional vision has been
progressing for some years. The use of such robots able to
coordinate the use of two hands and multiple fingers in the
assembly of batch products is under intense study. At the
University of Waseda, Tokyo, a robotic machine has been
built which has two hands, two legs and two video camera
eyes. This robot can recognize some speech and can speak to
a limited extent. The use of two video cameras give a three
dimensional view of objects.

IS THERE AN ADVANTAGE TO A TALKING ROBOT?

We know it istechnically feasible for an electronic cir-
cuit to recognize and accept human speech and to generate
some kind of response to those sounds. We also know it is
possible for an electronic circuit to generate human speech so
that it conveys intelligent messages back to us. These cir-

cuits are available at the presentfrom Telesensors, Radio

Shack, Texas Instruments, and other suppliers. We have
already discussed talking units, so we will focus on voice
recognition and human acceptance.
Obviously, for a central computer doing batch work
voice communication with each terminal or user is not effi-
cient. A high-level language is better. This is also true of
industrial applications where more than one robot is used and
the actions of all concerned need to be coordinated. However,

392
Fig. 10-7. The Eyecom electronics package with removable circuit cards (cour-
tesy Spatial Data Systems).

individual and domestic robots might become much more

efficient with voice recognition. The goal is to give the user
the maximum support rather than to try to optimize the
utilization of the computational resources.
English is not an exact language. Some people say "cut
off the light," some say "kill the light," and some say "turn off
the light." If we assign special words for each task, we are
actually inventing a high-level language, and have gained
nothing by adding voice recognition. In an effort to com-
promise Ruly English was developed.
Ruly English uses regular English syntax but limits each
word to one meaning. It is not a colorful language, but is
precise, and immediately understandable. One might say it is

393
 EYECOM
BUS

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Fig. 10-8. The Eyecom block diagram of the color system (courtesy Spatial Data
Systems).

a subset of the English language. It is possible to pictorialize

these ideas in an illustration. See Fig. 10-9.

SOME GENERAL RULES FOR

VERBALLY COMMUNICATING WITH ROBOTS
Sanyo Electric has demonstrated a television receiver
that responds to voice commands to turn itself OFF and ON
and to switch stations. The receiver intelligence unit does
this by comparing the voice input from selected persons to
voice patterns which have been stored in its memory. At the

394
 V EXTENDED
REFRESH
~1
MEMORY
1
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BLUE BLUE
REFRESH KlUIUHfc

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/

time of its demonstration this unit had a 30 word capability in

vocabulary and could distinguish the voices of two different
people. An expansion on this concept would permit people to
play computer games using vocal responses, according to the
research information which is available. However, this unit
has problems identifying a "learned" voice when it has a cold.
This could create problems in the workplace.
There are other problems. Many humans wouldn't mind
working next to a machine they can't program, but few will
work next to one they can't stop in an emergency. So the robot
would have to accept only certain voices for programming,
but any voice for operation. Of course, by the time these

395
 ^SPOKEN^X
INPUT )

v COMMAND J

^ GRAMMAR
LINGUISTIC
ANALYSIS -^
VOCAB-
ULARY
\
LANGUAGE-
-^
MACHINE ^
INTERFACE

GRAMMAR OF
1 COMPUTER
PROCESSING LANGUAGE
OF COMMAND
(COMPUTER)

1
d "* P
MACHINE
RESPONSE
'
w,
^
\v r

Fig. 10-9. A block diagram of a natural language man-machine communications

system.

robots arecommon in factories, today's children will be the

workers (maybe) and growing up with talking TVs and learn-
ing aids may cause them to accept all this much easier.
The popular adventure games are an example of trying to
get a computer to understand English. The earliest ones used
two word commands. This was not a noun and verb as you
might expect. Since these were commands, the noun was the
implied "you." To command was a verb and either a verb

396
modifier (GO NORTH) or a direct object (THROW KNIFE).
If the action implied an indirect object, as in this example, the
computer asked "TO OR AT WHAT?"
The computer looks to see that it "knows" the verb and
object. If not, it tells you it doesn't understand. Next it checks
to see the verb is applicable to the object. If not, it tells you so!
(CANT EAT HOUSE!) Finally it checks to see if you have the
object. You can't throw a knife you don't have! Since the first
simple programs, routines have been developed allowing the
computer to pick the important two words, plus indirect
object, from a complete English sentence.

Fig. 10-10. Texas Instruments Speak and Math machine (courtesy Texas In-
struments).

397
 There are four primary significant models of language
and these are; the fixed sentence model, the finite states
model the syntactical model, and the transformational model.
These are described in detail in Syntactic Structures by
Chomsky, (Monton & Co, the Hague, Paris, 1957). The first
two are the most applicable to present voice recognition
technology.
In the fixed sentence model there is simply a list of all
the allowed sentences. One defines each sentence with a
mathematical term. If we develop
whole list of sentences
a
which are unique then when the computer receives an order it
essentially compares that order to that series of sentences
and chooses one which matches or most nearly matches the
command.
The finite states model is essentially what the adven-
tures use.

SOME CONSIDERATIONS OF
AUTOMATIC SPEECH RECOGNITION BY MACHINES
Once the meaning of a sentence has been decoded, there
the problem of identifying the speaker.
is still

There are two general ideas for recognition of human

speech. These are a system where the pitch and spectral
characteristics can be analyzed and related to some person,
and a system where the electronic circuitry can extract
phonemes and from a tabulation of these phonemes identify
the different persons speaking.
In a study at the Rome Air Development Center, Griffiss
Air Force Base, New York, an analysis of human speech was
conducted. It was found speech sounds are primarily of
that
two types— voiced and unvoiced. For voiced sounds such as
the vowels the vocal chords vibrate and produce a line spec-
trum which has a fundamental frequency in the 70-180 Hz
region for males, with harmonics extending to 8,000 Hz and
even higher. The unvoiced sounds are produced by the turbu-
lence of the air stream as it exits the mouth and not from the
vocal chords at all! There are also sounds such as Z which
require both techniques.

398
 There are about 40 basic phonemes in the English lan-
guage. There have been detailed studies to find out just what
identification characteristics there are in human speech, so
we can make machines do what we do, recognize who is
speaking.
A block diagram which shows a system for recognition of
human speech, based on pitch and spectral characteristics is
shown in Fig. 10-11. In a typical operation using this type
system for speech recognition, the speech is fed into the
spectrum analyzer and the pitch extractor as shown. The
output of these units issampled every 20 milliseconds,
digitized, and sent to the computer. The computer knows
what characteristics it is looking for because it has previously
stored patterns of speech.
The system shown in Fig. 10-11 uses some clues to
identify whom is speaking, or has spoken. One set of clues is
to use the speakers fundamental frequency— the average
pitch and the maximum and minimum of his speech tonal
range. A second set of clues may be extracted from the speech
spectrum, the measured value of the highest peaks of sound,
the ratio of the amplitude of the sound, to the valley amplitude
following the highest peak and the measurement of the peak
amplitudes, and where they occur in the spectrum. One man-
ner in which the information may be used is to form multi-
dimensional histograms. Then during the recognition process
the summed-squared-deviation between what is in the com-
puter memory and the sound now coming in through the
system can be compared. If the sound being evaluated has the
same or close to the minimum summed-squared-deviation of
the memorized pattern, then the computer decides that this is
the speaker whose histograms are being used as a reference.
Refer to Fig. 10-12.
Examine a block diagram of the method of speech iden-
tification that uses the automatic phoneme recognition con-
cept. This can be illustrated as shown in Fig. 10-13. This
block diagram is the one which would use the algorithm
illustrated in Fig. 10-12. Basically, this equipment would
make use of analog threshold-logic operating on the rectified

399
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output of the filter banks to provide such features as spectral
energy, spectrum slopes, local maxima-minima, transitions,
sequences, and simultaneous occurances. All of these fea-
tures are used in speech recognition systems.
In the RCA equipment which is illustrated in the block
diagram, Fig. 10-13, the input is conversational speech and

the equipment used to recognize, and segment from the

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speech, a set of phoneme-like elements. During the occur-

rence of each such element the slope of the logarithmatical
spectrum was employed to measure the speaker's
characteristics-of-speech by integrating the spectrum slopes
of the analog signals, which are derived from the filters, and
then quantizing these to three levels; positive, negative, and
zero.

TEXAS INSTRUMENTS DEVELOPMENTS IN SPEECH CIRCUITRY

Texas Instruments has done much advanced research in
both speech synthesizing, speech recognition. They hold a
patent for a single stage digital speech-synthesis filter. We
have indicated how important filters are in breaking down the
components of speech so that they may be analyzed. In fact,
the unit shown earlier represented a major price break in
voice synthesis using a breakthrough called linear predictive
coding, which we discussed in an earlier chapter. Figure
10-14 shows the circuitry. Since using the inverse of this
technique may provide a similar breakthrough in speech rec-
ognition, we will take a closer look.
We have indicated the algorithm solving unit in the
microprocessor block of Fig. 10-15. It represents the summa-
tion of a series of terms from i = 1 to i = n.

"Brute force storage of speech signals can be ac-

complished by sampling and converting speech at an 8 to
10 kHz clock rate. This results in a digital data rate of
100,000 bits per second of speech. Pulse-coded modula-
tion codecs and companding techniques have found ac-
ceptance in new, all digital, telecommunications sys-
all

tems, but their data rate of 64,000 bit per second is still
high.

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 "Linear Predictive Coding produces speech quality
nearly comparable to either of these techniques, yet it

only requires about 1,200 bits per second. With the

advent of 128K bit and larger storage devices, LPC
packs minutes of high quality speech into memories that
could hold only one or two seconds of speech using other
techniques."
The secret is that LPC predicts the parameters of the
next speech sample from a linear combination of the values of
the preceeding speech samples. This is possible because of
redundant information in speech signals caused by a limited
number of the formants in the human speech production
system. LPC essentially eliminates unnecessary information
in human speech and keeps only the data required to drive the
synthetic model.
Speech sounds are recorded and digitized using special
recording facilities that virtually eliminate background noise
and preserve a high signal-to-noise ratio for the digitizer.
Then the sophisticated signal algorithms of the type we have
examined previously, are used to extract pitch and energy and
slope information from the recorded data. Using a mini-
mum-mean-square predicted-error criterion, the computer

Fig. 10-17. The TMS5200 speech chip from Texas Instruments. FIFO stands for
first-in-first-out and relates to signals into the buffer.

407
program computes an optimal set of coefficients for the vocal
tract filter of the model electronics unit. The response of this
filter, then, when suitably excited, will closely resemble the

original speech model

In the next stage of the LPC system a frame repeat
analysis takes place. Here, similar sets of reflection coeffi-
cients (40 bits each) are eliminated from the data stream and
replaced with one-bit "repeat" code signals. Stop codes are
added at word-phrase boundaries, allowing the synthesizer to
"speak" a complete word or phrase and stop automatically
with no supervision from a host microprocessor.
After thousands of samples of speech are analyzed by
expert speech persons, those samples judged to be suitable,
from a pronunciation and diction standpoint are ready to be
committed into a "memory image" format. The fully analyzed
data-set is encoded according to the pitch, energy, and filter

parameter coding tables of the selected synthesizer. Then the

final speech product is ready for listener tests and acceptance
or rejection for various consumer uses. Figure 10-16 is a
block diagram of the speech analysis and coding electronics

Fig. 10-18 Some possible uses, in addition to robotics, for the Tl speech chips
(courtesy Tl).

408
system. This makes robotic speech a reality. It uses very
littlepower and requires very little space. Figure 10-17
shows such a speech chip from TI. Of course, it has other uses
too, as shown in Fig. 10-18.
Let us hope that TI continues to experiment with speech
so that someday a single chip voice recognizer will be avail-
able. Because we like to give verbal commands,eventually we
will have robotic units which respond to this type of input. It
would be nice if they were cheap.

409
 Ranging Systems

Polaroid's auto focusing camera uses a sonic ranging system.

The unit has the ability to range accurately over reasonable
distances is rather immune to extraneous ultra sonic sounds,
and does not emit an audible sound. Polaroid offers a kit (Fig.
11-1) which can be obtained for experimentation. Write to:
Ultrasonic Ranging Marketing, Cambridge, MA 02139.

PRINCIPLES OF CIRCUIT
OPERATION POLAROID ULTRASONIC RANGE SYSTEM
Sound waves which are compressions and rarefactions of
the atmosphere, travel like the waves of the ocean at around
343 meters/second at 20 degrees centigrade. This converts
to 1125 feet per second, which is the figure most of us are
more familiar with. The speed of sound varies with humidity
and temperature but is relatively free from effects of altitude.
The signal fall off is the inverse square of the distance

traveled ^- where r is the range or distance . And when there

is a reflected echo, as when they are used in a distance

measuring mode or ranging application then the echo also

reduces in intensity. Thus we get tt as the total fall off ratio.

We know that since the energy travels at a specific speed, we

can measure the time it takes for it to go to a given target and

411
return. We can then multiply the time and the speed of travel
and we come up with the round trip distance. Divide this by
two and we get the distance to the object.
Emission of a single tone may permit extraneous notes
at that pitch to enter the system. But a "chirp" signal, the
emission of several tones, can override this difficulty to some
extent, also "chirp" gives the detector of the system an ability
to look at several echoes at different frequencies, or just one
which may come from a secondary frequency in the "chirp"
pattern. If just one tone were used, there might not be an
echo, as the reflecting material might absorb the signal total-
ly! Polaroid uses a four tone "chirp" at frequencies of 60,57,

53 and 49.7 kHz to overcome this kind of difficulty. A very

high reliability of echo response has been obtained in their
system.
A pamphlet has been prepared by the Audio Engineering
Society, 60 East 42nd Street, New York, NY 10017, titled
Polaroid Ultrasonic Ranging System, and this can provide you
with more details of the circuit operation, and some other
considerations which were mandatory when developing this
system.

USING A SOUND RANGING SYSTEM IN ROBOTIC APPLICATIONS

It is not necessary for a robot to be "intelligent" to make
use of sonar anymore than it is necessary for a bat to be
intelligent. Both are essentially blind, and the sonar reflec-
tion triggers reflexive action.
Such a sonic system can be used to trigger relays which
have been arranged to control the drive motors, the steering
motors, headlights, voice track, or voice synthesizer. An
industrial application might be sonic ranging in a gripper. Like
the photo-electric eye system, it can provide information that

objects are on a conveyor belt, their spacing, and even the

distance they are placed from the edge of the belt. Advance
information of this type can be used to cause the microproces-
sor to adjust the robotic arm position to meet the on-coming
objects precisely. And, unlike the photo-electric type device,
the ultrasonic system needs no receiver other than its own
transducer, and gives ranging information.

412
 ULTRASONIC
RANGJNG
SYSTEM

r##//////////////.-

B
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i

Fig. 11-1. The polaroid ultrasonic ranging kit includes two instrument-grade
Polaroid transducers, a modified Polaroid ultrasonic circuit board, two Polaroid
Polapulse 6-voit batteries, a battery holder, a wiring assembly and a technical
manual (courtesy Polaroid).

But there may be some disadvantages. If the robot is

working in an environment where there is a high sound level,
and a multipitch sound spectrum, then it might get signals
which would cause malfunctioning and problems. It is possi-
ble to filter the sonic signals (as Polaroid does) so that most
other tone signals or ultrasonic signals are not received in
sufficient strength to cause alarm, but, in a machine shop, for
example, where tooling, grinding, etc., are taking place, you
will find spikes of ultrasonic energy all over the low frequency
spectrum to 100 kHz or even into the low rf frequency
range. Look at the block diagram of the experimental dem-
onstration circuit board package of the Polaroid Ultrasonic
ranging system in Fig. 1 1-2. The range of the Polaroid system
is from 0.9 foot to 35 feet, and that ranging information is

presented on a digital display. Of course one could intercept

the signals to the display and use them to activate other
devices if this is desired.
A hobby robot will, no doubt, use TV camera type eyes, a

413
voice synthesizer for speech, and a multitude of sensor de-
vices to provide information as to where it is, what it is

encountering, and what is around it. Some persons, talked to

in the preparation of this book, said that they find, in the larger
toy stores, a multitude of electrically driven cars, trucks,
tanks, and such, which make ideal starting units for robot
development. Some, of course, start "from scratch" and built
up from just an idea. Such was the origin of G ARC AN which
was illustrated in an earlier chapter.
John Cledhill discussed his robot in Robotics Newsletter,
Sept. 1979. Some of what he said is interesting to us at this
time. "It's surprising that most of the complexity of a com-
puter (in robotics) is a result of the necessity of communica-
tions with humans. A dedicated, on-board robot computer
doesn't have to have a keyboard, address/data light, etc., if

you have a separate system for generating software. In my

robot, decisions aremade by a SC/MP-II microprocessor
from National Semiconductor. But one could use the
Motorola 6802.
My robot's basic senses begin with a bumper that encir-
cles the frame and wheels. Eight micros witches provide input
identifyingif and where an object has been struck. The 8

microswitches for one 8-bit word are ANDed with constants

by the computing section, so it knows which switches have
been closed. The computer then knows what corrective ac-
tion is necessary.
Since number 2 will be sonar using a National Semicon-
ductor chip LM1812. The computer will tell the chip when to
transmit and then time the echo response. Extreme accuracy
is not necessary, as this will be used only to find out if there is

anything in the field of view. Once something has been found

in the field of "view", the bumper becomes the back-up device
and will generate the operational signals causing whatever
action necessary.
is
This analysis and excerpt from that hobbyist's report
gives us some indication of one way ultrasonic systems might
be used in a very secondary role. With the Polaroid unit and
with proper circuitry, there is no reason why ultrasonics can't
be used as the primary control sensor. The Ultrasonic ranging

414
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415
system of Polaroid might be useful. With Ultrasonics your
robot would not have to strike anything to get a signal that it
was approaching something, or getting close enough to stop
moving or to turn away!
MESOTECH SYSTEMS LTD of Vancouver, B.C.
makes a mode-952 Bottom-Scan-Profiling-Sonar with some
features that might be useful to think about in connection with
robotics applications. Of course the transmission of sound in
water is somewhat different than the transmission of sound
through the air, especially with regard to the frequencies
used. We know that some frequencies propagate very well
through water and others do not. We have no correlation for
the propagation of these sound frequencies through air versus
other frequencies which might be used. One might have to do
some experimentation in this area. In any event, the sonar
system under discussion is one which, from a single location,
records a profile of water depths along a particular line of
bearing. By changing the orientation of the transducer, pro-
files of several lines can be made.
This transmitter unit, the sonar head, transmits a narrow
beam, high frequency acoustic pulse. The narrow beam is
swept through a vertical plane, and, of course, the returning
echoes are timed which gives the distance to the reflecting
surface, which, in this case, is the ocean, channel, or harbor
bottom surface. The complete system consists of the sonar
head and the recorder case (which charts the bottom profile)
and a 100-foot cable which connects the two units. Inside the
sonar head are the acoustic transducer and the stepping motor
which sweeps it. There is also an inclinometer which senses
ships rolling, and the sonar transmitter and receiver circuitry.
The beam width in this unit is only 1.5 degrees, but its
operating frequency is 360 kHz. It ranges to 160 meters with
an accuracy of plus or minus .5 percent. Its angle measure-
ment resolution is plus or minus 0.75 degree.
What is very interesting to us in robotics is the narrow
beam concept of this unit. If such an acoustic device could be
used in air, on a mobile robot, one could have a device which
could accurately measure objects around it, and distances to

them. The use of a stepping motor for the sweep also means

416
that a microprocessor memory unit would be able to deter-
mine exactly in what direction the transducer head was point-
ing. In essence, we might obtain good or better accuracy than
with a radar unit.
Insome applications the Mesotech type unit may be used
to keep track of underwater robots that are free to move in
their environment, yet are under observation and control of a
parent ship on the surface above. No cables are necessary to
send control signals. Coded acoustic pulses can convey this
information, as well as give range and bearing from the
mother ship's reference position. The TV signals, however,
do at present, require cables. It could be a problem knowing
where your underwater robot was, and also communicating
with it, unless you have very good sonar systems in use.
There are some frequencies which tend to "channel" in water
and go a long way with a reasonable amount of power. "Win-
dows" these frequencies are called. It is safe to assume that
360 kHz is such a sonic window.

A RANGING SYSTEM USING LIGHT

One ranging system which uses the reflected light from
an object to adjust a camera lens into focus has been incorpo-
rated into the Japanese Sanyo Autofocus Camera Control
System, in their ES-44XL-VAF super 8 camera. In this sys-
tem, basically, two mirrors are used to see the object through
the camera window. The light from the object is reflected
through a prism onto a photo-electric detector element
which, in turn, sends the voltage generated from its two

elements into a which measures the balance. When the

circuit
balance is exact a signal is generated which is then compared
to a signal which indicates the position of focus of the lens. If
the two signals are not in agreement, a small motor is ener-
gized which then adjusts the focus. Figure 11-3 shows a
skeletonized view of the system.
The use of a prism to focus the light rays onto a silicon
type photodiode (actually two of them) is easily seen in the
illustration. The use of the prism to get two beams of re-
flected light can be better understood in the inset of the
figure. I titled this chapter Ranging Systems. This system

417
 MOTOR
DRIVE
SYSTEM

MIRROR

v PHOTO
LIGHT \MIRROR DETECTOR

1
PRISM j>

If— SIGNAL

MIRROR
TOP VIEW

Fig. 11-3. A sketch view of Sanyo's autofocus system for cameras.

would calculate a range to an object by use of the focus

information.
There would be problems adapting this system into a
robot for its eyes. You should have a good illumination level,

and that is not always possible. Of course you might incorpo-

rate an automatic lighting system into the robot so that a
photo-illumination bright light will come on when the robot
starts to move about. Then, it could get a good reflection,
even if this causes some temporary blindness in the people it
confronts!

418
 Numerically
Controlled
Robotic Machines

It is essential that we examine what an NC machine is, learn

how it is operated, and how it fits into the general picture of
robotic machines. It is a machine which is controlled "by the
numbers". What that means is that it is a lathe, a milling
machine, a drilling machine, or something of the sort, that is
programmed to move the cutting tool, drill, or whatever,
exact distances to within .0001 inch to perform whatever task
has been programmed for it, using a perforated tape contain-
ing the movement commands and instructions. A computer,
naturally, is located in the system, and it receives the instruc-
tion numbers from the tape and knows what they mean.
For example, if a drilling tool is to move one inch on the
X axis, over some plate which is to be drilled, and move two
inches up the positive Y axis to exactly locate the center of the
hole to be drilled, then the tape instructions would consist of
two numbers. If the drill is to go down one inch to pierce
through the metal plate at the specified position, then a third
number is added to the instruction sequence. Since these
instruction numbers are always in the same sequence, that is,
the X axis instruction, the Y axis instruction and the Z axis
instruction, then all that is needed is some way to space these
commands on the perforated tape, which is read by an optical

419
reader. This gives the commands to the computer which, in
turn, controls the stepping motors, or the closed loop ser-
vomechanism, to make the machine elements do what the
instructions say it should do.
The way the commands
are spaced is by using a tab key
on the tape perforating keyboard. This, like a typewriter tab
key will cause the instructions to line up properly by forming
a special kind of "end of command block" code which lets the
computer know that another set of movements will be the
next block's numerical grouping. After the machine drills the

hole, as previously specified, it moves to a home or starting

location where the coordinates are (0), (0), (0). The next
command, which might consist of the numbers (5000), (6000),
and (1000), tells it what to do next. See if you can interpret
what the above figures mean using the information we have
already given you.The tape used to store and present the
command-instructions to the computer may look like that
shown in Fig. 13-1. The numbers are in Binary form, i.e., the
1 2
rightmost column is the 2°, the next, 2 , the next 2 and so on.
Thus the position of the holes in the tape specifies a given
number, and that number is a command for the machine tool
movement. The rows of holes come in a specific se-
quence, as previously stated, which tells the machine's com-
puter control brain how to move the tool, first in the X
coordinate, then in the Y coordinate and in the Z direction.
This, as you can realize, gives the position of a point in three
dimensional space.

CHANGING TOOLS AND RANGE OF OPERATIONS

The NC machine can do marvelous things. If a source of
tools is supplied to on a circular retaining unit, for example,
it,

it can, when so instructed, change its operating tool for each

required operation. What it does is to move toward the circu-
lar retainer, which, itself has rotated under computerized
command working head to the
to a given position, attach its
tool in a specific position, then the head is moved back to the
work and to the position where that tool is to be used. When
the task for tool number one is finished, the head will return
the tool to the circular retainer, which grips it, the retainer

420
 NUMBER HOLES (8ARE USED)
"ARE PUNCHED IN TAPE

26
2 (1ST POWER) = 4
22 + 2 1 =6
2 (1ST POWER) =2

ZERO
23 =8
23 +2 2

TAPE PULLING
SPROCKET HOLES"

TAPE HOLES ALSO HAVE

SPECIAL MEANINGS SUCH AS
(X) COORDINATE (Y) COORDINATE
ETC.

Fig. 1 2-1 . A sketch representation of an NC

machine's control tape. The tape is
punched number across the rows.
with holes which are converted into a binary
Many rows of holes produce many numbers which designate the machine's
operation. The column in which the punched hole appears governs its numerical
or "special" operational meaning.

rotates again bringing a new tool into the acquisition position,

and the head latches onto this new tool, and repeats the
working procedure. A very wide range of operations from
milling, to drilling, to smoothing, to contour shaping, can thus
result.

FUTURE OF NC MACHINES AND ROBOTICS

Some of the scientists who develop and design these
machines believe that in the future there will be a marriage of
the NC machine and the robotic machine. The NC machine
will be tended by an industrial robot at each advanced work
station. All control data will be verified by computerized
graphics. Sony has a color TV plant in Taiwan that produces a
package product, ready to ship, with less than $1.50 invested
in labor. Much of the work is done by work stations like this.

421
 A reference on NC machines which might be of interest
to you is NUMERICAL CONTROL PART PROGRAM-
MING written by James J. Childs and published by Industrial
Press Inc.

422
 00
Ideas and

Discussions 13
4k

This last chapter will be a series of small paragraphs, each

presenting an idea dealing with the design or concept of
building a robot. Some are cheaper ways of doing things we
have already discussed, others bring up factors that need to
be considered in a society populated with robots. The first

story will give you the flavor of the chapter.

LAWS
In Japan, an attempt to bomb the home of a syndicate
leader with a radio controlled helicopter, toy variety, was
foiledby the police. We may have to have some controlling
laws governing the functions and operations of hobby robots
as they increase in capability.

TYPES OF HOBBY ROBOTS

In the general case a robot is constructed to prove that
one has the intelligence and mechanical-electronic-
electrical-physical capability to make a machine that resem-
bles in some way, a person, or the actions of a human. Thus, if
nothing else, the construction of a robot of the hobby variety
is a challenge, and makes one investigate most of the fields of

science and engineering before the task is accomplished. We

423
might say, then, that we build hobby robots to learn, and to
fascinate ourselves and our friends.
Many persons and companies as well as scientific in-
stitutions are making, or developing kits for, or are inves-
tigating the use of, hobby type robots. This type robot is

distinguished from its industrial brothers in that the industrial

robot has a definite task to perform, or many of them, and it

does this well and for long periods of time. Tasks as demand-
ing as making printed circuits and inserting parts on such
circuit boards, something a human tires of very quickly, to the
handling of thousands of pounds of equipment or materials in
various plants. The hobby robot, on the other hand, is just for
the pleasure or education, or satisfaction of the creator. Some
types have been constructed just to investigate how one
far
can go in putting some kind of intelligence into a machine of
some type. That, in turn, leads to much study and research.
But for the many units which simply run around, or draw lines
on something under computerized command it seems the
satisfaction is simply to have built such a machine. It is our
belief that with technology at the current state of the art that it
is, even hobby robots should do something useful.
One robot which has been built and named Midnight
Special, uses various types of light sensors to get information
about paths through mazes. The information he derives is
sent to a computer where it is stored and analyzed. When the
Midnight Special has made one trip through such a maze it
then can repeat its path without any deviations or problems or
trial and error efforts. This kind of operation is said to be one
in which a robot has been given some kind of intelligence.
Certainly, it is a system in which the robot learns by its

mistakes. Hobby robots should have this kind of capability.

WHO?
The robot builder comes from a diversified segment of
our population. From the college professor to the high school
science major. We
found it interesting that a former college
Physics professor found pleasure constructing hobby type
robots. He said that his interest is in constantly trying to
make his robot do more things, and do them more intelli-

424
gently. That brings to mind the giant robot of Benjamin Skora
which is able (so they say) to vacuum the carpet, walk the dog,
serve drinks to friends, and answer the door!
There will be more and more hobby robot kits available
as time passes. They will be able to do more and more things,
and will give their constructors hours of fun and pleasure
putting them together, and watching them work. Like the
radio controlled model airplane activity, the stage of hobby
robot development is rapidly passing from the "built it all,
figure it out, put it together, make it work" stage into the level
where anyone can simply buy a kit and have it do almost
anything the human mind can conceive of it doing.

REMOTE CONTROL OF HOBBY-TYPE ROBOTS

We refer you to the sketch of Fig. 13-1. It will receive
feedback signals of voice, TV, mechanical movements, heat,
light, and so on from the robot via radio communication. The
its instructions and voice generation commands
robot will get
from the home computer by a return radio link. It is not such a
long way off. The technology for this kind of operation is

available. Modern radio control transmitters already are able

to handle streams of pulses with reliability, and they are small
and compact and do not use much power. They could easily be
incorporated into a robotic form, or used at a home base
station. The output computing section would modulate
of the
the transmitter, and in the robot we would find the second half
of our communications system which would take the com-
mands, use the memorized software programs, and cause the
robot to do whatever we have planned for it to do.

MAGNETIC CONTROL
To make such a robot function around the home,it might

be possible to use magnetic induction loops in rooms, and the

robot could have sensors which would be able to pick up the
signals from the centrally located computer in the house and
do the things the computer directs it to do. Essentially we are
saying that hobby robots, as well as commercial, industrial
robots do require computer direction as they do things
better.

425
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426
THE MOUNTAIN HARDWARE SUPERTALKER: SD200
A talking circuit which was designed to be used with the
Apple computing system is illustrated in Fig. 13-2. This
system memorizes certain phrases and words and can use the
memorized information to respond vocally to persons, under
various conditions. This unit works with the Apple II Com-
puter. It digitizes human speech and stores it, then it can play
back this digitized speech through a speaker. The voice sys-
tem consists of a card which plugs into a peripheral slot on the
Apple II, and the mike, circuit board, and speaker shown.
There is an extensive software package which permits the
user to interactively develop a phrase diskette which may
contain many tables of phrases. Each table can contain several
words, phrases or complete sentences, which the computer
can select.
Here is how the system operates. The Supertalker board
Fig. 13-2, has electronic circuits which convert the analog

Fig. 13-2. The Mountain Hardware Supertalker system for the Apple computer
(courtesy Mountain Hardware).

427
mike signals into a digital pattern which can be saved in
memory units. The board's circuits accept these digital pat-
terns and transform them back into analog signals for use by a
loud speaker.
The circuit board has an on-board ROM that is a 256 byte
type. This ROM is accessible from BASIC by a call instruc-
tion to address CNOO (Hex) where N equals the slot number
that the board is in. Calling this address will place you in the
talk mode, and a call to CN03 (Hex) is for the listen mode.

3 REM
5 REM MOUNTAIN HARDWARE'S
7 REM SLIPERTALKER DEMO PROGRAM
9 REM
18 HI MEM: 4095
20 GOSUB 25800: REM CALL AUTO SLOT FINDER
30 PP(2) = 16: REM SET STARTING PAGE OF PHRASE TABLE
40 PP(3) = 127: REM SET ENDING PAGE OF PHRASE TABLE
41 PP(4) = 3: REM SET VOLUME <l-4>
42 PP(5) = 4: REM SET SAMPLE RAT E (1-4)
50 GOSUB 25010: REM INITIALIZE SUPERTALKER WITH PP ARRAY
108 CALL - 936: PRINT
110 PRINT "HIT RETURN KEY WHEN YOU ARE"
120 PRINT "READY TO BEGIN RECORDING. "
130 PRINT
140 PRINT "HIT RETURN KEY A SECOND TIME"
150 PRINT "WHEN YOU ARE DONE RECORDING "
160 INPUT A*: REM WAIT FOR FIRST RETURN KEY
170 P = 1 GOSUB 25028 REM CALL LISTEN SUBROUTINE
180 P = 1: GOSUB 25020: REM CALL TALK SUBROUTINE
190 GOTO 100
25000 REM TALKER AUTO SLOT FINDER AND ADDR CALCULATOR
25061 PP(1) = l:Pi = - 16068
25862 IF PEEK (PI - 1) = 8 flND PEEK (PI -f 3) = 3 THEN GOTO 25884
25803 PP(1) = PP(1) + 1:P1 = PI + 256: IF PP(1) < 8 THEN GOTO 25602
25004 IF PP(1) = 8 THEN PRINT "SUPER TALKER IS NOT IN THE APPLE II" IF PP(1) = 8 THEN
GOTO 25069
25065 P3 = 256 :P4 = PP(2) IF PP(2) < 128 THEN
: GOTO 25687
25886 P3 = - 256 P4 = 256 - PP(2)
25887 P5 = P3 * P4P2 = - 16256 + 16 * PP(1)
25083 RETURN
25010 REM TABLE INITIALIZATION (ASSUME PP ARRAY IS SET UP)
25011 P3 = 256 :P4 = PP(2) IF PP(2) < 128 THEN GOTO 25013
25012 P3 = - 256 :P4 = 256 - PP(2)
25013 P5 = P3 * P4: POKE P5,PP(4) POKE P5 1PP(5)
25614 POKE P5 + 3, PP(3): POKE P5 + 4,134: POKE P5 + 5, PP(2)
25815 RETURN
25020 REM TALK ROUTINE
25621 POKE 1528- PP(1): POKE 1656, PF(1) * 16
25024 POKE 1144 + PP(1),P - 1: POKE 1272 PP(1),PP<2) POKE 1406 + PP(1), PEEK (P5
+ 3) + 1
25625 POKE 1784,(4 - PEEK (P5 + 1)) * 16 + <4 - PEEK (P5))
25627 CALL - 16384 + PP'l) * 256
25028 RETURN
25036 REM LISTEN ROUTINE
25031 POKE 1528, PP(1): POKE 1656, PP(1) * 16
25834 POKE 1144 + PP<1>, P - 1: POKE 1272 + PP(1),PP(2): POKE 1460 + PP(1), PEEK (P5
+ 3) +1: POKE P2 + 3, (4 - PEEK (P5 + 1)) * 16
25836 CALL - 16384 + PP(1) * 256 + 3
•L5037 RETURN

Fig. 13-3. One Supertalker demonstration program (courtesy Mountain

Hardware).

428
 CONFIGURATION
&
CONFIRMATION

*l RE-BOOT DOS
J

A.B.C.D.F.I.L.M,

iCTRL-C/*- O.R.T.or V
COMMANDS

D,L.M.R.S.T.orV

COMMANDS

RE-BOOT DOS
I CTRL-E.CTRL-S
COMMANDS

CTRL-T
icTRL-cV COMMAND
<c?

Fig. 13-4. The Supertalker computer flowchart (courtesy Mountain Hardware).

One Supertalker sample program is shown in Fig. 13-3,

and the computer flowchart is illustrated in Fig. 13-4.

429
CHECKING ERRORS IN DATA
TRANSMISSION AND SOME ROBOTIC-SYSTEM PROBLEMS
Among the professionals, there are several methods by
which data information can be checked and the capability of a
system to transmit the bits accurately and completely is
determined. One of these methods is to use a parity bit for
each word or character and inspect this. Parity is a system in
which we add a pulse to a coded group in such a way that for
even parity, the sum of all the l's will be an even number, and
for odd parity, the sum of all l's will be an odd number. In the
transmission of an even parity code, those bytes which have
an even number of l's are not changed. In effect, a zero is

added to the extreme left of the byte binary sequence. But, if

the number of l's in the byte is odd, then a 1 is added to the left
to make the numerical total of l's even. A byte with the wrong
number of l's has an error in it.
Other writers, in discussing the checking of data in
transmission systems have indicated that a cyclic redundancy
check might be used. This means, essentially, that you re-
transmit the same information several times and if it all
comes out the same, then the system has no errors— at least
for that transmission period.Checks using special messages,
such as the "Quick Brown Fox" which require transmission of
characters representing all keyboard letters and numbers
might be used. If, on the receiving end, one knows what the
sequence of transmission is for this kind of special message,
then errors in the transmission system can easily be noted.
Finding the cause may prove difficult.

The number of methods of checking for errors in a

computing system and its transmission system increase in
proportion to the amount of information transmitted, and the
number of people or stations involved in the generation,
reception, and use of this kind of data. If one knows the
particular weaknesses of his own system, which he learns by
experience, then perhaps he can imagine and fabricate a
checking system which will let him know how well his own
system is operating. You need such a check in robotics, be it
hobby type or industrial type robot system you are using, if it
uses a computer and/or a communications system.

430
 Checking a robotics system which involves mechanical
movements, and computer control, and data and sensor
transmission systems may be done using a test program. This
program feeds data into the computing section to cause cer-
tain specified movements of the robot's arm in accord with the
range of operations of which the robot is capable. If the robot
is a welder or a paint sprayer, or such, then, of course, the test

program must include some actual welding or painting or

whatever to insure that the unit operates correctly from
signal input to desired output. But, sometimes, as with com-
puters, if there is a malfunctioning in the system, it won't
respond as it should, and so location of the problem area is
necessary although it may be difficult.
Piece-by-piece checking of a robotics system may be one
answer to the error checking procedure. In professional cir-
cles this is called open loop checking. It is accomplished in
this manner: First the end element is checked by feeding a
signal into its nearest control point. One desires to eliminate
all possible elements in between the signal insertion point
and the end device and only those elements required are to be
operated. Meantime all other elements of the system are
turned off or disconnected.
When determined that the end element responds
it is

correctly to the types of signals which experience or

all

design or both show it should respond to, then one says that
this part of the robot is working as it should. The next step is
to move one element back toward the front-end or input of the
system. When it is checked, of course the final element is also
checked because we use the output of the robot as an indica-
tion of how well it is responding to test-input signals into the
next-to-last unit. If there is an error or the robot does not do
what it is supposed to do, and we know that the output
element is working correctly because we have just checked it
out, then we can say that the next-to-the-last unit is malfunc-
tioning. We then check it out stage-by-stage or step-by-step
until we find out what is wrong.
And so we move slowly back toward the input end of the
system. At the input end we might have to use a conveyor belt
to test input sensors, or devise other tests which simulate

431
actual operational inputs of the same type that the input
actually gets. We must test the input sensor system or input
signal system just as completely as we have checked all
intervening elements or system blocks. Finally, we might run
a systems check. This is a closed loop test which actually is
the robotic system in operation, doing what it is supposed to
do.
In a robotics system, then, you'll check the computer
section for accuracy and correct operation, you'll check the
software to see that it was correctly prepared and inserted,
you'll check the transmission system (cables, lines, and
whatever) to see that the signals actually get to the operating
units. You'll check the control amplifiers, and the motors and
the hydraulics and the pneumatics and whatever. All this in a
step-by-step procedure to insure that you actually will find
the problem area.
Ifsystem develops more than one malfunction simul-
a
taneously, then, unless you use the open loop test concept,
you might not ever find the real causes of trouble! It has also
been said by those who know about these things that some-
times two malfunctions make a no malfunctioning condition
exist. The two malfunctions tend to cancel one another. This
may happen if one depends too much on just a closed loop type
of test.
Testing of hobby robots is performed much in the same
manner. Usually you start at one end of the system, say the
mobility end, the drive motors and gearing and power and
such, and move back toward the input end of the system,
checking as you go, to make sure everything is operating
correctly. Lots of times this prevents troubles and helps you
find and correct trouble spots which might not have been
noticed, unless you check for correct operation as you pro-
ceeded backward, toward the input end of the system. It
sometimes is very difficult to find trouble spots in any kind of
system like this if you wait till you have it all built, and
put-together, and then try to make it operate as it should. If it

doesn'twork correctly when completely assembled then you

suddenly find there are ten thousand places where things

432
might not be exactly Every solder joint, every cable
right.

connection, every switch, every mechanical device, and

every electronic device suddenly becomes suspect.
The replacement of computer cards and circuit boards is
a technique which, like current TV repair procedures, is
standard. So, if you have a computerized robotic system, then
you will want to make certain that its computing section can
be broken down into small units which can be replaced if need
be when a malfunction occurs and keeps on occurring and
cannot be attributed to such things as transients, lightning, or
static.

Through the courtesy of Ohio Scientific Company we

show, in Fig. 13-5 an example of their computer's circuit
board with its attachment cabling, and even, to the left, some
internal battery powering units. Notice that neatness and
good spacing between integrated circuit chips are
relatively
predominant in this fine engineering example.

THE TRS-80 AND THE OUTSIDE WORLD

Weexamine the use of the TRS-80 in a control applica-
tion, courtesy Radio Shack and we can, from the information
gleaned, expand our imagination to extend to other applica-
tions of such a computer in a robot. It is indicated, in instruc-
tions on the use of the TRS-80 in this control type application
that external circuitry is required, and also that you will have
to have proper software to make the control functioning
possible. If you have a Level I machine then you'll have to
write the software program. If you have a Level II machine,
then you can use the POKE and PEEK or the OUT or IN
machine instructions.
It is said that when you design the hardware (circuitry)

for computer control of something, you need to have thought

out your software program completely so that the two are
compatible. How you design your hardware will be deter-
mined by the instructions you use to operate that hardware.
There are two operational approaches with the TRS-80 (and
perhaps other similar microcomputers ( which can be used,

433
Fig. 1 3-5. The Ohio Scientific's computer circuit board (courtesy Ohio Scientific).

these are the memory mapped system (Fig. 13-6) and the
second is the port system (Fig. 13-7).
you use the memory map technique then you must
If

specify a memory address that will be the location of the

hardware circuitry controlling your device(s). To write data
to your control system (send it instructions) you address it via
the address lines and send it the instructions over the data
lines.

434
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435
 One example of control of something external with the
TRS-80 is to turn on a coffee pot. A sample program is shown
below. At the same time let's look at the circuit for control of
this operation.

100 REM ***COFFEE POT POWER CONTROL***

200 CLS PRINT@512, "DO YOU WANT THE COFFEE
:

POT TURNED ON";

300 INPUT A$: IF A$ = "NO" GOTO 7840
400 REM ***IF NO, BRANCH TO "RUNNING LATE"
ROUTINE***
500 REM ***ANYTHING ELSE, TURN ON COFFEE
POT RELAY***
600 POKE - 4092,2
700 REM ***NOW TEST IF CONTROL RELAY
CHANGED STATES***
800 B=2: A-PEEK 4096 -
900 IF A AND B = THEN GOTO 1980 ELSE GOTO 3744
1000 REM ***IF RELAY WORKED, BRANCH TO
"WEATHER SENSOR" ROUTINE**
1100 REM ***IF RELAY DID NOT WORK, BRANCH TO
"SYSTEM FAULT ISOLATE"***
Look at what happens in the memory mapped system. If

the address is 8FFF

(Hex) and binary data 02 will turn the
circuit on by causing the control relay to close. A POKE
statement for this task would be POKE 36863,2. In the port
based system you specify a port address out of the 256 ports
the CPU will address. The address is selected using only 8
lines instead of the 16 lines used in the memory mapped
system. The data bus is still used to get information to and
from the CPU and the selected port. If the system had used a
port based type of control, some of the program above would
have to be changed, for example: Lines 600,800 will have to
be changed. Line 600 would read OUT 254,2 and line 800
would be: B = 2: A = INP 254. The flowcharts for both
methods are Figs. 13-8 and 13-9.

PLANNING A ROBOT
The first step is to write down what you want the
machine to do. This can take a multitude of thoughts and

436
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437
 GARBAGE ON / DISASSEMBLE UNIT
SCREEN AT / CONNECT VIDEO AND POWER
POWER ON/-> D(n pLUGS
/ PRESS ON POWER SWITCH

TURN OFF POWER

WAIT 10 SECONDS
TURN ON POWER

TURN OFF POWER

REMOVE DIP SHUNT
ATZ71. TURN ON
POWER

RAM ERRORS

TURN OFF POWER

REMOVE ROMS
TURN ON POWER

CPU PROBLEMS''

Fig. 13-8. Section isolation flowchart for TRS-80 (courtesy of Radio Shack).

438
 CPU
CLK SOURCE
BAD

SOLDER
SHORT''

CHECK SWITCH
S-2 AND
RESET LOGIC

POWER-UP
CLEAR LOGIC
DEFECTIVE

OPEN PCB ETCH' —

' ACTIVE ^
^ MRCQ? YES
MAY NOT BE
CPU PROBLEM \t
SECTION ISOLATE YES
REPLACE Z40
(CPU)

\f

CAS /RAS
LOGIC

Fig. 13-9. CPU flowchart for TRS-80 (courtesy of Radio Shack).

statements in some cases, and only one statement in other

cases. For example, one person had the initial objective "I
want a robotic machine which will entertain people." And
from that basis he did construct a robot which did exactly that,
and delightfully so. There is quite a difference in what you will
want to incorporate into the machine if it is for entertainment
rather than being built to do some specific task. One machine
might be much more complex than another, and how it is

439
controlled may be vastly different depending upon what it is

to do.
You will immediately add that the appearance of the
machine will, or might be, governed by what it is to do, and
you would be exactly right. For entertainment purposes we
might want a robot which looks manlike, or girl-like, but for
job purposes, such as taking objects from one place to
another, the robot might better resemble a small car with a
flat bed on it and have somewhat different arms which load

and unload the material, than those found on the kind-of-

human-duplicate the entertainment robot might be. So, when
thinking about what the machine is to do, or to state the
purpose for building the machine, you will probably also be
thinking about what it might look like in the finished version.
This is a second step.
Next, and closely associated with the previous thinking,
will come those thoughts related to mobility. We can make
some doodling sketches as we have done in Fig. 13-10 which
may assist us in our thinking.
You can expand on this concept and come up with,
perhaps, a dozen different possible illustrations of how a
baseplate of a robot might be made and how it might be
propelled. In our illustration at A we show a conventional
drive using a common axle and one drive motor for one rear
wheel. This is important because you can't get the robot
around a corner if you make both rear wheels a drive type.
One must be free, that is, its hole slightly larger than the axle
so it can turn freely and on own. The other wheel is fixed
its

rigidly to the axle or so mounted that a gear can be attached to

it and this gear is meshed with the motor drive gear to propel

the baseplate (and robot). The steering is just like any au-
tomobile steering, or toy car or truck, using a turning motion
for both front wheels which are linked together. This will
work, but the robot may have some problems because the
turning radius of the base is large. It is a stable base, however,
and can carry lots of weight as we know.
At B is a diagram showing two independent motors
driving two wheels, and use of small idler wheels, front and
rear, to give the platform balance. This type system is com-

440
441
monly used when you have stepping motors for drive power.
If you step the drive motors at the same speed the base goes

straight forward (or backward). If you step the motors at

different speeds, a turning motion results. Stepping one
motor forward and the other backward at the same speed
gives a very tight turning circle. It is easy to synchronize the
speed of stepping motors just by observation. If the robot
starts to turn somewhat as it goes forward, you just move the
control (assuming radio control) of the slow motor to increase
its pulsing rate slightly and synchronism is quickly obtained.
The GARCAN robot which we discussed in an earlier chapter
uses this system.
At C of Fig. 13-10 you see how one idler wheel has been
removed. The platform is not as stable as before, but can be
all you want to try to
right for level floor operation. Also, if

use the idler wheel as a drive wheel, and you

this is possible,
can so arrange the mechanics of the system that the one
driven wheel can be turned for steering purposes. You might
use a single motor in that case. Or with the three wheeled
configuration you might use a single motor to drive both rear
wheels as in (A), or use two stepping motors. There are many
variations.
So, you doodle and try to come up with some kind of a
base-and-drive-and-steering system for your robot, if it is to
have mobility. Of course, not all robots (domesticated types)
will need mobility. They may be permanent fixtures in the
house wall section somewhere, yet they can control all kinds
of functions around, and in, and from the home. These are
decisions which you must make in your planning.
You can select a wheel size and from that as a starting
point calculate the gearing needed and the motor horsepower
and so on. You select the wheel diameter based on where the
robot is to move. If the surface is smooth and has little change
in level, then a relatively small wheel size, say 4 to 6 inches
diameter might be all right. But, if you plan the robot going
into grass or on rough terrain or unpaved streets and
sidewalks and such, then a larger wheel diameter is neces-
sary, say 12 to 18 inches might not be unreasonable. Some
may argue this point so we won't say it is required, we just say

442
the larger the wheel diameter the easier it is for the wheel to
get over small rocks, and thick grass, and earth depressions
and indentations.
But there is a torque penalty as you increase the size of
the wheel which is driven. In Fig. 13-11 we show this rela-
tionship, again on a doodling basis. In A you see a large wheel
with a given size gear drive. Notice that the forces retarding
motion will be the resistance or opposing force (torque) times
the lever arm to the wheel rim from its axle. Now the motor
torque must, at least, equal this value, and here its lever arm
is much smaller, so where do we get the higher number to

make equality? We have to get a larger motor torque value

than the opposing torque value. The length of the torque
arrows (vectors) illustrate this. Now examine B where a
smaller wheel is shown, the lever arm is smaller for the
opposing torque so the frictional retarding force may be less,
thus the motor drive torque needed is less. This is one effect
of using a large wheel vs. the use of a small wheel. Notice also
the rock in the path of the wheels. For the small wheel it is a
high obstacle, for the large wheel, it is not too large an
obstacle. The larger wheel may go over the rock, the smaller
wheel may not.
In our planning, then, we come up with something as to
its size, what it is how we will steer it or control it, or
to do,
have some notion that it might steer itself, and then we doodle
a little, trying to see how and what we want to put together to
make it, and from this initial effort we find out other things we
need to research and look into to determine how we will put
our robot together. We will have looked at where it will
operate.

AFTER MOBILITY AND STEERING, THEN WHAT?

That's a good question. You might not have finished with
the steering planning, even if you have decided, approxi-
mately how you make your robot move and what
are going to
power supply you'll use and so on. You might be thinking that
you'd like to have the robot autonomous, and so that means
that some of the steering, at least, must be done by a com-
puter type electronics device. We don't say a computer di-

443
 FORCE LEVER ARM

OPPOSING FORCE (TORQUE)

MOTION DIRECTION

DRIVE LEVER ARM f A

ROCK

OPPOSING FORCE
(TORQUE)
OPPOSING FORCE
LENER ARM

MOTION DIRECTION

DRIVE FORCE DRIVEFORCE LEVER ARM

(TORQUE)

o
Fig. 13-11. Torque versus wheel size considerations for robots.

rectly because most have display screens, and maybe disk

memories and such, which you actually may not need. They
also have keyboard inputs which may or may not be appro-
priate to your planning. Actually, what you may want for your
robot may be more of a comparison type system with memory
banks, which can be programmed, and with sensor inputs
from all the various devices you imagine might be useful to
the machine. It would be nice if you have a kind of plug-in

444
keyboard which you can connect to the robot via a cable, and
through which you can adjust its memory. By adjust we mean
program, erase and re-program, as you make command
changes, and put in directions.
We have examined how a robot is taught in an industrial
application. He is "programmed" through certain maneuvers
using a small hand-held controller. The electronic circuits are
so arranged that as long as the arm is in movement, the
computer does not remember what it is doing, but when the
arm stops for any period of time, the computer makes a note of
this. Later, when the arm is under autonomous computer
control, the computer sends the arm to the various end points
precisely, quickly, and directly and the arm path may not be
the oneyou used to get it there. It might be possible to easily
program a hobby robot much in the same manner but using a
radio-control system as the hand-held controller. Suppose we
consider that in your robot you will have a radio control
receiver whose output goes to a computer and various de-
vices to be controlled, Radio-control systems such as are
used in model airplanes can be obtained with up to 8 or so
channels. If you need more than that, use two systems,
operating on different radio frequencies.
Of course you might also use a hand-held controller with
lots of push buttons, attached to a cable system which can
plug-into the robot's body, and you can follow the robot as you
command it to do whatever you want it to do. The signals
could be recorded on some kind of tape, or placed in the
memory of a computing section or whatever and then played
back later.

MORE CHEAP SPEECH

To know what is on the shelf in the way of equipment
which you might use in a hobby or industrial type robot is
often very helpful. Thus we call attention to the Radio Shack
Voxbox and Voice Synthesizer shown in Figs. 13-12, 13-13.
The Synthesizer allows the computer to "say" anything built
from phonemes. The Voxbox is designed to work with the
TRS-80 computer and is designed with a 32 word memory
which permits it to remember 32 words which you teach it,

445
 m

444
447
and produce a logic output when such words are spoken to it.
Through the courtesy of Radio Shack we show the block
diagram of the Voxbox in Fig. 13-14.

COSTS AND ACCOMPLISHMENTS

It has been said by many who are experts in the field of
human studies that humanity cannot be happy unless they can
accomplish something. In fact, this is one fear of those who
think about such things— that the age of robotics will deprive
persons of doing something worthwhile— in other words,
working. Every job performed, in spite of its problems and
frustrations and exhausting demands, means that someone
has done something which they consider worthwhile. The
sociologists think that this, perhaps, has meaning for the
happiness and contentment of the human race. Thus, when we
evaluate what we have when we have finished our hobby
robot, whatever type it may be, we must evaluate our efforts
in more terms than just of money or time spent. We must also,
always, evaluate in terms of what has been learned and in
terms of pleasure received, and personal satisfaction ob-
tained.
There are very few if any, persons, who will say, direct-
ly, that the future does not hold a place for industrial robots.
There are too many foreign countries developing such de-
vices for use in their areas of productivity. And with such
success that our own industrial leaders say that a clear view of
those operations. Much planning and consideration must go
into the concept of using more automation in existing plants,
because of the worker commitment to the various jobs. Yet
the profit motive, being the primary reason for the existence
of the plant or industry in the first place, will demand the most
economical, efficient, and productive operation possible at
the smallest possible costs. Let us examine what might be
some of the consideration for the use of industrial robots.
Do they contribute to productivity, efficiency, reduction
of error, a better product, faster production, reduce hazard-
ous situations, reduce tedium, improve the work environ-
ment, reduce costs? In many cases this requires a complete

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review of the whole operation, down to the most minute
detail, of the business, or plant, or industry wherein the use of
industrial robots is being considered. We are in mind of a
system of plan evaluation or job operation planning called
PERT (Program Review and Analysis Techniques) or, as it is
called by some, the critical path planning approach to-
whatever job or task or operation is in mind. Can it help show
the need for automation or robotics?

WHAT IS THE CRITICAL PATH APPROACH

If we take the start and end of a series of tasks and call
them events, and we take the activities in between the start
and end of each such task and call that an activity, we can make
a diagram showing this concept as illustrated in Fig. 13-15.
Notice that there are many activities (arrows) shown, 5 in
total. Also know that it will take the completion of all 5
activities before the end event can be said to be done! At this
point we do not know from whence the other activities origi-
nate, or how they may be inter-related, or interdependent
upon other end events, but be assured that in our modern
industrial world, there will be a rather complex network
before we come to that stage where the end event actually
means the completion of the job!
The starting event can be merely a time and date at
which some activity begins. The end event can be a time and
date when the job is finished. The activity can have a length
which somehow related to the time it will take to do that
is

based on the educated guesses of many experienced

activity,
personnel who have some knowledge and, hopefully, experi-
ence with doing that kind of activity. Thus we might say
activity #3 will take 4 days to complete, by best estimates.
Think what this means if it is required that all the other
activities same time frame in order
must be done within that
for the end event to properly occur on time! As you might look
over the time and date estimates of each activity, you might
findone which is so long that it is a bottleneck. It will be that
long-time activity which will hold up the job which needs
some attention. The path through that activity from its start-

ing event, to the end event, is the path known as the critical

450
Fig. 13-15. Some pert or critical path definitions.

path. It isa trouble area for some reason. It is stated that this
critical path is the one which requires the most time for any
process or object to get from the initial event to the end event.
Also, it is stated that if there is any further delay along this
critical path, then the final event wiil be delayed by whatever
time the delay on the critical path assumes.
So, how do we relate this to robotics in an industrial
sense? If we consider an example where lots of parts must

arrive at a given station at a given time in order for assembly

to be accomplished, and that a delay is found on one path, we
willassume a simple case here, wherein the distance the part
has to move, and the processes which have to be ac-
complished on this part, are responsible for that delay, then
we can see how an automated situation may remedy the
problem. It is not unreasonable to think of robots doing the
processing, and perhaps saving time doing so. It is not un-
reasonable to think of robotic conveyors transferring the
parts more quickly. Thus we change what was a critical path

451
for the parts movement, into a non-critical path and every-
thing is accomplished in the required time and lots of profit
results!
There are many approaches to consider when trying to
make a decision as to whether or not to robotize some, or all,
of your operations. There are many things to consider. For
example, you must always have in mind what will happen if a
machine fails. No one likes to think of this, but it can and does
happen. We are reminded of a situation wherein some robots
failed because the human attendant did not keep the hydraulic
oil tank filled properly, nor did he (she) report leaks which had

been observed, etc. It was determined that it was that worri-

some case of a human hating a robot and thus hoping it would
cause trouble and helped it to do so!
There is no question but that, in some cases, the robot
will displace humans in certain work functions and activities.
It is just an axiom but for some things, robots can do it better.

CONSULTING THE EXPERTS

Of course this is done. One just doesn't expect all the
people in his own operation to, necessarily, know all about
robots and robotic installations, and operation and mainte-
nance and what can and what cannot be done with these
machines. Sometimes, and this is true in most cases, an
analysis of your operation by a robotic expert will help to
show what should or should not be done. However, one must
always consider that probably any representative from any
robot manufacturing company will be a salesman. But most
will give a good, honest, and reliable report on the situation at
hand.
Because a conversion to industrial robots is an expen-
sive operation, probably in more ways than just changing
equipment, management will also want to inspect and discuss
robot plants with thosewho have already done this in part, or,
as some Japanese have done, completely robotized a plant or
industrial operation. One question which always comes to
mind is, "What do you do if some machine fails or stops, and it
is a line item which must function in order for the whole
operation to function?" First, of course, there needs to be an

452
alarm system. We have mentioned this in some previous
pages while discussing industrial robots. The alarm can be of
several levels. One, a warning that trouble is imminent, and
where it might occur, second, that trouble is happening and
where and why (sensors can determine this in many cases),
and what should be done about it: a rerouting, stopping all
machines, or whatever is appropriate, even to the extent of
human intervention and human substitution for the machine
until the robot is fixed.

There are many other items which need be considered,

such as a loss of electric power, even for just a short period of
time, and how this might affect computer programs, move-
ment, and synchronization and so on. One might use the
operating room technique wherein a substitute power plant
comes on immediately in case the main source of power starts
to fail. When consulting the experts in the field, one will

become knowledgeable of these various situations and prob-

lem solutions for these situations. It is also considered good
management if one can obtain the help and advice of the
normal plant complement of persons, who can give sugges-
tions which will make their job work easier or more palatable,
and thus they provide insight into possible areas of automa-
tionwhich will be accepted by them. Education and instruc-
tion of plant personnelis, of course, mandatory. The experts

can help with this type of public relations.

ROBOTS AROUND THE WORLD

It is also interesting to consider the robotic development
of some foreign industrialists. A study by Professor Gustav
Oiling of Bradley University states that Japan has 13,000 of
the world's 17,500 industrial robots.They have some 70
companies who are developing new robots and this compares
with some 27 companies in the U.S. It has been reaffirmed
that the Japanese goal is still the unmanned, robot operated
factory.
The progress in industrial robotics has been remarkable
and will continue at an astonishing pace. It has been said that

the new robots are simply programmable arms with some

high degree of manipulative skill. But that they have poor

453
senses and a somewhat low intelligence which is not yet able
to comprehend and really handle the information which is
presented by the various types of sensors. But that even so
they are most valuable in industry. It is not uncommon for
industrialists to recover their capital investment in robots in
somewhat under three years.
It has been pointed out that robots need something
better than the type of grippers which are now common. But
these improvements are under research and development,
especially in Japan and in Russia. Robots which have fingers
that can handle objects as delicate as an egg without any
danger of rupture, and quickly adapt to different and varied
object forms have been made. It has been stated in various
studies that one of the most valuable ways a robot can im-
prove plant production is by speeding materials through a
plant. It was found that materials are worked on only some 5%
of the time, and the rest of the time that material is lying idle
or being transferred from one place to another. When robots
some very
are specifically designed for a task, they can offer
remarkable work. For example, the Fiat Robogate, installed
in its Rivolta and Cassino factories is said to be able to
accomplish all the required welds on a car body in less than
one minute. There are more than 50 robots on each welding
bay. The precision of each job is the same so that quality
control problems are reduced, and should improvements be
needed, a slight change to the control program affects the
desired result.
The use on an assembly line seems to be
of robots
inevitable and no matterwhat the task, it now seems possible
that the job can be done by such automated machines. The
human system seems to break down when subjected to the
constant boredom of doing the same task over, hour after
hour, day after day. It was found that in Silicon Valley of
California where chips or integrated circuits are developed
and made, that this type boredom has led to such advanced
human problems as drug usage. That, of course means profit
loss to management in that quality is sacrificed, and integrity
of the firm or plant is jeopardized. That means a loss of buyer
confidence. Again, here, in this type environment and task

454
situation the robot type machine offers no such problem. It
does what it is programmed to do (what it has been taught)
endlessly, hours on end, without error, loss of quality, or
complaint.
As robotics components are developed and improved,
such as thenew TV cameras-on-a-chip developed by Hughes
AircraftCompany using the new advanced charge-coupled
technology which we have discussed somewhat in earlier
pages on robotic eyes, the ability of the robot to do more
things better will be almost beyond imagination. These
Hughes Omneyes, as they are called, consist of a chip of some
1,024 light-sensing elements for one type application, and
another chip with some 10,000 picture elements for higher
resolution. It is envisioned that the ultimate use of these
robotic eyes will be on the assembly lines to help the
machines size, orient and identify parts and objects. Because
of their small size and low power requirements, they can be
used close-up if necessary on smaller and smaller type ob-
jects,perhaps ultimately, even down to integrated circuits
themselves.

JOBS
When one considers the use of robots in a factory or plant
the questions and job-loss fear of employees, and Manage-
ment's commitment to the workers, becomes very real situa-
tions to deal with. Some questions asked by workers are,
"Will robots in factories eliminate jobs?" The answer, of
course is, yes. The robots will eliminate a majority of the old,
dull, hazardous, and non-progressive jobs. But, if one is wil-
ling to learn and adapt to a new world of robotics, then there
are opportunities which one should consider. The following
comes from a study conducted on Careers in Robotized Fac-
tories.
Robots need repair sooner or later. Robot repairmen will
be demand and will be very well paid. These personnel
in high
will also check and test the robots to insure maximum per-
formance with a minimum of breakdown. There will be robot
trainers, i.e., those who program the robots, and that will be a

field in which computer knowledge and new skills in machine

455
programming will be learned at special schools provided by
the user plant or the robot manufacturer. There will be those
who will be responsible for moving the robots to desired
workplaces if the robots are the fixed location types. These
persons will coordinate the robot's work load, and will see to
it that they are productive at their new line locations. Of

course there will be more and more need for robot designers.
These persons who have engineering backgrounds in control
and electronics and mechanical engineering and physics will
obtain very high salaries and find their work challenging and
very productive. Industrial robot use and plant analysis may
be another rewarding career field in which people, sociologi-
cal problems and machinery are all considered together. It is
going to be a long, long time before robots will be able to
repair and adjust and teach themselves much more than very
elementary operations. So they will need lots of care, adjust-
ment and help.
The respected Wall Street Journal has reported that
some factories in which robots are built by other robotic
machines without human control, have been under construc-
tion by some Japanese electronics firms. This has been the
beginning of a deep seated fear of job loss among many people
who are not knowledgeable about such machines. It is en-
tirely feasible to specify, down to the smallest detail, the
parts and layouts and connections of those parts, to make up a
robot, and then to design machines which will do the assem-
bly work so that at the end of the assembly line, a so called
robot will appear, ready to go to work.
Are robots on the increase in industry? Ransberg and
Renault have formed a venture to make and deliver industrial
robots with each system selling at $100,000 to $200,000 each.
It is said that they have invested some 15 million dollars into
this venture. The chairman Ransburg Corp. (France)
of the
has estimated that the U.S. market for industrial robots is
expected to be in the vicinity of $500 million dollars annually
by 1985.
If there is a process in a factory or plant or industrial
complex which cannot be robotized, it is just because no one

456
has examined it yet for that purpose. The many fine robotics
companies are leaping ahead, year after year, with advanced
and improved designs as the technological explosion con-
tinues, and there seems to be no end in sight. It may well be
that in the not too distance future, factories and plants and
industrial complexes and shops and stores and assembly
places and whatever will have to consider using robots in self
defense— in self defense of profits, that is.

THE COMPUTERIZED HOME AND ITS SECURITY AND CONTROLS

The computerized home might also be called a robotic
home. What is a robotic home? It is a home in which there are
many automated devices which make that home more secure,
easy to keep, and pleasurable for you to live in. In a sense this
means that you will make your entire house a kind of robot and
you will live in its protective embrace.
On the practical side, of course, what we mean is that
your home will have some kind of centralized computer which
can sense and control a multitude of functions in and around
the house. One such computer is the Scientific Instrument's
C8P which we use for an example here, although there are
many other types which can also do this kind of job (a job is an
action requiring many tasks) for you. Briefly, here are a few
other control items.
With the speech capability, the person might not have to
touch a bar at all. They simply say "Return" and this activates
the return program in the computer. Or they could say
"Help", and this would activate another computerized sub-
program which would sound an alarm and indicate where the
trouble exists. We have previously stated that such things are
possible. We look at Fig. 13-16 to see one example of a voice
system produced by Ohio Scientific in their CA-14A system.
system.
When you want to make things happen in the house, such
as to turn on the coffee pot, and turn on and off various lights
and other electrically operated devices, you need a kind of
special type computer unit and remote controlled modules.
One example of this type system is shown in Fig. 13-17.

457
Fig. 13-16. Votrax, a voice system produced by Ohio Scientific in their CA-14A
system.

The master control unit is so programmed that when you

press down the various buttons you can cause the circuits
controlled by the modules to energize, thus you turn on lights
at will from a remote location. Again, using the button con-
trols, you can deactivate those remote circuits also. Since the
control signals are sent over the house wiring, it is no task at
all to install such units, you simply plug-in the remote mod-

ules into a convenient electric outlet, and run the cord from

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the master box to the outlet in your remote command loca-
tion.You plug-in the devices you wish to control into the
modules receptacles and you are ready to operate. By the
way, don't do as some do, they plug in lights but forget to turn
the switch on. When the signal is sent from the remote
location to energize that light (or whatever), it won't work,
because its own switch is off. There is a unit made that
interfaces this system to a TRS-80.
In this robotic home concept we must not forget the
possibility of remote control, from some pleasant beach re-
sort to our homes back in our own home town. Yes, it is
possible and feasible when we use a device called a telephone
interface such as is shown in Fig. 13-18.
Looks complex, doesn't it. It is. But that is no problem to

us. When this is connected so the telephone has an input to it

you can communicate with your home computer from almost
any place in the world. If your telephone system is a
Touchtone phone you can obtain status reports on various
things in the home when you send certain coded groups of
numbers which the computer can recognize and respond to.
For example, you can tell the computer to water your plants,
give you a report on the integrity of your windows and doors,
test the air for smoke or other bad odors, also to play back for
you, any recorded messages which are on file in the telephone
message recording machine.
With appropriate sensors you might get a report on the
grass height and the dryness of the ground. If the grass needs
watering, then you can tell the computer to water, using the
robotic sprinkling system, for a specified period of time.
Imagine also that you found the grass too high, in your status
report. You simply send in a new series of coded numbers and
the computer will order the robot lawnmower into action. It
will cut the grass, following a carefully prearranged routine
path route and then return itself to its garage home or wher-
ever. It could be that in the future all mail will be electronic.
When you query from Hawaii or elsewhere the computer will
tell you to pay such and such bills and ask you if it is all right
for it to issue the checks! Yes, 'tis true, all things are possible
nowdays in our computerized, robotic world.

460
Fig. 13-18. CA-15 Universal Telephone Interface (courtesy Ohio Scientific).

SOME STEPS IN ROBOTIC DESIGN

Be it hobby type or industrial type, there are certain
steps which are generally followed in the design of robots.
These can be listed as follows:
(a) List the functions desired to be accomplished— what
it is to do now and in the future.
(b) Draw block diagrams showing the interconnection of
various units such as drive system, signal processor, etc. Use
as many block diagrams as necessary to come up with some
kind of complete picture of the machine.

461
 (c) Check the availability of the parts needed for each
block of your block diagram. If some parts are not available
then improvise, invent, construct, or change the system in
that block.
(d) Construct breadboards of your circuits and test them,
adjust them and modify them until you get the necessary and
correct operation from each board reliably and repeatably.
(e) Construct models (miniatures) of all moving, working
parts. Check for construction difficulties, needed materials,
and make such changes as necessary to accomplish the end
objective for each unit. Test and adjust each unit.
(f) Construct a full size working model of the robot-
leaving room physically for changes and modifications—
being sure you have easy access to parts and test ports. Check
the operation of each unit and the complete assembly.
(g) Construct the final package which has the desired
shape, size, and appearance you want. Test and adjust it.

Operate it, or let it operate itself. Check for faults and reliabil-
ity. Study it for improvements. Then, have fun!

462
 Index

ASEA 283
robot, description of,
Abilities, robot, 4 ASEA robot,programming the, 317
Accuracy, 18, 30, 249 ASEA robot control, 313
Accuracy of arm, 260 ASEA robot operation, 8, 300
Actuator, rotary hydraulic, 350 Assembly line, use of robots on, 27
Adaptive control, 4, 131, 134 STEP command, 250, 251
AHMAD robot, 71 Attractiveness of robots, physical, 60
Airplane servos, 89, 97 Automatic system, point-to-point, 151
Algorithms, 3, 401 Automation, 56
American Robot Corp., 6 Axes of arm, setting position of, 156
Android, definition of, 45
B
Android, domestic, 45 Base coordinates, 308
Android robots, 28
Base structure, inside the, 82
Arm, correcting position of, 159 BASIC commands, 249, 252
Arm, flexibility of, 193 BASIC language, 139, 248
Arm, powering the, 201 Bellows for power, 214
ARMBASIC language, 248 Benefits in using robots, 28
ARMBASIC pick-and-place Binary code, 263
program, 255 BIOT, 62
Arm compared to human arm, Boole, George, 126
robotic, 191
Boolean, algebra, 126
Arm design, 240
Branch, interrupt, 129
Arm details, 113
Branch, offset, 129
Arm dynamics, 10
Branch action routine,
Arm mobility, 191
See subroutine; industrial
Arm motion, recording of, 157
robot, general purpose, 122
Arm movements, examination of, 200
Branching operations, 129
Arm operation, 240
Arms, fixed location, 24 C
Artificial intelligence, 12 Camera construction, 375
ASEA robot, 280 Camera operation, 375

463
Camera-robot interface, 368 Controls, operational, 153
Cams, use of, 68 Controls, review, 183
Cartesian coordinate program, 258 Controls in programming, 152
Cassette connectors, 1 55 Control switches, 313
Central processing unit (CPU), 40 Control system, 59, 365
Chain drive system, 86 Control system, computerized, 113
Chef, robot, 52 Control unit, teaching, 117
Cincinnati Milacron T Coordinate determination, vision, 362
Industrial Robot, 112, 116 Coordinates, base, 308
Cincinnati Milacron T robot, 347 Coordinates, rectilinear, 33
Circuit, conditions of, 128 Coordinate system, 240
Circuit, talking, 427 Coordination of arm parts, 115
Circuit operation, 41 Coordination of robots in groups, 27
Circuitry, 98 Costs, 28, 115, 448
Closed loop servosystem, 219, 227 CPU, 40
Command, 122 path approach, 450
Critical

Commands in BASIC, 249, 252 path definitions, 444

Critical
Commands in programming, 112 Cyro 5-plus-2 arm robot, 34
Communication, 110, 261
Communication, languages for, 239
Communication, machine, 110
Communication, robot, 26 Data analysis function, 379
Communication between robots, 27 Data systems, spacia spatial, 381
Communication with robot, Data systems, use of, 135
two-way, 262 Data transmission,
Communication with robots, checking errors in, 430
rules for, 394 Deadband, 232
Communications, voice, 57 Decision generation, 371
Communications signals, 274 Degrees of freedom. See freedom,
Communication systems, robotic, 263 degrees of
Computer, 13, 20 Delay intelligence, 24
Computer, interfacing with Design considerations, 60
radio-control mechanism, 96 Design of robots, 134, 461
Computer, the, 365 Determining need for robots, 276
Computer-control output, 247 Diagnostic programs, 144
Computer interface, 248 Diagnostics, 25
Computer languages, 138 Digital keyboard, 325
Computer memories, 15 Dimensions of robots, 47
Computer programming and, 390 Display robots, 74
Computers, speed of, 33 Distance traveled, controlling, 136
Computer uses, 16, 132 Domestic uses for robots, 49-50
Computers for Door opener, 65
control of multiarmed robots, 143 Drives, types of, 202
Conditional branches, 129 Drive unit of ASEA, 290
Conditional-branch subroutine, 125 Duplication of actions, 19
Control, adaptive, 4, 131, 134
Control, magnetic, 425
Control, motor, 105
Control, numeric, 419 Elbow joint, robot's, 193
Control, remote, 425 Electric motor, 202
Control devices, automatic, 126 Electric system, all-, 279
Control of robots, 58 Electrohydraulic servosystem, 232
Control panel for ASEA robot, 320 Electro-mechanical states, 218
Controls, editing, 186 Employment and robots, 455
Controls, function, 160 English, Ruly,393
Controls, manual, 156 English language, 393

464
Error elimination, 230 H
Errors, checking, 430 Hand, robot, 194
Experimentation, robots for, 239 Hand compared to
External changes, adjusting to, 131 human hand, robot, 224
Eye, matrix, 362 Hardware design 0, 433
EyeCom digitizer flow operation, 389 HHTU connectors, 155
EyeCom System, 382 High-level language, 139
Eye control, 365 Hobby robots, 423
Eyes, robotic, 356, 361 See also vis-
;
Home, computerized, 457
ion Household robots, 45
Eyes attached to grippers, 389 Hughes Aircraft Industry, 62
Hughes Mobot, 62
Human actions, emulating, 10
Hydraulic drive system, 207
Hydraulic power, 203
Failsafe systems, 58
Fatigue, robotic, 28
I
Feature extraction, 377
Feedback, 5, 30, 146, 223, 227, 265, Image recognition, 379
301,248 Improvements needed, 454
Industrial applications, 6
Feedback measurement, 31
Industrial robot, multiarmed, 142
Feedback servomechanisms, 134
Industrial robots, improving, 353
Fiber-optic sensors, 339
Industry, video-inspection
Finger considerations, 331
Fingers, robot, 194
system for, 374
Information, conveying, 264
arm, 193
Flexibility of robot
Inspect-reject-accept mode, 385
FORTRAN language, 139, 140
Instruction codes, 151
Fourier Transformers, 134
list of, 183
Freedom, degrees of, 196, 200, 242
Instructions, entering, 160
Function command
Intelligence, artificial, 12
value meaning, 184
Intelligence, delay, 24
Function controls, 160
Future of robots, 448
Intelligence, providing robots with, 23
Intelligence capacity, machine, 16
Interfacing units, 368
G International robot developments, 453
GARCAN control system, 106 Interrupt branch, 129
Interrupt signals, 131
GARCAN electronics, operation of, 96
Gear system, 86
J
Greek letters, 318
Gr pper, robot, 194 Jerry Rebman Electronics Co., 73

Gr pper functions of ASEA, 286 Jog to position, 158

Gr pper of robot arm, 115
Gr pper operation, 244
Gr pper powering methods, 339 Keyboard, digital, 325
Gn pper powering units, Keyboard control system, 252
comparison 332
of, Kinematics, arm, 200
ppers, 19, 214, 326 Kitchen, automated, 54, 55
ppers, electrically operated, 338 Kitchen, robots in the, 51, 54
ppers, Fibro-Manta, 215
ppers, hydraulic-activated, 336
ppers, pneumatic, 337 Lamp test, 155
ppers, types of, 329 Languages, models of, 398
vet characteristics, 16 LaPlace Transforms, 134
vet control unit, 8 Laws governing robots, 423
vet Series 5, 5, 7 Laws of Robotics, 276
vet teaching unit, 9 Learning, 4

465
Least Squares Optimization, Multiarmed robot, 142
Wiener's, 134 Multiloop servosystem, 229
Light beam, infrared, 65 Multiplexing, 264
Limit switches, 145, 198 Multiplexing, time division, 265
Linearity, 233
Linear Predictive Coding (LPC), 40
Linkage motion, 296 NC machines, future of, 421
LISP language, 142 Next position number request, 158
Lord Company, 42 Noise, 32
LPC, 40 Nuclear inspection, robot use for, 62
Null, 232
Null shift, 232
Machine language, 13 Numeric control operations, 420
Machines, 1

Magnet device, 198

Magnetic control, 425 Open loop servosystem, 219, 230
Malfunctions, 36, 58 Optics control, 355
Manufacturing problems, 27 Optimum response, 135
Mark IV robot, 54 Optomation system operation, 372
Mathematic principles for Optomation video system, 367
robot design, 134
Mathematics in robot operation, 18
Matrix eye, 362 Palletize operation, 145
Maximum principle of Pontryagin, 134 Parallel servomechanisms, 223
Mechanical considerations, 47 Patchboard, 217
Mechanics, robotic, 48 Path control, 67
Mechanisms, robot, 77 Path control, computerized, 70
Memory, 15 Path programming, 125
Memory, loss of in Personality, robot, 59
microcomputers, 309 Pert definitions, 444
Microwave motion detector, 68, 71 Phonemes, 399
Mini-Mover 5, 240 Piston, 207
Mini-Mover 5 cable operation, 242 Piston-transfer valve, 210
Mini-Mover 5, programming the, 253 Planet Corp., 203
Mini-Mover 5 teaching program, 257 Planning a robot, 436
Mobile robot, 37 Pneumatic power system, 212
Mobile robot, programming, 135 Point to point automatic system, 151
Modifying position, 159 Polaroid Ultrasonic
Monitoring of systems, 25 Ranging System, 412
Motion detector, microwave, 71 Position, recording the, 157
Motion detector, Position, setting the, 156
Solfan microwave, 66 Position sensors, 342
Motion detector antenna patterns, 68 Power, arm, 201
Motion, in all axis, 151 Power of arm, 260
Motion, rectilinear, 33 Power of ASEA, 286
Motion, types of, 120 Power supply, 49, 82, 201
Motions of ASEA, 286 Power systems, 214
Motions, Versatran arm, 177 Prab Conveyors, Inc., 145
Motor, electric, 202 Precision, 32
Motor, stepping, 136, 203, 244 Preparation, program, 152
Motor components, 92 Principle of Optimization,
Motor control, 105 Bellman's, 134
Motor-control circuit, 98 Problems, detecting, 25
Motors, in robot design, 242 Program erase, 154
Mountain Hardware Program examples, 186
Supertalker system, 427 Programming, 109
Movement, schematic, 196 Programming, control, 139

466
Programming, industrial robot Robots in residential uses, 457
Versatran, 151 Robot system problems, 430
Programming, methods of, 139 Robot uses, 14, 62
Programming, mobile robot, 135 Robot uses, android, 49
Programming, path, 125
Programming procedure,
five-step, 152 Safety, 36
Programming robots, 13 Sanyo autofocus system, 417
Programming robots for Schematic symbols, 195
selected chores, 23 Search function, 131
Programming rules, 152 Search function, robot, 130
Programming the Mini-Mover 5, 253 Section point, 22
Program number request, 154 Security, robot use for, 63
Program preparation, 152 Security needs, home, 457
Programs for Versatran robot, 146 Selsyn-type power system, 203
Programs, simple, 186 Sensor, tactile, 131
Program teach panel, 152 Sensors, 5, 121, 199, 265
Pulse code modulation, 266, 269 Sensors, fiber-optic, 339
Sensors, fixed, 65
Sensors, gripper, 339
Sensors, position, 342
Quasar Industries, 45, 49, 59, 62 Sensors for diagnostics, 25
Series servomechanisms, 221
Servo amplifier, 305
Servo Driver unit
Radar, 67, 69, 71 electronics schematics, 237
Radio-controlled robot, Servomechanism considerations, 218
See GARCAN robot Servomechanism definitions, 218
Ranging system, 411 Servomechanisms, 32
Ranging system using light, 417 Servosystems, 219, 227, 229, 301
Receiver, infrared, 65 Shoulder joint, robot's, 192
Recognizer, the, 365 Signal, 122
33
Rectilinear coordinates, Signals, interrupt, 131
Rectilinear motion,33 Signal transference in
Reference point, 122 ASEA system, 310
Remote control, 425 Size of robots, 47
Response, optimum, 135 Sociology of robot use, 275
Response time, 15 Software, 110, 146
Robot, definition of, 42, 46 Software design, 433
Robot, derivation of, 2 Solfan, 66
Robot, display, 134 Sound -ranging system
Robot, industrial, 282 disadvantages, 413
Robot, mobile, 37 Sound-ranging system
Robot, multiarmed, 142 in robotics, 412
Robot, programming of, 151 Speak and Math machine, 397
Robot building, who, 424 Speak and Spell learning aid, 37
Robot design, 134, 461 Speech, 445
Robot diagram, Speech, robotic, 37
computer-controlled, 101 Speech, synthetic, 38
Robotics experimentation, 239 Speech chips, 408
Robot Institute of America, The, 42 Speech circuitry, 402
Robotnik, 2 Speech for robot, 392
Robot pilot, 2 Speech recognition
Robots, android, 28 automatic, 398
Robots, domestic, 45 GARCAN robot, 73
Robots, improving industrial, 353 See also voice recognition system,
Robots, types of hobby, 423 400

467
Speed of operation, 32, 41, 135 TRS-80 computer, 248, 433
programming, 162 Truth table, 128
Speed arm, 24
of robot Tubes for power, 214
Standard branching, 125
Stepping motor, 136, 203
Stepping motor, operating the, 244 Ultrasonic Ranging Marketing, 411
Subroutine, 122, 124 Uses of robots, 62
Subroutine, conditional-branch, 125 future, 454
Subroutines, linking, 139
Subroutines, nested, 175
Subroutines, unnested, 176 Vector, 20, 21
Sucker device, 198 Velocity of ACC/DEC values, 164
Suction device, 198 Verbal communication, rules for 394
Supertalker flowchart, 429 Versatran flowchart, 175
Switch, mode select key, 153 Versatran robot, 145
Switches, limit, 145, 198 Video cameras, 63, 366
Switches, mechanical, 221 Video-inspection system,
Switching devices, automatic, 126 industrial, 374
Synchronization, 86 Video signal, following the, 376
Vision, robotic, 392
Vision coordinate determination, 362
TARC control unit, 6 Vision recognition system, 368
TallBoy robot, 95 Vision system, diagram, 358
Tape player, 86 Vision tracking system, 361
Task, defining activities in, 152 Vision window, 360
Task, definition of, 20 Visual inspection systems, 385
Teaching program, 257 Vocabulary, increasing robot's, 40
Teaching robots, 6 Vocal robot, advantage to, 392
Teaching unit, 9, 117 Voice control, 57
Telemetry systems, 271 Voice recognition, 40, 71
Test robot, 6 Voice Synthesizer, 445
Testing movement of arm, 158 Voice synthesizer chip, 38
Testing programs, 144 Voice synthesizer system, 439
Testing robot systems, 432 Voice tract configuration, 403
Texas Instruments, 37 Votrax 9, 446, 458
speech circuitry, 402 Voxbox system, 438, 441
Thinking process, human, 17
Threshold, 233 W
Time factor in programming 111 Wiring of robot, 77
Time periods for movement, 70 Wrist, of robot arm, 115
Timing robot movements, 70 Wrist, robot, 193
Tl solid state speech system, 37 Wrist, three-roll, 354
Tops for robot bases, 77 Wrist design, 354
Torso, robot's, 192
Transfer valve operation terms, 232
Transforms, 134 Z-80 machine code, 250

468
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