1.

With a neat sketch explain the three degrees of freedom associated with the
5 robot wrist.

1. It is term used to describe a robots freedom of motion in three dimensional

space-specifically, ability to move forward and backward, up and down and
left and right.
2. The number of degree of freedom defines the robot’s configuration. For
example, many simple applications required movement along three axes X,Y

and Z.
These task required three joints or three degree of freedom. The three degree of
freedom in the robot arm are:

1. Roll: The first degree of freedom is the ability of the end effector to roll around the
x-axis. This motion is achieved by rotating the first joint (Joint 1) about the x-axis.
This motion allows the end effector to change its orientation about the X-axis.
2. Pitch: The second degree of freedom is the ability of the end effector to pitch
around the y-axis. This motion is achieved by rotating the second joint (Joint 2) about
the y-axis. This motion allows the end effector to change its orientation about the Y-
Axis.

3. Yaw: The third degree of freedom is the ability of the end effector to yaw around
the z-axis. This motion is achieved by rotating the third joint (Joint 3) about the z-
axis. This motion allows the end effector to change its orientation about the z-axis.

Together, these three degrees of freedom provide the end effector with the ability to
orient itself in any position within its workspace. Additionally, the remaining two joints
(Joint 4 and Joint 5) allow the end effector to move within its workspace and perform
various tasks.
 Q.2:- Briefly explain the need for robots in industries.
Robot in Czech is a word for worker or servant. A robot is a reprogrammable,
multifunctional manipulator designed to move material, parts, tools or specialized
devices through variable programmed motions for the performance of a variety of
tasks. Robots have become an integral part of modern industry due to their ability to
automate a wide range of tasks that would otherwise be time-consuming, dangerous,
or impossible for human workers. Here are some of the key reasons why robots are
used in industries.

1. Efficiency and productivity: Robots can perform repetitive tasks quickly and
accurately, with consistent results, and without getting tired. They can work
24/7 and do not need breaks, leading to increased productivity and efficiency
in manufacturing processes.
2. Quality control: Robots can be programmed to perform tasks with a high
degree of precision and accuracy, ensuring consistency and high-quality
output. This is especially important for tasks that require tight tolerances or
delicate handling.
3. Safety: Robots can perform tasks that are dangerous or hazardous to human
workers, such as handling heavy or sharp objects, working in extreme
temperatures or hazardous environments, or performing tasks that require
exposure to harmful substances.
4. Cost savings: Robots can reduce labor costs and improve efficiency, leading
to cost savings for industries that use them.
5. Flexibility: Robots can be programmed to perform a wide range of tasks, and
can be easily reprogrammed to adapt to changes in production processes,
making them ideal for industries with high product variability or short
production runs.

Overall, the use of robots in industries can lead to improved efficiency, productivity,
quality, safety, and cost savings, making them an essential tool for modern
manufacturing processes.
 Q.3:- Briefly explain the robot anatomy and related attributes
The manipulator of an industrial robot consists of a series of joints and links.
A robotic joint provides relative motion between two links of the robot. Each joint, or
axis, provides a certain degree-of-freedom (DOF) of motion. In most of the cases,
only one degree-of-freedom is associated with each joint. Therefore the robot’s
complexity can be classified according to the total number of degrees-of-freedom
they possess.
Each joint is connected to two links, an input link and an output link. Joint provides
controlled relative movement between the input link and output link. A robotic link is
the rigid component of the robot manipulator.

The robotic base and its connection to the first joint are termed as link-0. The first
joint in the sequence is joint-1. Link-0 is the input link for joint-1, while the output link
from joint-1 is link-1—which leads to joint-2. Thus link 1 is, simultaneously, the output
link for joint-1 and the input link for joint-2. This joint-link-numbering scheme is
further followed for all joints and links in the robotic systems.

Overall, the attributes of robots can include precision, accuracy, speed, strength, and
endurance, making them ideal for a wide range of industrial applications. They can
work around the clock, perform tasks with consistent quality, and handle dangerous
or hazardous materials, freeing up human workers for other tasks.
 Q. 4:- Explain the different types of translations involved in the robot motions
and write their equations
In the context of robot motions, there are two types of translations that are typically
involved: linear translation and angular translation. These translations are used to
describe the movement of a robot in a particular direction or orientation.

1. Linear Translation: Linear translation refers to the movement of a robot in a

straight line, either along one axis or along a combination of axes. The
equation for linear translation is given by
X = X0 + vt

Where x is the position of the robot at time t, x0 is the initial position of the robot, v is
the velocity of the robot, and t is the time elapsed.

2. Angular Translation: Angular translation, also known as rotation, refers to the

movement of a robot around a particular axis. The equation for angular
translation is given
Ɵ = Ɵ 0 + wt

Where θ is the final angle of the robot, θ0 is the initial angle of the robot, ω is the
angular velocity of the robot, and t is the time elapsed.

These equations can be used to program the motion of a robot to move in a desired
direction or orientation. The specific values of velocity and angular velocity will
depend on the robot's physical characteristics and the desired motion.
Q.5: Discuss about the salient features of different drive systems used in
robots.

A robot will require a drive system for moving their arm, wrist, and
body. A drive system is usually used to determine the capacity of a robot. For
actuating the robot joints, there are three different types of drive systems available
such as:
(i) Electric drive system,
(ii) Hydraulic drive system, and
(iii) Pneumatic drive system.
The most importantly used two types of drive systems are electric and hydraulic.

(i) Electric Drive System:

The electric drive systems are capable of moving robots with high
power or speed. The actuation of this type of robot can be done by either DC servo
motors or DC stepping motors. It can be well –suited for rotational joints and as well
as linear joints. The electric drive system will be perfect for small robots and precise
applications. Most importantly, it has got greater accuracy and repeatability. The one
disadvantage of this system is that it is slightly costlier. An example for this type of
drive system is Maker 110 robot.

Ø Hydraulic Drive System:

The hydraulic drive systems are completely meant for the large –sized robots. It can
deliver high power or speed than the electric drive systems. This drive system can
be used for both linear and rotational joints. The rotary motions are provided by the
rotary vane actuators, while the linear motions are produced by hydraulic pistons.
The leakage of hydraulic oils is considered as the major disadvantage of this drive.
An example for the hydraulic drive system is Unimate 2000 series robot.

Pneumatic Drive System:

The pneumatic drive systems are especially used for the small type robots, which
have less than five degrees of freedom. It has the ability to offer fine accuracy and
speed. This drive system can produce rotary movements by actuating the rotary
actuators. The translational movements of sliding joints can also be provided by
operating the piston. The price of this system is less when compared to the hydraulic
drive. The drawback of this system is that it will not be a perfect selection for
the fasteroperations.
Q. 6. Discuss in detail the selection and design considerations of grippers in
robot.
Grippers are an important component of robots that are used to manipulate objects
in a wide range of applications such as manufacturing, warehousing, and agriculture.
The selection and design of grippers play a crucial role in the performance and
efficiency of a robot. In this answer, we will discuss the key considerations that
should be taken into account when selecting and designing grippers for robots.
Type of Gripper: The first consideration is the type of gripper that is needed for the
application. There are several types of grippers available, including parallel grippers,
angular grippers, and vacuum grippers. The type of gripper that is chosen will
depend on the nature of the task and the characteristics of the objects being
manipulates.
1. Type of Gripper: The first consideration is the type of gripper that is needed
for the application. There are several types of grippers available, including
parallel grippers, angular grippers, and vacuum grippers. The type of gripper
that is chosen will depend on the nature of the task and the characteristics of
the objects being manipulated.
2. Payload Capacity: Another important consideration is the payload capacity of
the gripper. This is the maximum weight that the gripper can lift and hold. The
payload capacity of the gripper should be sufficient to handle the weight of the
objects being manipulated.
3. Gripping Force: The gripping force of the gripper is also important, as it
determines how tightly the gripper can hold an object. The gripping force
should be sufficient to hold the object securely, but not so strong that it
damages the objects.
4. Gripping Range: The gripping range of the gripper is the range of object sizes
that the gripper can handle. The gripper should be able to adjust its gripping
range to accommodate a variety of object size.
5. Gripping Speed: The gripping speed of the gripper is the speed at which it can
open and close. The gripping speed should be optimized for the application to
minimize cycle time and increase productivity.
6. Durability and Reliability: The gripper should be designed to be durable and
reliable, as it will be subjected to frequent use and may be exposed to harsh
environmental conditions.
7. Control and Integration: The gripper should be easy to control and integrate
with the robot’s control system. It should be compatible with the robot’s
software and control interface, and its operation should be programmable.
8. Safety: The gripper should be designed with safety in mind, to prevent injury
to operators or damage to the objects being manipulated. Safety features may
include sensors to detect objects or people in the gripper’s path, and
mechanisms to prevent the gripper from closing too tightly.
9. Cost: The cost of the gripper is also an important consideration, as it will affect
the overall cost of the robot system. The gripper should be cost-effective while
still meeting the performance requirements of the application.
In summary, when selecting and designing grippers for robots, it is important to
consider the type of gripper, payload capacity, gripping force, gripping range,
gripping speed, durability and reliability, control and integration, safety, and cost.
By carefully considering these factors, a gripper can be selected or designed that
meets the needs of the application, maximizes efficiency, and ensures safety.
Q.7. Briefly explain any 3 of the following gripper systems with industrial
application i. Mechanical
ii. Magnetic
iii. Vacuum
1. Mechanical grippers: Mechanical grippers use a set of mechanical jaws to grip
and hold objects. They are commonly used in applications that require high
gripping force and a reliable grip, such as picking up heavy objects in
manufacturing or construction. One example of a mechanical gripper system
is the parallel gripper, which has two jaws that move parallel to each other to
grip objects. These grippers can be used to pick up a wide variety of objects,
ranging from small parts to large sheets of metal.

2. Magnetic grippers: Magnetic grippers use magnetic fields to grip and hold
objects. They are often used in applications that require a fast and reliable
grip, such as handling metal parts in a manufacturing environment. One
example of a magnetic gripper system is the magnetic plate gripper, which
uses a flat magnetic plate to grip and hold metal parts. These grippers can be
used to pick up metal parts of various sizes and shapes, and they are ideal for
applications that require a high level of speed and precision.
3. Vacuum grippers: Vacuum grippers use suction to grip and hold objects. They
are commonly used in applications that require a gentle grip, such as handling
delicate objects in a manufacturing or packaging environment. One example
of a vacuum gripper system is the suction cup gripper, which uses one or
more suction cups to grip and hold objects. These grippers can be used to
pick up a wide variety of objects, ranging from small parts to large sheets of
paper or cardboard. Vacuum grippers are also ideal for applications that
require a clean and dust-free environment, such as in the electronics or
semiconductor industries.
 Q. 8. Describe the classification of sensors and the factors to be
considered for its selection
Robots use a variety of sensors to perceive and interact with their environment.
These sensors can be classified based on the type of information they gather,
such as position, velocity, force, and tactile feedback. In this answer, we will
discuss the different types of sensors used in robots and the factors that should
be considered when selecting a sensor for a specific application
Classification of Robot Sensors:
1. Position Sensors: Position sensors are used to determine the position of a
robot’s end-effector or other moving parts. These sensors can be based on
different technologies such as optical encoders, magnetic encoders, or
potentiometers.
2. Velocity Sensors: Velocity sensors are used to determine the speed or
velocity of a robot’s moving parts. These sensors can be based on
technologies such as tachometers, laser doppler velocimeters, or
accelerometers.
3. Force Sensors: Force sensors are used to measure the amount of force
being applied to a robot’s end-effector or other moving parts. These sensors
can be based on technologies such as strain gauges, load cells, or
piezoelectric sensors.
4. Tactile Sensors: Tactile sensors are used to provide feedback on the texture,
hardness, or softness of an object that a robot is touching. These sensors can
be based on technologies such as pressure sensors or tactile arrays.
Factors to Consider for Sensor Selection:
a. Accuracy: The accuracy of a sensor is the degree to which it can provide
precise and reliable measurements. The accuracy of a sensor should be high
enough to meet the requirements of the application.
b. Resolution: The resolution of a sensor is the smallest detectable change in
the quantity being measured. A sensor with high resolution is better able to
provide detailed measurements, and is therefore preferred for applications
that require high precision.
c. Range: The range of a sensor is the minimum and maximum values that it
can measure. A sensor with a wide range is more versatile and can be used
in a variety of applications.
d. Sensitivity: The sensitivity of a sensor is the degree to which it can detect
small changes in the quantity being measured. A sensor with high sensitivity
is better able to detect small changes, and is therefore preferred for
applications that require high accuracy.
e. Environmental Conditions: The environmental conditions in which the
sensor will operate should also be considered. For example, sensors used in
harsh or hazardous environments may need to be ruggedized or protected
from dust, moisture, or extreme temperatures.
f. Cost: The cost of a sensor is an important consideration, as it can affect the
overall cost of the robot system. The sensor should be cost-effective while still
meeting the performance requirements of the application.
In summary, when selecting a sensor for a robot, it is important to consider the
accuracy, resolution, range, sensitivity, environmental conditions, and cost. By
carefully considering these factors, a sensor can be selected that meets the
needs of the application, ensures the performance and safety of the robot, and
optimizes cost.
 Q. 9. Explain different types of robot programming methods
Robot Programming is the defining of desired motions so that the robot may
perform them without human intervention.
Different types of programming methods
1.Manual Method
2.Walkthrough Method
3.Leadthrough Method
4.Off-line Programming
1. Manual Method
This method is not really programming in the conventional sense of the word. It
more like setting up a machine rather than programming. It is the procedure to
used for simpler robots and involves setting mechanical stops. Cams, switches.
Or relays in the robot control unit. For this low technology robots used for short
work cycles(e.g: pick and place operations), the manual programming method is
adequate. Manual programming is a method of programming robots where the
operator manually enters code or instructions into the robot controller using a
computer or handheld pendant. This method is typically used for simple or one-
off tasks that do not require complex automation.
2. Walkthrough Method
Programmer manually moves the robot arm and hand through the motion
sequence of the work cycle. Each movement is record into memory for subsequent
playback during the production.
The speed with which the movements are performed can usually be controlled
independently so that the programmer does not have any worry about the cycle time
during the walkthrough.
The main concern is getting the position sequence correct.
The walkthrough method would be appropriate for spray painting and arc welding
robots.
3. Leadthrough Method
The lead through method makes use of teach pendent to power drive the robot
through its motion sequence. The teach pendant is usually a small hand held device
with switches and dials to control the robot’s physical movements. Each motion is
recorded and into memory for future playback during the work cycle. The
leadthrough method is very popular among the programming methods because of
ease and convenience.
Advantage:
1. Easy – No special programming skills or training
Disadvantages:
1. not practical for large or heavy robots
2. High accuracy and straight-line movements are difficult to achieve, as are
any other kind of geometrically defined trajectory, such as circular arcs, etc.
3. difficult to edit out unwanted operator moves
4. difficult to incorporate external sensor data
5. Synchronization with other machines or equipment in the work cell is difficult
 6. A large amount of memory is required.
4. Off-line Programming
This method involves the preparation of the robot programming off line, in a
manner similar to NC programming. Off-line robot programming is typically
accomplished on a computer terminal. After the program has been prepared, it is
entered into the robot memory for use during the work cycle.
Programs can be developed without needing to use the robot
• The sequence of operations and robot movements can be optimized or easily
improved
• Previously developed and tested procedures and subroutines can be used
• Programs can more be easily properly documented and commented.
External sensor data can be incorporated, though this typically makes the
programs more complicated, and so more difficult to modify and maintain
• Existing CAD data can be incorporated-the dimensions of parts and the
geometric relationships between them, for example.
• Programs can be tested and evaluated using simulation techniques, though this
can never remove the need to do final testing of the program using the real
robot.
Q.10. Explain different types of robot programming languages
Non computer controlled robots do not require programming language. They are
programmed by the walkthrough or lead through methods while the simpler robots
are programmed by manual methods. With the introduction of computer control for
robots came the opportunity and the need to develop a computer oriented robot
programming language.
1. VALTM Language
2. MCL Language
3. APT based language
1. VALTM Language
The VAL (victor assembly language) language was developed by the victor
scheinman for PUMA robot, an assembly robot produced by unimation
corporation. It is basically off-line language in which program defining the motion
sequence is can be developed off-line but various point location used in the work
cycle are defined by lead through.

VAL statements are divided into two categories a) Monitoring command b)

Programming instructions.

Monitor command are set of administrative instructions that direct the operation
of the robot system. Some of the functions of Monitor commands are

a. Preparing the system for the user to write programs for PUMA
b. Defining points in space
c. Commanding the PUMA to execute a program
d. Listing program on the CRT

Examples for monitor commands are: EDIT, EXECUTE, SPEED, HERE etc.

Program instructions are a set of statements used to write robot programs. One
statement usually corresponds to one movement of the robots arm or wrist.

Example for program instructions are Move to point, move to a point in a straight
line motion, open gripper, close gripper. (MOVE, MOVES, APPRO, APPROS,
DEPART, OPENI, CLOSEI, AND EXIT)

Examples of a program instructions includes

a. Move to a point

b. Move to a point in straight line

c. Open gripper

d. Close gripper

2. MCL Language
 MCL stands for Machine Control Language developed by Douglas. The
language is based on the APT and NC language. Designed control complete
manufacturing cell. MCL is enhancement of APT which possesses additional
options and features needed to do off-line programming of robotic work cell.
Additional vocabulary words were developed to provide the supplementary
capabilities intended to be covered by the MCL. These capability include Vision,
Inspection and Control of signals
MCL also permits the user to define MACROS like statement that would be
convenient to use for specialized applications.

MCL program is needed to compile to produce CLFILE.

Some commands of MCL programming languages are DEVICE, SEND,

RECEIV, WORKPT, ABORT, TASK, REGION, LOCATE etc.

3. APT based language

It is robot programing language which is used for writing robot controlling
program. It is a high level language that provide simple way to program robot for
specific task such as pick and place operation for welding.

APT provide a range of feature including

1) Intuitive Syntax making it easier for user to learn and write program.
2) GUI provided for programing robot which make user to visualise and test their
program.
3) Task level programing : It provide desired outcome for a task rather than how
the task is executed.
4) Standardisation:- It is standardised language which means program written in
APT can be used for variety of Robot.

Some command used in APT are

MOVE

SPPED

GRIPPER

WAIT

LOOP

IF

SUBROUTINBE
Q:- 11. What are the advantages of Electrical Discharge Machining process
over the conventional Processes
EDM machines offer a broad range of benefits that other manufacturing methods
cannot match. Some reasons to choose a Wire EDM Machine include:

1. Precision: When you need highly accurate machining, EDM manufacturing is

your best option. It is capable of making cuts that match your designs within ±
0.0001”.

2. Intricacy: Wire EDM is an excellent option for manufacturing delicate and

intricate parts. With Wire EDM, it is possible to manufacture the same intricate
part over and over again with the same accuracy.

3. Shorter lead times: Because the EDM process is so accurate, it makes it

possible to significantly shorten the lead time by getting it right on the first try.
Decreasing the time it takes to get a product from the prototype phase to the
marketplace.

4. Less set up time: EDM manufacturing reduces the need for tooling, which in
turn lessens the amount of time that it takes to set up.

5. Tapers: EDM machining is useful for cutting long tapers that other machining
methods cannot produce.

6. Accurate internal cuts: Square-edged internal cuts are difficult to produce

with other machining methods, but Wire EDM makes it possible.

7. Better results: EDM machining is capable of producing parts that do not

have burrs or require tooling. Wire EDM also creates a better surface finish
than other forms of manufacturing.

8. Fine hole drilling: EDM drilling is capable of producing tiny holes that are
difficult to produce with other methods.

Limitation

• Metal-removal rates are low.

• Material to be machined must be electrically conductive.

• Rapid electrode wear can become costly.

Electrodes smaller than .003 in. in diameter are impractical.

Q. 12. Explain the working principle of Electrical Discharge Machining with a
neat sketch.

Wire Electrical Discharge Machining (EDM) is a manufacturing process that

uses a thin metal wire to cut through electrically conductive materials, such as metal.
The wire is charged with electricity and is guided along a programmed path through
the work piece. As the wire travels through the workpiece, it generates a spark that
erodes the material and creates a cut.

The principle of wire cut EDM is based on the phenomenon of electric

discharge or spark erosion. When an electrically conductive material is placed in a
dielectric fluid and subjected to a high voltage electrical discharge, a spark is
generated that vaporizes a small portion of the material. This spark erosion process
is repeated many times as the wire is guided along the programmed path, resulting
in a cut through the workpiece.

The wire used in wire cut EDM is typically made of brass or tungsten, and is
very thin, usually ranging from 0.1 to 0.3 mm in diameter. The wire is continuously
fed through the workpiece as it is being cut, and is held under tension to maintain a
constant cutting force.

The EDM process is typically carried out in a dielectric fluid, which serves
several purposes. The fluid helps to cool the workpiece and the wire, and also
serves as an electrical insulator, allowing the electric discharge to occur only in the
desired location. The fluid also helps to flush away the eroded material and other
debris.

Wire cut EDM is a highly precise and accurate machining process, capable of
producing complex shapes with tight tolerances. It is often used in the production of
high-precision components for the aerospace, medical, and electronics industries,
among others.

Four main operating systems of wire-cut electrical discharge machines

 i. Servo mechanism

It Controls cutting current levels, feed rate of drive motors, and traveling speed of
wire. Automatically maintains constant gap of .001 to .002 in. between wire and work
piece Important there be no physical contact. Advances work piece into wire, senses
work-wire spacing, and slows or speeds up drive motors to maintain proper arc gap.

ii. Dielectric fluid

Usually deionized water serves several functions:

1. Helps initiate spark between wire and work

2. Serves as insulator between wire and work

3. Flushes away particles of disintegrated wire and work from gap to prevent
shorting

4. Acts as coolant for both wire and workpiece

iii. Electrode

Spool of brass, copper, tungsten, molybdenum, or zinc wire ranging from .002 to
.012 in. in diameter (2 to 100 lb)

Continuously travels from supply spool to take up spool so new wire always in spark
area.

Both electrode wear and material-removal rate from workpiece depend on: Material's
electrical and thermal conductivity, its melting point and duration and intensity of
electrical pulses.

Characterstics of electrode Material

• Be good conductor of electricity.

• Have high melting point.

• Have high tensile strength.

• Have good thermal conductivity.

• Produce efficient metal removal from workpiece.

iv. Machine control unit