Module - 1

Industrial Automation: Definition, Types of automation, List basic Devices in

Automated Systems, Distinguish Different Controllers Employed In Automated

Systems. Identify Safety in Industrial Automation

Basic Concepts: Definition and origin of robotics – different types of robotics –

various generations of robots – degrees of freedom – Asimov’s laws of robotics

Definition: Industrial automation refers to the use of control systems, such as

computers or robots, and information technologies to handle different processes

and machinery in an industry to replace human intervention. This automation

aids in improving efficiency, reliability, and quality while reducing costs and

increasing safety.
 Types of automation
Automated manufacturing systems
can be classified into three basic
types:
(1) Fixed automation,
(2) Programmable automation,
(3) Flexible automation.
 Fixed Automation
Fixed automation is a system in which the sequence of processing (or
assembly) operations is fixed by the equipment configuration.

Typical features of fixed automation are

(1) High initial investment for custom-engineered equipment

(2) High production rates, and

(3) Inflexibility of the equipment to accommodate product variety.

 Programmable Automation
The production equipment is designed with the capability to change the sequence of
operations to accommodate different product configurations.
The operation sequence is controlled by a program, which is a set of instructions coded so
that they can be read and interpreted by the system. New programs can be prepared and
entered into the equipment to produce new products. Some features that characterize
programmable automation
(1) high investment in general-purpose equipment,
(2) lower production rates than fixed automation,
(3) flexibility to deal with variations and changes in product configuration,
(4) high suitability for batch production
 Flexible Automation

Flexible automation is an extension of programmable automation.

A flexible automated system is capable of producing a variety of parts or
products with virtually no time lost for changeovers from one design to the
next.
There is no lost production time while reprogramming the system and altering
the physical setup (tooling, fixtures, machine settings).
The system can produce various mixes and schedules of parts or products
instead of requiring that they be made in batches. Features of flexible
automation include
(1) high investment for a
custom-engineered system,
(2) continuous production of variable mixtures of parts or products,
(3) medium production rates, and
(4) flexibility to deal with product design variations.
 Basic Devices in Automated Systems
Common devices used in automated systems include:
• Sensors: Detect physical changes or conditions.
• Actuators: Execute control commands, such as motors, valves, or solenoids.
• Programmable Logic Controllers (PLCs): Control devices used to automate
processes.
• Human-Machine Interface (HMI): Allows operators to interact with the
automation system.
• Industrial Robots: Mechanisms capable of performing tasks autonomously or
semi-autonomously.
Controllers Employed in Automated Systems:
• CPLCs (Programmable Logic Controllers): Widely used for industrial
automation due to their flexibility and reliability.
• Distributed Control Systems (DCS): Common in process industries for
controlling multiple processes or units.
• SCADA (Supervisory Control and Data Acquisition) Systems:
Monitor and control industrial processes in real-time.
• PACs (Programmable Automation Controllers): Combine features of
PLCs and PCs for enhanced functionality.
 Safety in Industrial Automation:
• Safety is paramount in industrial automation to protect personnel,
equipment, and the environment. Safety measures include:
• Risk assessment and hazard analysis.
• Implementation of safety protocols and procedures.
• Use of safety-rated components and devices.
• Safety interlocks and emergency stop systems.
• Personnel training and awareness programs.
• Compliance with industry standards and regulations (e.g., ISO 13849,
IEC 61508).
 Basic Concepts
• Official definition of robot was given Robot Industry Association
(RIA), formerly known as Robot Institute of America.

“ A robot is a reprogrammable, multifunctional manipulator

designed to move material, parts, tools, or specialized devices
through variable programmed motion for the performance of a
variety of tasks”
Origin of Robotics
 Four Common Robot Configuration
Industrial robots are available in a wide variety of sizes, shapes and
physical configuration. The vast majority of today's commercially
available robots possess one of the basic configuration.
1. Polar Configuration
2. Cylindrical Configuration
3. Cartesian Coordinate Configuration
4. Jointed-arm Configuration
 Generation of Robots
1. First Generation (1950s-1970s): These were primarily large, bulky machines
used in industrial settings, often performing repetitive tasks like assembly line
work. They were typically operated by analog or basic digital controls.
2. Second Generation (1980s-1990s): This era saw the introduction of computer-
controlled robots capable of more complex tasks. They were still mainly used in
industrial applications but began to incorporate sensors for feedback and more
advanced programming.
3. Third Generation (2000s-2010s): These robots started to become more versatile
and capable of working alongside humans. They often featured improved sensors,
more sophisticated programming, and were used in a wider range of industries,
including healthcare, logistics, and even consumer products.
4. Fourth Generation (2010s-present): This generation is characterized by
advancements in artificial intelligence and machine learning. Robots are
becoming smarter, more autonomous, and more adaptable to various
environments. They can learn from experience, interact with humans more
naturally, and perform increasingly complex tasks with greater efficiency.
5. Future Generations: While it's challenging to predict with certainty,
future generations of robots are likely to continue the trend of increased
autonomy, intelligence, and adaptability. This may include breakthroughs in
areas such as human-robot interaction, mobility, dexterity, and ethics,
leading to robots that are even more integrated into our daily lives and
capable of performing tasks we once thought only humans could do.
 Degrees of Freedom

• Vertical traverse: This is the capability to

move the wrist up or down to provide the
desired vertical attitude.
• Radial Traverse : This involves the extension
or retraction (in or out movement) of the
arm from the vertical center of the robot.
• Rotational Traverse. This is the rotation of
the arm about the vertical axis.

The degrees of freedom associated with the

arm and body of the robot are shown in figure
for a polar configuration robot.
 Three degrees of freedom associated with the robot wrist.
The wrist movement is designed to enable the robot to orient the end effector
properly with respect to task being performed. The wrist normally provided
with up to three degree of freedom.
1. Wrist roll : Also called wrist swivel, this involves rotation of the wrist
mechanism about the arm axis.
2. Wrist Pitch : Given that the wrist roll is in its center position, the pitch
would involve the up or down rotation of the wrist. Wrist pitch is also
sometimes called wrist bend.

3. Wrist yaw: Again, given that the wrist swivel

is in the center position of its range, wrist yaw
would involve the right or left rotation of the
wrist.
 Asimov’s laws of robotics
The Three Laws of Robotics are a set of rules devised by science fiction
author Isaac Asimov for his stories and novels about robots. They are:
1. A robot may not injure a human being or, through inaction, allow a
human being to come to harm.
2. A robot must obey the orders given it by human beings, except
where such orders would conflict with the First Law.
3. A robot must protect its own existence as long as such protection
does not conflict with the First or Second Laws.
 Module 2
Fundamentals of Robotics: robot anatomy, work volume, robot drive
systems, control systems, precision of movement, end effectors,
Introduction to Manipulator kinematics, Robot Dynamics.

Basic control systems and components: Basic control systems concepts

and models, Controllers, control system analysis,
 Robot anatomy
The Anatomy of Industrial Robots deals with the
assembling of outer components of a robot such
as wrist, arm, and body. Before jumping into
Robot Configurations, here are some of the key
facts about robot anatomy. Arm:
The arm is the main structural
Base: component of the robot.
The base is the foundation of the robot. It consists of multiple segments
It provides stability and support for the or links connected by joints.
entire structure. Often includes a Joints allow the arm to move in
rotating mechanism to allow the robot various directions, providing
to move around its workspace. flexibility and reach.
End Effector:
Joints: The end effector is the tool or device
Each joint enables a specific type of attached to the end of the robot's arm.
movement. Common types of joints include It interacts directly with the
revolute (rotational) joints and prismatic environment to perform tasks.Examples
(linear) joints. The number and configuration of end effectors include grippers,
of joints determine the robot's range of welding torches, and suction cups.
motion.
Actuators:
Actuators are the components responsible for moving the
robot's joints and end effector.
Electric motors, pneumatic cylinders, and hydraulic
actuators are common types of actuators used in
robots. Actuators convert energy into mechanical motion
to drive the robot's movement.

Sensors:
Sensors provide feedback to the robot's control system. They gather
information about the robot's surroundings, position, and
status. Examples of sensors include proximity sensors, encoders, and
vision systems.
 Work Volume
Work volume is the term that refers to the space within which the robot
can manipulate its wrist end.
The work volume is determined by the following physical
characteristics of the robot:
• The robot's physical configuration (type of joints, structure of links)
• The size of the body, arm, and wrist components
• The limits of the robot's joint movement
 Robot drive systems
1.The drive system determine its speed of operation, load carrying capacity,
and its dynamic performance. To some extent, the drive system determines,
the kind accomplish.
Types of drive systems
1.Hydraulic drive
2.Electric drive
3.Pneumatic drive
4.Advanced actuators
 Control Systems
In order to operate, a robot must have a means of controlling its drive system to
properly regulate its motion.
Four types of robot controls
Commercially available industrial robots can be classified into four categories
according to their control systems. The four categories are
1. Limited-sequence robots – Pick and place robot
2. Playback robots with point-to-point control
3. Playback robots with continuous path control
4. Intelligent robots
 Limited-Sequence Control
• This is the most elementary control type
• It can be utilized only for simple motion cycles, such as pick-and-place
operations
• Interlocks are sometimes used to indicate that the particular joint actuation
has been accomplished so that the next step in the sequence can be
initiated.
• However, there is no servo-control to accomplish precise positioning of
the joint. Many pneumatically driven robots are limited-sequence robots.
 Playback with Point-to-Point Control
• Playback robots represent a more
sophisticated form of control than
limited-sequence robots.
• Playback control means that the
controller has a memory to record
the sequence of motions in a
given work cycle, as well as the
locations and other parameters
(such as speed) associated with
• In point-to-point (PTP) control,
each motion, and then to individual positions of the robot arm
subsequently play back the work are recorded into memory
cycle during execution of the
• Feedback control is used during the
program. motion cycle to confirm that the
individual joints achieve the specified
locations in the program.
 Playback with Continuous Path Control
Continuous path robots have the same playback capability as the previous type. The
difference between continuous path and point-to-point is the same in robotics as it is
in NC. A playback robot with continuous path control is capable of one or both of the
following.
•Greater storage capacity. The controller has a far greater storage capacity than its
point-to-point counterpart, so the number of locations that can be recorded into
memory is far greater than for point-to-point.
o In PTP, only the final location of the individual motion elements are controlled, so the path
taken by the arm to reach the final location is not controlled.
•Interpolation calculations. The controller computes the path between the starting
point and the ending point of each move using interpolation routines similar to those
used in NC. These routines generally include linear and circular interpolation
 Intelligent Control
• an intelligent robot is one that exhibits behavior that makes it seem intelligent.

o Some of the characteristics that make a robot appear intelligent include the capacities to interact with its

environment, make decisions when things go wrong during the work cycle, communicate with humans,

make computations during the motion cycle, and respond to advanced sensor inputs such as machine

vision.

• In addition, robots with intelligent control possess playback capability for both PTP and continuous path

control. All of these features require

o a relatively high level of computer control and

o an advanced programming language to input the decision-making logic and other “intelligence” into

memory
 Precision of movement
A robot is expected to perform repeated tasks in a real world and hence its
performance is ultimately measured by its ability to position and orient the
end effector at the desired located a large number of times.
1.Spatial resolution
2.Accuracy
3.Repeatability
Spatial Resolution : The spatial resolution of a robot is the smallest increment
of movement into which the robot can divide its work volume. Spatial
resolution depends on two factors: the system's control resolution and the robot's
mechanical inaccuracies. It is easiest to conceptualize these factors in terms of a
robot with one degree of freedom.
Accuracy : Accuracy refers to a robot's ability to position its wrist end at a
desired target point within the work volume. The accuracy of a robot can be
defined in terms of spatial resolution because the ability to achieve a given
target point depends on how closely the robot can define the control increments
for each of its joint motions.
Repeatability : Repeatability is concerned with the robot's ability to position its
wrist or an end effector attached to its wrist at a point in space that had
previously been taught to the robot. Repeatability and accuracy refer to two
different aspects of the robot's precision.
Accuracy and Spatial Resolution
Repeatability and Accuracy
 End effectors
For industrial applications, the capabilities of the basic robot must be
augmented by means of additional devices.
They include the tooling which attaches to the robot’s wrist and the sensor
systems which allow the robot to interact with its environment.
In robotics, the term end effector is used to describe the hand or tool that is
attached to the wrist. The end effector represents the special tooling that
permits the general-purpose robot to perform a particular applications. This
special tooling must usually be designed specifically for the applications.
End effectors can be divided into two categories : Grippers and tools.
Grippers would be utilized to grasp an object, usually the workpart, and hold it
during the robot work cycle.
A tool would be used as an end effector in applications where the robot is
required to perform some operation on the workpart. These applications
include spot welding, arc welding, spray painting, and drilling.
 Manipulator Kinematics
Manipulator kinematics deals with understanding the motion of robot arms without
considering the forces that cause the motion. It involves studying the position,
velocity, and acceleration of different parts of the robot's arm as it moves through
space.
Forward Kinematics: This involves determining the position and orientation of the
end-effector (the tool or hand of the robot) given the joint angles. It's like figuring out
where the robot's hand is when you know how its joints are moving.
Inverse Kinematics: Inverse kinematics is the opposite process; it determines the joint
angles needed to achieve a desired position and orientation of the end-effector. It's
like figuring out how to move the robot's joints to reach a specific point in space.

Differential Kinematics: This relates the joint velocities to the end-effector's linear
and angular velocities. It's essential for controlling the speed and direction of the
robot's movements.
 Robot Dynamics:
Robot dynamics focuses on the forces and torques that cause the motion of the
robot. It's concerned with how the robot's motion changes over time due to
applied forces or torques.
Forward Dynamics: Given the forces or torques acting on the robot's joints,
forward dynamics predicts the resulting motion of the robot. It's like simulating
how the robot will move under given forces.
Inverse Dynamics: Inverse dynamics calculates the forces or torques needed at
the joints to achieve a desired motion of the robot. It's used in control systems to
determine the required inputs to make the robot move as desired.
Lagrangian Dynamics: This is a common method for deriving the equations of
motion for robotic systems. It's based on the principle of least action and is
particularly useful for complex systems with multiple degrees of freedom.