Industrial Robotics FAT Answer

Module-1
1 .Manipulator configuration: Polar and articulated (write about the mechanical joint and link arrangement, draw its
work volume finally its advantage and disadvantages.)

Polar Manipulator Configuration

Also known as spherical configuration, the Polar manipulator has a base that allows it to rotate about the vertical axis, a
moving arm attached to the base, and a linear extension/retraction capability.

1. Rotational Joint: Allows the arm to rotate around the base.

2. Revolute Joint: Provides the up-and-down movement of the arm.
3. Prismatic Joint: Extends and retracts the arm linearly.

Work Volume

The work volume of a Polar manipulator is defined by a spherical shell. The range is determined by the rotation
around the base, the vertical movement, and the linear extension of the arm.

Advantages

Simplicity: Mechanically simpler due to fewer joints.

Strength: Can be built to handle heavy loads.

Reach: Excellent reach with fewer constraints on the workspace.

Disadvantages

Limited Flexibility: Not as versatile as other configurations due to fewer degrees of freedom.

Complex Control: Requires more complex algorithms for precise movements.

Articulated Manipulator Configuration

Commonly referred to as a robotic arm, the articulated configuration mimics the human arm with multiple rotary
joints.

1. Rotational Base Joint: Allows the entire arm to rotate.

2. Shoulder Joint: Allows the arm to lift and lower.
3. Elbow Joint: Provides additional flexibility by bending the arm.
4. Wrist Joint: Enhances dexterity with multiple degrees of freedom.
Work Volume

The work volume of an articulated manipulator is generally larger and more complex, resembling a spherical or
cylindrical shape, allowing greater flexibility and accessibility.

Advantages

High Flexibility: High degree of flexibility and range of motion.

Precision: Capable of intricate and detailed tasks.

Reach and Accessibility: Can access hard-to-reach places easily.

Disadvantages

Complexity: Mechanically more complex with multiple joints.

Cost: Higher manufacturing and maintenance costs.

Control: Requires sophisticated control algorithms.

2 .Closed loop positioning system (draw the closed loop positioning system and explain, write down its related
formulas).

A closed-loop positioning system, often used in automation and robotics, ensures precise control of a device's
position. It constantly monitors and adjusts the position to match the desired set point, utilizing feedback from sensors to
correct errors.

Components of a Closed-Loop Positioning System:

Controller: Processes the input signal and determines the necessary output to achieve the desired position.

Actuator: Moves the system to the desired position.

Feedback Sensor: Measures the actual position and sends this information back to the controller.

Comparator: Compares the actual position with the desired position and generates an error signal.
Work Process:

Command Issued: The controller sends a command to the actuator to move to a specific position.

Movement: The actuator moves the system towards the desired position.

Position Measurement: The sensor continuously measures the actual position of the system.

Feedback: The sensor sends the actual position data back to the controller.

Error Calculation: The controller compares the actual position with the desired position to calculate the error.

Correction: If there is any discrepancy (error), the controller adjusts the command to the actuator to correct the position.

Related formulas
3 .Precision in positioning system: Control resolution and accuracy.

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 location a large number of times. We will define precision as a
function of three features:

1. Spatial resolution
2. Accuracy
3. Repeatability
Spatial Resolution

1. The spatial resolution of a robot is the smallest increment of movement into which the robot can divide its work
volume.
2. 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.
3. The control resolution is determined by the robot's position control system and its feedback measurement system.
4. It is the controller's ability to divide the total range of movement for the particular joint into individual increments
that can be addressed in the controller.
5. The increments are sometimes referred to as "addressable points."
6. The ability to divide the joint range into increments depends on the bit storage capacity in the control memory.

Accuracy

1. Accuracy refer to a robot ability to position its wrist end at a desired target point with in the work volume.
2. Accuracy is defined in terms of spatial resolution (The ability to achieve a given target point depends on how closely
the robot arm can define the control increment for each of its arm motion).
3. In this case Accuracy is defined as one-half of the spatial resolution.
4. Because actual programmed point will probably be different form the target point due to limitation of control
resolution.
5. Best Performance Program Resolution (or) Addressable Point is equal to the control resolution.

Illustration of the accuracy and control resolution when mechanical inaccuracies are assumed to be zero

Illustration of the accuracy and spatial resolution in which mechanical inaccuracies are represented by a statistical
distribution
Repeatability

1. Ability of the robot to reposition itself to a position to which it was previously commanded or trained.
2. T is the target point.
3. The robot is commanded to reach T due to limitations in accuracy its programmed position point P.
4. Difference between T and P is Accuracy error.
5. Subsequently, the robot is commanded to return the point P. However it does not return to same position. Instant it
returns to position R.
6. Difference between P and R is repeatability error.
7. Repeatability error form a random variable and it will represent in statistical distribution.
8. Manufacture quotes the repeatability as the radius of idealized sphere.

Illustration of Repeatability and Accuracy

Module-2
4 .Write about how to describe the position, orientation and frames. (draw the coordinate system diagram and
explain)

Description of the Position

 The position of an object in space is typically described using a coordinate system.

 In a three-dimensional space, this is often done using Cartesian coordinates (x, y, z).
 The position specifies the location of a point relative to a reference origin.

For example, if you have a point P, its position can be described as (P(x, y, z)), where ( x ), ( y ), and
( z ) are the distances from the reference origin along the respective axes.

Description of the Orientation

The orientation of an object refers to how it is rotated in space relative to a reference frame. This can be described using
several methods:

Rotation Matrices: A 3x3 matrix that represents the rotation of an object. Each column of the
matrix represents the direction of one of the object’s axes after rotation.

Euler Angles: Three angles (often denoted as roll, pitch, and yaw) that describe the object’s
orientation by rotating it around its own axes.

Quaternions: A four-element vector that can represent rotations without the singularities and
ambiguities of Euler angles.

Axis-Angle Representation: Describes the orientation by specifying an axis of rotation and an

angle to rotate around that axis.

Description of the Frames

A frame is a coordinate system attached to an object, used to describe its position and orientation. There are typically two
types of frames:

Reference Frame: A fixed coordinate system used as a reference for measuring positions and orientations. For example, the
ground or a laboratory frame.

Body Frame: A coordinate system attached to a moving object. The position and orientation of the body frame are described
relative to the reference frame.

5 .Write down the six rules for affixing frames to the link and also summarize the rules for the link parameters in
terms of the link frames.

Six rules for affixing frames to the link

1. Z-axis: The z-axis is aligned with the axis of the joint. For a revolute joint, it is the axis of rotation; for a prismatic joint,
it is the axis along which the link slides.
2. X-axis: The x-axis is perpendicular to both the current z-axis and the previous z-axis. It is chosen to be along the
common normal between the two z-axes.
3. Y-axis: The y-axis is determined using the right-hand rule, ensuring it is perpendicular to both the x-axis and z-axis.
4. Origin: The origin of each frame is placed at the intersection of the x-axis and the z-axis.
5. Frame 0: The base frame (frame 0) is fixed and does not move. It serves as the reference frame for all other link
frames.
6. End-Effector Frame: The frame attached to the end-effector (last link) is used to describe the position and
orientation of the end-effector in space

Summary of Link Parameters in Terms of Link Frames

Link Length (a): The distance between the z-axes of two consecutive frames along the x-axis.

Link Twist (α): The angle between the z-axes of two consecutive frames, measured along the x-axis.

Link Offset (d): The distance between the x-axes of two consecutive frames along the z-axis.

Joint Angle (θ): The angle between the x-axes of two consecutive frames, measured along the z-axis

6 .Denavit Hartenberg matrix

I .Link parameter

II .kinematic diagram

III .D-H parameter table

Link ai α i-1 di Θi
0–1 0 0 0 Θ1
1–2 l1 0 0 Θ2
2–T l2 0 0 0

IV .Transformations Matrix
V .Overall Transformations Matrix

Module-3
7 .Two link planar (RR) Forward kinematics
#Forward kinematics of 2D #Manipulator#Robotics#tamil - YouTube

8 .Two link planar (RR) Inverse kinematics

#Robotics#inverse#kinematics#2D#Manipulator#tamil
 Module-4
9 .Two link planar differential kinematics (velocity)
 Module-5

10 .Join space trajectory (Point to point)

The robot’s displacements inside of its workspace are usually considered as joint displacements and for this reason
the robot is analyzed in a joint space reference.

Using Joint Space Trajectories has many advantages, i.e. less computation, easier to plan trajectories in real time or no
problem with singularities, but that the pose of the robot is sometimes unclear, particularly in the presence of obstacles.

The motion diagram represents graphically described time depending on functions of the change in the position,
velocity and acceleration of the manipulator link, gripper or tool.

Thus the motion from the initial position q0 to the final position qf in tf second (t0 = 0), starting and ending with zero
velocity and acceleration is considered.

Cubic polynomial trajectories:

Since one has a polynomial with four independent coefficients, only four constraints are required: those related to
position and velocity.

Matrix:

Quintic polynomial trajectories:

Planning trajectories using multiple cubic trajectories leads to continuous positions and velocities at the blend times
but to discontinuities in the acceleration.

Linear segments with parabolic blends (LSPB):

Another way to generate suitable joint space trajectories is by the so-called Linear Segments with Parabolic Blends or
LSPB for short. This type of trajectory is appropriate when a constant velocity is desired along a portion of the path.
11 .Cartesian space trajectory (continuous)

1. Cartesian-space trajectories relate to the motions of a robot relative to the Cartesian reference frame, as followed by
the position and orientation of the robot's hand.
2. In addition to simple straight-line trajectories, many other schemes may be deployed to drive the robot in its path
between different points.
3. In fact, all of the schemes used for joint-space trajectory planning can also be used for Cartesian-space trajectories.
4. The basic difference is that for Cartesian-space, the joint values must be repeatedly calculated through the inverse
kinematic equations of the robot.
5. Cartesian space trajectory planning is essential for programming robots to perform precise tasks like assembly,
painting, or welding by ensuring they reach specific points accurately.
6. This planning typically includes interpolation techniques, which determine intermediate points along the desired
trajectory to create smooth and continuous motion.
7. In Cartesian space, trajectories are often defined using cubic or quintic polynomials to provide smooth acceleration
and deceleration profiles.
8. Collision detection is an important aspect of Cartesian space trajectory planning, ensuring that the robot avoids
obstacles during its movement.
9. Real-time trajectory adjustments can be made based on sensor feedback, allowing robots to adapt their paths
dynamically in response to changing environments.

Procedure:

1. Increment the time by t=t+At.

2. Calculate the position and orientation of the hand based on the selected function for the trajectory.

3. Calculate the joint values for the position and orientation through the inverse kinematic equations of the robot.

4. Send the joint information to the controller.

5. Go to the beginning of the loop.

Module-6

12 .Disturbance rejection second order linear control system

 Module-7

13 .Disturbance rejection second order linear control system

A mechanical gripper is a device used in various automation systems to handle objects by gripping them. Think of it
like the claw in those arcade games that pick up stuffed animals, but designed for industrial tasks with a lot more precision and
reliability.

Components of Mechanical Gripper:

Jaws/Fingers: These are the parts that actually come into contact with the object. They can be designed in various
shapes and sizes to handle different types of objects.

Actuators: These are responsible for the movement of the jaws. They can be powered by different sources like
pneumatic (air), hydraulic (fluid), or electric motors.

Sensors: These ensure the gripper picks up objects correctly and without damaging them. They can detect the
position of the jaws, the force applied, and sometimes even the presence of an object.

Control System: This integrates all the components and coordinates the operation of the gripper.

Types of Mechanical Grippers:

1 .Two-Finger Grippers: These are the most common and are used for simple pick-and-place tasks.

2 .Three-Finger Grippers: These provide better stability and control, often used for handling cylindrical objects.

3 .Adaptive Grippers: These can conform to the shape of the object, making them versatile for handling different items.

Applications:

Manufacturing: For assembling parts, welding, and other tasks on production lines.

Robotics: In robots used for picking and placing items.

Medical: For handling delicate instruments or components in surgeries and medical device manufacturing.

14 .Magnetic gripper
A magnetic gripper is a device used in automation and robotic systems to handle and move ferromagnetic objects
through the application of magnetic forces. Ferromagnetic materials include iron, steel, nickel, and certain alloys that can be
magnetized and attracted by a magnet.

1 .Magnetic Force Application:

Permanent Magnets: These are always magnetized and do not require any power supply. They are made from
materials like neodymium-iron-boron or samarium-cobalt.

Electromagnets: These use electric current to generate a magnetic field. They can be turned on and off by controlling
the current flow, making it easier to grip and release objects without additional mechanisms. When the power is turned off, the
magnetic field disappears, and the object is released.

2 .Grip and Release Mechanism:

The gripper's magnetic field pulls the object towards itself, holding it securely. To release, either the magnetic field is turned
off (in the case of electromagnets) or a mechanical system is activated to push the object away from the permanent magnet.

Types of Magnetic Grippers

1. Electromagnetic Grippers:

2. Permanent Magnetic Grippers:

Applications

Industrial Automation: Widely used in assembly lines, especially in the automotive and aerospace industries, for
handling sheet metals, pipes, and heavy components.

Material Handling: Used in warehouses and logistics for moving steel plates, rods, and other ferromagnetic
materials.

Packaging: Involved in picking and placing metal cans, tins, and containers.

Advantages

Quick Operation: Magnetic grippers can rapidly pick and place objects, enhancing productivity.

Non-Contact Gripping: Reduces wear and tear on mechanical parts.

Versatility: Can handle various shapes and sizes of ferromagnetic objects.

Safety: Fewer moving parts mean reduced risk of mechanical failure and accidents.

15 .Pick-and-Place Applications

Pick-and-place refers to the automation process where items are picked up from one location and placed at another.
Magnetic grippers excel in this area, especially for handling ferromagnetic materials like metal sheets, components, and
assemblies.

Speed and Precision: Magnetic grippers can quickly and accurately pick up objects without needing to precisely align
mechanical jaws.

Versatility: Capable of handling a wide variety of shapes and sizes, from flat sheets to cylindrical parts.

Non-Invasive: No need to physically clamp or squeeze the objects, reducing the risk of damage.

Assembly Lines: In manufacturing environments, magnetic grippers are used to transport parts to different assembly
stations.

Packaging: Gripping metal cans, tins, and other containers for packaging.

Sorting: Used in recycling facilities to sort ferromagnetic materials from non-magnetic ones.

16 .Machine Tending Applications

Machine tending involves loading and unloading parts to and from machines, such as CNC (Computer Numerical
Control) machines, lathes, or presses.

Automation: Magnetic grippers automate the process, reducing the need for human intervention.

Efficiency: They can handle heavy and awkwardly shaped metal parts that would be difficult for mechanical grippers.

Reliability: Durable and consistent performance even in harsh industrial environments.

CNC Machining: Loading raw metal blocks into CNC machines and removing finished parts.

Press Brakes: Feeding metal sheets into press brakes for bending operations.

Injection Molding: Transferring metal inserts into injection molding machines for insert molding processes.