Fundamental of Robotics

Prof. Ganesh D. Shrigandhi

Industry
• In a general sense the term “Industry” is defined as follows.

• Systematic Economic Activity that could be related to Manufacture /

Service / Trade

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Automation
• The word ‘Automation’ is derived from Greek words “Auto” (self) and
“Matos” (moving). Automation therefore is the mechanism for systems that
“move by itself”.
• Automated systems achieve significantly superior performance than what
is possible with manual systems, in terms of power, precision and speed of
operation.
Definition:
• Automation is a set of technologies that results in operation of machines
and systems without significant human intervention and achieves
performance superior to manual operation.

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Automation continued …
A Definition from Encyclopedia Britannica –
• The application of machines to tasks once performed by human beings or,
increasingly, to tasks that would otherwise be impossible. Although the
term mechanization is often used to refer to the simple replacement of
human labor by machines, automation generally implies the integration of
machines into a self governing system.

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Need of Automation
• To increase labour productivity

• To reduce labour cost

• To diminish effect of labour shortage

• To improve workers safety

• To improve product quality

• To reduce manufacturing lead time

• To accomplish the processes that can not be done manually

• To reduce or eliminate routine manual and clerical tasks

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Advantages & Disadvantages
Advantages:
• Increased productivity
• Improved quality
• Reduces direct human labour cost and expenses
• Reduces operation time and work handling time significantly
Disadvantages:
• Excessive Development Cost
• High Initial cost
• High maintenance cost

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Role of automation in industry
• Manufacturing processes, basically, produce finished product from raw/unfinished
material using energy, manpower and equipment and infrastructure.
• Since an industry is essentially a “systematic economic activity”, the fundamental
objective of any industry is to make profit.

• Profit = (Price/unit – Cost/unit) x Production Volume

• So profit can be maximized by producing good quality products, which may sell at
higher price, in larger volumes with less production cost and time.

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Types of Industrial Automation

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Fixed Automation
• It is used when the volume of production is very high and it is, thus appropriate to
design specialized equipment to process products at high rates and low costs.

• Example, in the automobile industry, where highly integrated transfer lines are used to
perform machining operations on engine and transmission components.

• The economics of fixed automation is such that the cost of the special equipment can
be divided over a large number of units produced, so that the resulting unit cost can
be lowered relative to alternative methods of production.

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Programmable Automation
• Volume of production relatively low.

• Production equipment designed to be adaptable to variations in product configuration.

• Operate equipment under the control of program.

• ln terms of economics, the cost of the programmable equipment can be spend over a
large number of products even though the products are different.

• Due to the programming feature, and the resulting adaptability of the equipment, many
different and unique products can be processed economically in small batches.

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Flexible Automation
• Lies between fixed automation and programmable automation.

• ‘Flexible Manufacturing Systems' (FMS) and 'Computer-Integrated Manufacturing' (ClM)

• Suitable for mid volume production range.

• Typically consists of a series of workstations that are interconnected by material handling and
storage equipment to process different product configurations at the same time on the same
manufacturing system.

• A central computer is used to control the various activities that occur in the system, routing the
various parts to the appropriate stations and controlling the programmed operations at the
different stations.

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Types of Industrial Automation

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Robot Definition
Industrial definition (RIA = Robotic Institute of America)
• re-programmable multi-functional manipulator designed to move materials,
parts, tools, or specialized devices through variable programmed motions
for the performance of a variety of tasks, which also acquire information
from the environment and move intelligently in response.
ISO 8373:2012 definition
• an automatically controlled, reprogrammable, multipurpose manipulator
programmable in three or more axes, which may be either fixed in place or
mobile for use in industrial automation applications
General definition (“ visionary”)
• intelligent connection between perception and action
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What is not Robot?
• Prosthesis

• Telecheric

• Locomotive Mechanism

• Exoskeleton

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Robotics
• Robotics is an interdisciplinary field

• The goal of robotics is to design machines that can help and assist humans

• Origin of the word Robot – 1923, Karel Capek, Robota – A Czech word

• The word robotics first appeared in Isaac Asimov’s science-fiction story Runaround
(1942).

• First industrial robot – 1954, George C Devol for Universal Automation / Unimate
[Used by General Motors at New Jersey]

• Anatomy – Manipulator, end effector, actuators, sensors, control system, processor,

software.

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Interdisciplinary areas in Robotics
• Mechanical Engineering
• Kinematics: Motion of robot arm without considering the
forces and /or moments
• Dynamics: Study of the forces and/or moments
• Sensing: Collecting information of the environment

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Interdisciplinary areas in Robotics
• Computer Science
• Motion Planning: Planning the course of action
• Artificial Intelligence: To design and develop suitable brain for the robots
• Electrical and Electronics Engg.
• Control schemes and hardware implementations
• General Sciences
• Physics
• Mathematic

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3Hs in Robotics
• 3 Hs of human being are copied into robotics, such as Robotics,

✓Hand

✓Head

✓Heart

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History

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History

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History

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History

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Development in Robotics

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Development in Robotics

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Development in Robotics

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Robotics
• An Industrial robot is a general purpose, programmable machine which possesses
some anthropomorphic characteristics.
• Heavy-duty machines designed to automate the manufacturing process.
✓ Hazardous work environments
✓ Repetitive work cycle
✓ Consistency and accuracy
✓ Difficult handling tasks
✓ Reprogrammable and flexible
✓ Interfaced to other computer systems

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An Industrial Robot

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Industrial Robot Applications

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Asimov’s famous Three Laws of Robotics
First Law

A robot may not injure a human being, or, through inaction, allow a human being to
come to harm.

Second Law

A robot must obey the orders given it by human beings except where such orders would
conflict with the First Law.

Third Law

A robot must protect its own existence as long as such protection does not conflict with
the First or Second Law.

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Robot Anatomy

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Robot Anatomy
• Robot anatomy is concerned with the physical construction of
the body, arm and wrist
• Most robots used in plants are mounted on a base and
fastened to the floor.
• The body is attached to the base, and the arm assembly is
attached to the body.
• At the end of the arm, carries the wrist.
• Wrist allows it to be oriented in a variety of positions.
• Relative movements between the links are provided by a series
of joints
• The robot’s wrist receives a hand or a tool called the “end
effector
• The end effector is not considered as part of the robot’s
anatomy

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Robot Anatomy

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Robot Anatomy

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Robot Anatomy

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Robot Anatomy

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Robot Anatomy

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Links

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Joints

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Manipulator Joints

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Joint notation scheme

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Arm Configuration

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Arm Configuration

1. Polar Configuration

2. Cylindrical configuration

3. Cartesian coordinate configuration

4. Jointed arm robots

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Arm Configurations

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Polar Coordinate Body-and-Arm Assembly

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The Polar System

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Cylindrical Body-and-Arm Assembly

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The cylindrical system

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Cartesian coordinate Body and Arm assembly

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The cartesian system

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Jointed Arm Robot

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SCARA Robot

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The SCARA System

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Wrist Configurations

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Example

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Solution:

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The work Envelope

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The work Envelope

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Workspace

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Working Envelope

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Specification of a Robot

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Yaskawa moto mini Specifications
• Smallest and Lightest 6-Ax is Robot in the Industry
• Equipped with the highest acceleration in a small-sized robot the Moto Mini is 20%
faster than comparable small robots, reducing cycle time and boosting productivity.
• The Moto Mini can be programmed and controlled by IEC61131-3 and PLC open
programming standards.
• Applications: Assembly, Dispensing, Inspection, Kitting, Machine Trending, Material
Handling, Packaging, Parts Feeding, Sorting, STEM Education
• Payload: 0.5 kg
• Horizontal Reach: 350 mm
• Vertical Reach: 495 mm
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Resolution:

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Accuracy, Repeatability

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Basic Specifications

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Part Names and Working Axes

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Dimensions and P-Point Maximum Envelope

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Home Position and Operating Range of Each Axis

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Kuka KR 16 Specifications
The KR16 is available in the following variations:
• KR16: 16kg / 1611mm
• KR16 L6: 6kg / 1911mm
SPECIFICATIONS:
• Capacity: 6kg
• Reach: 1911mm
• Robot weight: 240kg
• Controller weight: 380kg
• Power requirements: 400volts 3 phase; 18 amps

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Kuka KR 16 (Work Envelop)

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Economic Considerations
• Robots are expensive equipment's hence cost is an important factor to be
considered while robotizing the production facility.
• Robot costs
– Initial investment
– Operating cost
– Earnings and savings
– Miscellaneous costs

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Cost Comparison
Cost Comparison Chart
• Before robotizing, other production Graph plotted against logarithmic
process should be considered to scale on both the axes.
B1, B2, B3 – Break even points
Cost per
arrive an optimal conclusion. unit
Manual production
• Earnings made for certain production B1 B2

volume should be compared with

manual production and fixed Fixed automation

automation. Robotic production

B3

• Only when substantial cost benefits

are realized it will be a profitable
business. Production volume
DESIGN AND APPLICATIONS OF INDUSTRIAL ROBOTS
SABARIGIRIVASAN.R

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Cost Estimation
• Two simple techniques for making estimates of earnings to justify
robotization are
– Payback period method
– Return on Investment method

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Payback Period Method
• The investor calculates the payback period to recoup the money spent on
robots.
• Payback period is the time in years required to take back the money spent
as investment and expenditure on robots.
• Payback period is given as,
NPB = Payback period in years
I = Total capital investment
E = Cost of labour replace by robot
e = Cost of robot maintenance

• The robot has salvage value after payback period.

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Return on Investment Method
• The investor calculates the rate of return from the robotic operations.
• Rate of return is the percentage of investment earned per year.

rA = Return on investment
I = Total capital investment
E = Cost of labour replace by robot
e = Cost of robot maintenance

• The actual rate of return should be greater than the expected rate of
return only then the business will be profitable.

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Robot Selection
• A robot is selected by considering its various operational parameters.
• The features of a robot required to do the required operations are
determined in advance using results of the study made by the Industrial
Engineering department.
• The robot should meet the required criteria so that it can perform all the
operations effectively to which it is intended for.

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Robot Selection Criteria
• Precession – Accuracy, resolution and repeatability
• Speed
• Payload
• Type of drive system
• Programming methods
• Memory capacity
• Number of Degrees of Freedom
• Power interface
• Communication interface
• Availability of standard end effectors
• Cost, the most important deciding factor

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Responsibilities of Robotics Engineer
• A robotics engineer is a professional who designs, builds, and maintains robotic systems. Their
job involves a combination of engineering principles, computer science, and mechanical design
to create robots that can perform specific tasks autonomously or with human assistance. Here's
a breakdown of typical responsibilities and qualifications for a robotics engineer:

Responsibilities:

Design and Development: Create blueprints and schematics for robotic systems, considering
factors like mechanical structure, control systems, sensors, and actuators.

• Programming: Write code to control the behavior of robots, including algorithms for navigation,
manipulation, perception, and decision-making.

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Continued…
• Prototyping: Build prototypes or oversee the construction of prototypes to test the functionality
and performance of robotic systems.
• Testing and Evaluation: Conduct tests to assess the performance, reliability, and safety of
robots, and make improvements based on test results.
• Integration: Integrate robotic systems with other hardware and software components, such as
sensors, cameras, computers, and networks.
• Maintenance and Repair: Troubleshoot problems with robotic systems and perform maintenance
and repairs to ensure optimal performance.
• Documentation: Keep detailed records of design specifications, test results, and maintenance
activities.

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Continued…
• Collaboration: Work closely with other engineers, scientists, and technicians to collaborate on
multidisciplinary projects.
• Research: Stay up-to-date with advancements in robotics technology and research new
methods and techniques to improve robotic systems.
• Project Management: Manage projects from conception to completion, including budgeting,
scheduling, and resource allocation.

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Different job roles as Robotics Engineer
Robotics Programmer:
• Who is responsible for designing, building and implementing the automated business
processes using robotic technology.
• Also responsible for monitoring the production of a robot.
Robotics System Engineer:
• Who use Computer-Aided Design and Computer-Aided Manufacturing to design and develop
the robotic system.
• Also responsible for making sure that the system is safe and economical.
Robot Design Engineer:
• Who use the designing software and tools to design the different aspects of a robotic system.
• Also responsible for designing the specifications of the system as per the business process and
requirements.

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Different job roles as Robotics Engineer
Automated Product Design Engineer:
• Who designs the automated product and manufactures them as per the use cases.
• Also responsible to design cost-effective automation systems.

Robotics Test Engineer:

• Main responsibilities of a Robotics Test Engineer are to make sure that the designed robotic
system is safe for use by the customers and is working as per the designed specifications.
Responsible for testing the designed and developed automation system.

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 END OF UNIT-I

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 THANK YOU . . .

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