Unit 2:Robotic System

Prof. Ganesh D. Shrigandhi

Department of Mechanical Engineering, MIT-WPU, Pune 5-Aug-24 1

Content:
• Robot Terminologies

• Robot Joints and Links and its Types

• Robotic Configurations

• Types of Robots

• Robot Drive Systems

• Power Transmission System

• Robotic Workcell

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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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Links
• The links are the rigid members connecting the joints.
• The joints (also called axes) are the movable
components of the robot that cause relative motion
between adjacent links.

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Mechanical Engineering,
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Types of Links
• Rigid link: In this type of link, there will
not be any deformation while
transmitting the motion.
• Flexible link: In this type of link, there
will be a partial deformation while
transmitting the motion.
• Fluid link: In this type of link, motion is
transmitted with the help of fluid
pressure.

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LINK AND JOINT
• A mechanical linkage is an assembly of systems connected to manage
forces and movement.
• The movement of a body, or link, is studied using geometry so the link is
considered to be rigid.
• The connections between links are modeled as providing ideal movement,
pure rotation or sliding for example, and are called joints.

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Robot Joints and Types
• Robot joints refer to the movable components of
the robot that result in relative motions between
adjacent links.
• Linear joint can be designated by its letter L-
meaning it can perform both translational and
sliding motions.
• For this joint to achieve its linear motion the links
should be arranged in parallel axes.
• They are also known as prismatic because their
cross-section is referred to as the generalized prism.

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Different Types of Robot Joints
Robot joints is the important element in a robot which help the links to travel in different
kind of movements. A joint in an industrial robot is similar to that in a human body. It
provides with relative motion between two parts. Most of the industrial joints are
mechanical joints which can be classified into five types.

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Types of Joints
They include in two types that provide linear motion and three types that provide rotary
motion. These five types of joints are as follows:

1. Rotational joint

2. Linear joint

3. Twisting joint

4. Orthogonal joint

5. Revolving joint

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1.Rotational joint
Rotational joint can also be represented as R-joint. This type will also allow the joints to
move in a rotary motion along the axis, which is vertical to the arm axes or perpendicular
to the axes of the input and output links.

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2.Linear Joint
Linear joint can be indicated by the letter L. This type of joints can perform both
translation and sliding moment. These motion will be attained by several ways such as
telescoping mechanism and piston. The two links should be in parallel axes for achieving
the linear movement.

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3. Twisting Joint
Twisting joint will be referred as T-joint. This joint makes twisting motion among the
output and input link. During this process, the output link axis will be vertical to the
rotational axis. The output link rotates relation to the input link.

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4.Orthogonal joint
The O joint is a symbol that is denoted for the orthogonal joint. The joint is somewhat similar to
the linear joint so it provide linear motion. However, the input and output links are perpendicular
to each other. The only difference is that the output and input links will be moving at the right
angles.

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5.Revolving joint
The revolving joint is generally known as a R-joint. symbol that is denoted for the orthogonal
joint. This joint also provide rotational motion. Here the output link axis is perpendicular to the
rotational axis. As like twisting joint , the output link spins about the input link.

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JOINT CONSTRAINTS
Revolute (R) Joint Prismatic (P) Joint Universal (U) Joint Spherical (S) Joint
Constraints : 5 Constraints : 5 Constraints : 4 Constraints : 3
Freedoms : 1 Freedoms : 1 Freedoms : 2 Freedoms : 3

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Representation of JOINT

Revolute Joint (R) Spherical Joint (S)

Prismatic (P) Joint Hook Joint (U)

Cylindrical joint (C) Twisting joint (T)

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18
Robot Structure
• Delta Robot:
▪ The delta is another parallel robot. A very fast robot
(arguably the fastest) but with only 4 axes, so 4
degrees of freedom, so very limited movement.
▪ Largely used in food industry for fast pick and place
applications for lightweight products (e.g. chocolates,
biscuits, croissants etc.) as they can only take small
payloads of up to 8kg .
▪ Therefore, they have to be easy and safe to clean with
water, so their electrics are kept out of the way at the
top and covered additional protection during clean
down.
▪ Can also be used in other end of line applications i.e.
picking and packing.
Delta Robot

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Robot Structure
• Collaborative Robot:
▪ It consists of one or two jointed arms.
▪ A two arm collaborative robot will typically resemble to a human and be of
similar size to a large adult.
▪ Main design features that distinguish them from a normal industry jointed
arm is that they are designed for safety with soft parts and they stop quickly
with any collision detected.
▪ Designed with the intention of working next to humans on a production line
without the usual safety precautions particularly physical guarding or light
curtains. Some have screens as faces.

A collaborative robot with two 7

Fig : Single arm collaborative robot degree of freedom arms plus
by Fanuc cameras made by ABB Ltd. and
called “YuMi”.

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ROBOT CLASSIFICATION
• Classified on the basis of how they perform tasks, on the basis of their
application, on the basis of how they move.
• Most popular ways to do so :
1. by their application
2. by their locomotion / kinematics

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Based on Application :

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Applications
• Assembly Robots:
▪ One of the first industries to use industrial
robots for assembly was the auto industry.
▪ Beyond automotive applications,
assembly robots are used in many other
fields.
▪ The need for quick, robotic assembly
of microscopic parts is on the rise.
▪ Higher throughput and greater precision may
frequently be attained utilizing robotic
assembly than with human labor because of
its accuracy and speed.

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Applications
• Handling And Picking Robots:
▪ Handling and picking robots
include those that move objects about
a warehouse or take items out of a
tote and put them in a shipping
container.
▪ Robots that can pick and fill orders are in
high demand due to the growth of e-
commerce.

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Applications
• Cleaning Robots:
▪ Commercial floor scrubbing robots have the ability to
autonomously move around a building and clean the
floors.
▪ They feature sensors to help them avoid people,
forklifts, furniture, and other obstacles as well as an
internal map of the area they need to move across
and clean.
▪ While some robots use brushes to gather debris,
others specialize in wet cleaning techniques that
include applying wax.

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ROBOT CLASSIFICATION

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ROBOT CLASSIFICATION

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ROBOT CLASSIFICATION

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ROBOT CLASSIFICATION

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ROBOT CLASSIFICATION

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ROBOT CLASSIFICATION

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ROBOT CLASSIFICATION

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ROBOT CLASSIFICATION

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ROBOT CLASSIFICATION

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ROBOT CLASSIFICATION

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Robot Workcell
• Robots are designed to automate manufacturing operations that are
monotonous and dangerous in nature.
• The manufacturing cell that is serviced by one or more robots is known as
robot work cell.
• The robot work cell should have complete set of hardware, software and
cell control system.

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Structure of a Robot Work cell
➢A robot work cell has the following equipment's
✓Robots
✓Production machineries
✓Supply conveyor
✓Delivery conveyor
✓Cell controller
✓Communication peripherals
✓Protective barriers (Perimeter guard)

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Structure ofStructure
a RobotofWork cell
a Robot Work cell
M2
Protective
barrier
M1 M3

Robot
Supply Delivery
conveyor conveyor
Control panel for
manual override
Cell access door
M1, M2, M3 – Production machines
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DESIGN AND APPLICATIONS OF INDUSTRIAL
SABARIGIRIVASAN.R
ROBOTS
5-Aug-24 38
Operation of Robot Work Cell

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Classification of Robot Work cell
➢ Based on Number of Robots
1. Single robot work cell
– Only one robot is employed to perform all operations.
– Machine interference can occur.
– Interference is caused due to imbalance in machine cycle and robot service times.
2. Multiple robot work cell
– More than one robot will be employed to perform all the required operation.
– Cell control system is employed to avoid collision.

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Classification of Robot Work cell
➢ Based on the Position of Robots
1. Robot centered work cell.

2. Inline robot work cell.

– Intermittent part transfer

– Continuous part transfer

3. Mobile robot work cell

– Floor mounted rail system

– Overhead rail system

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Robot-centered work cell
• A robot-centered work cell, also known as a robotic workcell, is a complete system that
includes the robot, controller, and other peripherals such as a part positioner and safety
environment.
• It is a workstation that consists of at least one robot and its controller along with the safety
measures.
• The system is set up so that a robot or robots can complete multiple automation tasks in a
singular area, making for an efficient and cohesive automation process.
• Robot is fixed at center of work cell
• High utilization of robot
• Method of work part delivery (e.g.: conveyor, part-feeders, pallets)
• Install for single robot servicing one or more production machines
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Cell layout Robot Centered Work Cell
Machine 3

Machine 2 Machine 4

Machine 1 Machine 5

Supply conveyor Robot Delivery conveyor

Raw materials Finished products

Department of Mechanical Engineering, MIT-WPU, Pune

DESIGN AND APPLICATIONS OF INDUSTRIAL
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5-Aug-24 43
Robot-centered work cell

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Inline robot work cell
• One or more robots located along in- Inline Robot Work Cell
line conveyor Work piece
Robot
• Work is organized so each robot Moving production line

performs assembly operation on each

part (e.g.: welding line)

DESIGN AND APPLICATIONS OF INDUSTRIAL ROBOTS

SABARIGIRIVASAN.R

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Inline robot work cell layout

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Inline robot work cell layout

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 Robot Work Cell for Spot Welding
Robot work cell for spot welding
(Inline work cell – Intermittent part transfer)

Robot Spot welding endeffector

Robot

Conveyor Car frame

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S I G N A N D APune
PPLICATIONS OF INDUSTRIAL ROBOTS 5-Aug-24 48
Mobile robot work cell
Mobile Robot Work Cell
• In this arrangement, the robot is Floor
Floor mounted
Mounted railSystem
Rail stem
provided with a means of transport, such
as a mobile base, within the work cell to Machine 1 Machine 2
perform various tasks at different
locations.
• The transport mechanism can be floor
mounted tracks or overhead railing
Floor mounted rail
system that allows the robot to be
moved along linear paths.
Carriage Robot

DESIGN AND APPLICATIONS OF INDUSTRIAL ROBOTS

Note: Mobile robot work cells are suitable for installations where one robot must service more
SABARIGIRIVASAN.R

than one station (production machine) that has long processing cycles, and the stations cannot
be arranged around the robot in a robot-centred cell arrangement.
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Mobile robot work cell
Floor mounted
• Transport mechanism: floor
mounted or overhead railing
system
• Service for more than one
station
• Problem: to find optimum
number of station to service

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Mobile robot work cell
Mobile Robot Work Cell
OverheadRail
Overhead rail system
System

Overhead rail Carriage Robot

Supply Machine 1 Machine 2 Delivery

conveyor conveyor

DESIGN AND APPLICATIONS OF INDUSTRIAL ROBOTS

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Mobile robot work cell
Overhead rail system

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Safety Considerations
• Safety is of paramount importance in any industrial operation.
• The robot should be protected from damaging itself and injuring humans
while in action.
• Everything in the cell should be maintained well and checked for safe
operation so that no mishap occurs.

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Potential Hazards for Safety
• Oil leaks in hydraulic robots and pressure loss in pneumatic robots
• Broken power cables
• Poor maintenance
• Poor quality of components
• Software errors
• Uncoordinated robot motion with the production machine
• Careless attitude of workers
• Unauthorized entry of workers into the cell
• Careless attitude of management

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Protective Measures
• Providing multi tier security system
• Intruder alarm and glowing sign boards should be provided
• The robot should be stopped on detecting an intruder
• Protective barriers like wire mesh or guard railings should be provided
• Robots should be clearly visible and painted in bright colors
• Cell access doors should get automatically locked while the robot is in
action
• Control panel for manual override should be provided

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Protective Measures
• Emergency stop switch should be clearly visible and should be within easy
reach
• Dormant state of the robot should be indicated by visible light signals
• Unwanted objects should not be left inside the cell.
• High quality components should be used.
• Painting robots should be given proper covering.
• Robot should be stopped if any of the sensor fails.
• Adequate training and safety awareness should be imparted to the
workers.

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Robot Drive Systems
• Drive means operate the robot.
• The drive system is to provide a means to control the speed and also
torque (or) power.
• Drive system is used for converting hydraulic, pneumatic, and electrical
energy into useful mechanical energy.
• It is used to motion transfer and drive the robot.

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Classification of Drives
Drives
(Actuators)

Hydraulic Pneumatic Electrical

Reciprocating Reciprocating Servo Motor

Rotary Rotary Stepper Motor

Direct Drive
Motors
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Types of drive system
• Hydraulic drive systems

• Pneumatic drive systems

• Electric drive systems

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Hydraulic drive systems
• Pressurized fluid is used to transmit and control power.

• The hydraulic actuators receive pressurized hydraulic oil with control

direction and pressure through a system known as power packs.

• The hydraulic drive is mostly suitable for heavy load robot applications

• The term hydraulic refers to the transfer of energy from pressure difference
not from the kinetic energy of flow

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Features of Hydraulic drive system
• High force capability

• High dynamic response

• Assisted braking torque

• Good mechanical stiffness

• High power per unit weight and volume

• Provide stepless variation in speed

• Can be easily built using readily available standard elements

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 • It Consists of
– Actuators
– Control valve
– Power supply

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Elements of Power Pack and Functions

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Animation of Hydraulic Drive System

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Advantages & Disadvantages
• Advantages • Disadvantages
– No reduction gear is needed – High maintenance
– High accuracy and better response – More expensive system
– Excellent for heavy duty and large – Not suitable for clean air environment
robots – Requires pump, reservoir, motor and
– It provide more power than electric hoses
drives – More floor space is required

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Applications of Hydraulic Actuators
• Used to drive the spray coating robots

• Used in heavy part loading robots

• Useful in material handling robot system

• Used to drive the joints of assembly (heavy) robots

• Useful in producing translator motion in Cartesian robot

• Useful in robots operating in hazardous, sparking environments

• Useful in gripper mechanisms.

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Pneumatic Drive Systems
• Pressurized air is used to control the power.
• With pneumatic valves control the flow of energy from pressurized gas/air
• The exact positions of the actuators can be controlled by servo control
valves by differential movements.
• The pressure of air used in this varies from 6 to 10 Mpa.
• The main problem with pneumatic devices is that the working fluid (air) is
compressible, hence the actuator drifts under loads.

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Features of Pneumatic drive system
• Compressed air has most of the desired properties and characteristics of a
gas for pneumatic system.
• It is not poisonous and non flammable.
• Lowest power to weight ratio
• Reliable, Simple, low cost and easily available components.

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 • It Consists of
– Actuators
– Control valve
– Power supply

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Components of Pneumatic Drive System

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Advantages and Disadvantages
• Advantages • Disadvantages
– Good accuracy – Difficult to control
– Excellent speed – Air needs preconditioning
– Easy installation – Precision is less than electric drives
– Small leakage can be tolerated – More vibration is generated
– Economical than hydraulic drives – More noise is produced
– Low, inaccurate response due to low
stiffness

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Comparison
Sr. No. Hydraulic Drive Pneumatic Drive

1 Oil is used as working fluid Air is used as working medium

2 Hydraulic fluid is costlier Air is free

3 Suitable for heavy load application Suitable for light load application

4 It has low speed with good speed control. It has high speed and difficult to control speed

5 Silent operation and dirty setup Noisy in operation and clean setup

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Electric drive systems
• An electric drive system is defined as a form of machine equipment
designed to convert electric energy into mechanical energy and provide
electric control of the process.
• Features of Electric drive system
– Electric drive offers energy transformation
– The control components are used to limit the
amplitude(armature current of DC motor)

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Types of Electric Drives
• There are three major types of electric drives
– AC servo motor
– DC servo motor
– Stepper motor

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Components of Electric Drive
• Power modulator
• Motor
• Control unit
• Sensing unit

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Advantages and Disadvantages
• Advantages
– Simple construction
– Clean air environment
– Requires less floor space
– Electric drive robot is quiet operation
• Disadvantages
– Poor dynamic response
– A large and heavier motor must be used. It is most costly
– Electric drive system do not provide as much speed and power compared to
hydraulic system.

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Comparison of Hydraulic, Pneumatic & Electric Drives

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END OF UNIT-II
THANK YOU . . .
Based on Locomotion:
• Cylindrical robots: The body of this type of robot is such that the robotic
arm can move up and down along a vertical member, rotate about vertical
axis and the arm can also extend or contract.
• Spherical Robots: This type of robot works in a spherical system. It can
move in a bi-angular and single linear direction.

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Based on mobility level:
• Wheeled Robots and legged Robots: These type
of robots can move along the ground surface using wheels.
• Airborne Robots: These robots can fly through the air
• Aquatic Robots: These robots can work on or under water.

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