ENR ee NT es TU. 130 FUNDAMENTALS OF ROBOTICS [JNTU:HYDERABaD, mins, POINTS TO REMEMBER : ; i - multi aute tate. Tntegration The proces Of programming and providing equipments to the robots to perform multi = 3m repetitive actions in in, Industrial Robots : An automatic, freely progtammed, multi-axis robotic arm used to perform repet dustrial sectors {Collaborative Robotics: Integration or robotsand a automaton technoldgy to perform multiple fasks and assist human, ae System Integrator: The companies or teams which customizes the robots as per the needs, production process ang inal output Spot Welding The welding which involves fusion of two métalsthtough lates or welding guns is known as spot welding Palletizing Operation ; In material transfer application of robot. pallets are used for material handling and storage ncking Ts one of the parts mating processes during assembly During stacking, components are placed one above he ‘ther without using the pins and other devices to locate the comportents relative to one another, Rage Assembly Systems : Assembly robots are used in expanded production capabilities in the manufacturing system, Robots save the workers from tedious and dull assembly line jobs and increase production and savings inthe process, esting oan System Robots are used to perform inspection operations. They can be used to accomplish inspection a ‘operations for dimensions conformance and other physical characteristics. © Tepot Cell: It i a complete system consisting of a robgt, controller, positioners and safety environment for Fesennibg different operations on a product PART-A_ SHORT QUESTIONS WITH SOLUTIONS Q1. Define Robot System integration Answer : Mode! per Qi) ‘The process of programming and provi ling equipments to the robots to perform multi automated tasks known as robot system integration. ‘92. State the differences between industrial robotics and collaborative robotics. Answer : Industrial Roboties Collaborative Robotics 1, ] They are used to perform single repetitive task. 1, | They are used to perform multiple tasks 2. | They are isolated from humans (no contact between the |.2. | They work with the humans and are used to assist humans and robots), them, 3. | They are fixed at one place. 3. | They are movable robots. 4, | There is no harm caused to the humans. 4. | They might hurt the humans as they both work in the ‘same work space. 5. | More safety precautions are not required 5._| More safety precautions should be taken. Q3. What are the functions of a robot system Integrator? Answer : ‘The functions of a robot system integrator are, Model Papers, 10) 1. To conduct detailed study of the project 2, To suggest various cost reducing tips. 3, To design the best robot for the applications. 4, To select the appropriate tools and equipment for the process, 5 To train the operators about programming and using of robots in the work area. WARNIN' (erox/Phatacopying ofthis book s @ CRIMINAL act. Anyone found guilty is LABLE to face LEGAL proceedings.ee rere SOON eT ; LUNIT-S_ System Integration and Robotic Applications Ga. List the different types of robot assisted material handling equipments at oe (Mode Paper, O10) | Mayline, ‘The various types of materia 0) Mayline, (RAB, a Material transport equip dling equipments are as follows, 1 2, Storage systems 3. Unitizing equipment 44, _ Identification and tracking system. bot i mi i @5._ Describe rol bea janufacturing, ee Define robot applications in manufacturing. [Model Paper, a Answer 3) | Nov Dee, (R13), 040) ‘The following are the manufacturing applications of robots. 1. Material handling and machine loading 2, Spot welding 3. Arewelding 4. Spray coating 5, _ Assembly and inspection. ‘GE Describe material transfer applications. . NovsDee.17, (R13), 14) Answer: Material transfer applications of robot are palltizing and pick and place operations. Dalles are used for material handling and storage. Large number of containers are alaced ona pallet instead of handling shividual cartons. The pallets are moved mechanically within the manufscturing plant or warchouse, by form Tift trucks oF conveyors. Inpick-and-place operation the robot pickups that part at one location and moves itt tothe robot by mechanical feeding device or belt conveyor ina knoWwn locaton and aientation. A simple imi tc used to stop the component to allow the pat o be gried by rob. Te yobt then moves and poston the part at a desired Iain G7 What is the reason for using a robot in stamping press operation? Dee19, (R18), 1) OR Explain the robot role in stamping press operations. Answer + [Model Papers, Qe) | NoviDec-18 (RS), (8 ‘Stamping press operation is one ofthe secondary production process, which is usedto cut and form sheet metal parts, The proces is performed by using die sets el’in amachine too called a pres. The sheet metal tock used asthe rw material inthe Froces, Robots are used for handling arts in press working operations to obtain safety and noiseless operation ee. “The sobot is used to hold the blank during the cycle so thatthe formed paris removed from the press. The robot is also sed to transfer of pars from one press to another to form an integrated press working. 6. Explain robot in spot welding. 3 Answer = : ‘The welding, another location. The partis available which involves fasion of two metals through electrodes or welding guns is known as spot welding, In spot welding Tuto is obtained by generating hea athe dese pon, hough elestrdes, The elestodes are supplied with cuent for specific duration of time, depending on the metal thickness. ‘Arabic spot welding consists ofa robotic manipulator, welding gun, controller and power sources, The manipulator wth several ber of degrees offeedom is lied. The welding un s situated onthe robe wrist in connection with controllers and power sources. 9; What are characteristics of robot in assembly? Atiswer ¢ Characteristics of Robots in Assembly orm bots ye in assembly operations possess similar dsig comesponding otha of products Being assembled. 2. They have the capability to identify the part families effeeyel: Free obots are provided wit sensor 1 ensure bette adaptability of products, dring assembly operation, Bere aigippat oc end effete ofthese robots ae monly made compliant Wid Ar Esomety src [ALLIN-ONE JOURNAL FOR ENGINEERING STUDENTS |) 0) 91) gn [Model Papers, 14) | Nov Dee.-16, (R13), 1)ee ag 192 FUNDAMENTALS OF ROBOTICS [JNTU-HYDERABaD, PART-B ESSAY QUESTIONS WITH SOLUTIONS 5.1 Ronor Systew Inrecration Q10. What are the applications of Robotic integration. Answer : ‘The important applications of Robotic system intgratcn are: 1. Industrial Robotics These ftom ely programmed, mutans robotic rm usedto perf various repetive actions in industria secon Thess canbe easily reprogrammed spr he demand and eure Insti rbos te sed in the flloving sce (@) Welding (©) Spot welding (©) Material handling, (@) Testing and inspection (©) Material removal processes (9) Painting (B) Material cutting processes (b) Palletzing 2 Collaborative Robotics Tee, Meals ktown as Cobos. These ae the integration of robots and an aomation technology to perform multiple {ase and assist humans, Cobos work alongwith humar and arin close contact wth hem ic, bth Novae ead work in the same area. : Q11. List the benefits of Robot system integration. Answer : The benefits/ advantages of Robot system integration are, 1, High accuracy and quality Decreased production cost ‘Reduced production time More consistency Less or no labour cost [Easy updation as per the deinand Effective floor utilization ‘Reduced dangers and hazards in the working area, High efficiency and productivity Q12, Write about robot system integrator. Answer: Robot system integrators ae the companies which cusomizs the rabos as per the neds, production process and the fina ouput. They design a program and automation plan based onthe robotic system needs othe application me Thes provide {integrated solutions to various complex tasks and design the bes robot forthe task required To provide such best technica solution, a robot system integrator shouldbe always updad with evlutions and dvelopmeats in the control systems, manuficuring processes, automated stems, equipment, ml arcuate am and many more, TH) should also have knowledge in the wouble shooting, documentation, maintenance ad other task, They should ven ain ‘operators using the robots in the work space, (Wanna: xecxmotooning ot his bokis CRIMINA ae Anyon and ity UABLE eae LEGAL proceedsoee-49, (RYE), 2a) | Model Papers, a10()) ns of Robots ots are being used in the following Answer # Present Application Presently ro! applications, ‘Material transfer applications @ {iy Machine lading and unloading Gy Provesing operations lke (a) Spot welding {b) Continuous arc welding fo) Spray coating {@ Driling, reaming and lapping {@) Grinding, polishing, deburring and wire brushing (9. Riveting (q) Laser drilling and cutting, ee (ivy _ Assembly tasks or parts mating {) Inspection and automation Future Applications of Robots “The future applications of robots inchdes the following, ( Imeligence {ii) Sensor capabilites (i) Telepresence Gv) Mobility and navigation (v) Universal gripper ‘System integration and networking, wi) (vil) FMS (Flexible Manufacturing Systems) (wii, Hazardous and inaccessible non-manufacturing ‘environments (jx) Underground coal mining (a). Fire fighting operations (ai) Robots in space (aii) Security control (aif) Garbage collection and waste disposal operations (aiv) Houschold robots (av) Medical care and hospital duties, et ‘Gia How robot Is used for any operation. ining ‘ec49, R16), Q10(0) OR Explain the robot role in machining operations, Now/Dee-48, (R18), 010(0) Answer t Machining isa metal woking process in which the shape ofthe pais changed by removing material wih # cing oo Witgemealy secondary prosss to produce final orm At rior process sch as casting forging provides base SPs ibe gat There are anunber of ie! mashing Possses Ssh Robots used to perform the vt fad tod wlonding elo fished pat tte compen of te acho cy Toe ete cot ihn ol tet i adh Masti 0) Se (i) Gnd epee (iv), Pelletizing and depalletizing capacity (0) Programming features ete Robots are successfully implemented in handling of imegular elements, tool changes or pallet changes et. Q15. What are the general considerations in selecting ‘a robot for material handling? OR What are the general considerations in robot material handling? Explain. 44, 13), 10a) | May/June-13, (R08), 718] OR aon What are the considerations of Robots in processing applications? Now 13, (R09), 84a) ~ oR What are the considerations of robots in ‘material handling? 5) | Model Papert, 1048] Answer [NovDec-12, (R09), Ot “The general considerations to be followed in selecting ;obot for material transfer operation are as follows, Part Positioning and Orientation In application o* parts handling, the parts should be introduced to the robots in a specified position and orientation (i) Gripper Design For the pick aié place operation, distinguished end- effectors should be designed. Minimum Distance Travel ) ©The distance travelled by the parts in the material handling operation should be minimum. Robot Work-Vohime ‘The amount of work carried out by the robot should not ‘exceed the specified limit co)134 (%) Robot Weight Capacity Robots should he specified with sufficient load carrying ‘capacity, to ensure that capacity limit does not exceed. (vi) Accuracy and Repeatability High accuracy is required in the pick and place operations of ‘materials. Therefore, robots must be built with high accuracy. (vii) Machine Optimum Utilisation For an application to be effective, itis necessary that all the equipments in the cell should be used at optimum level. In order to ensure the optimum ‘utilisation of ‘machine, the robots should work effectively. «witty Robot Configuration, DOF's, Control, ete Maximum degree of freedom’s are required in the applications of machine loading. In the operation of pallet ing parts from conveyors, uirements for control are more complicated. Q16. Describe the material handling operations. Answer : Novsee.-17, (R13), 1014) Material handling operations involve usage of robots to ‘move the parts from and to the machine and to load or unload the parts from the machine. The three main operations are, 1, Machine Load or Unload While doing operation on 2 production machine, the Joading of raw materials and unloading of finished products is done by-robots. This reduces the human effort and ensures minimum wastage of time. For example, in case ‘oF machining operation, the job to be machined is fied in the machine and the final partis collected by the robot after ‘completion of finishing operations. 2. Machine Loading In this operation, the robot only loads the raw materials for machining, while the finished parts are collected by separate arrangements. Example: Presswork operation, in which the parts to be pressed are loaded by the programmed robot and the pressed parts are collected separately. 3. Machine Unloading In this operation, ihe raw materials are loaded by some external sources and finished parts are unloaded by a robot. Example: Die casting and plastic moulding. In order to improve the production rates, the robot assisted workhouse is developed, in which, a production ‘machine, robot, etc, are located. These workhouses are designed separately for different operations. Some are ‘designed such that, same identical parts are produced, ‘while in some workhouses, different types of models on different machines at different times are produced. In both cases, robot plays a key role in loading or unloading the parts. : FUNDAMENTAL! Q17. What is a palletizing operation where robot finds an applications. § OF ROBOTICS [JNTU-HYDERABAD, Dec-49, (R16), 210 oR Describe the palletizing operation of materia, transfer application of a robot. Answer : (Model Paper: {In material transfer application of robot, pallets ate used for material handling and storage. Large number of containers are placed on a pallet, instead of handling individual cartons The pallets are moved mechanically within the manufacturing plant or warehouse, by fork lift trucks or conveyors. The only handling of the individual cartons arises, when the component js placed onto the pallet or when it is removed from the pallet The loading of cartons onto pallets is typically a heavy work performed manually by unskilled labour. ‘Atypical pallet configuration is shown in figure below. Each carton is placed at a different location on the pallet, the variation in carton location is in three dimensions. The pallets are usually stacked on top of each other in layers, as shown in figure, 210(a) | Novitie.-17, (R13), ata Figure: A Typical Pallet Configureti The robot is to be programmed to perform desired motion pattern in palletizing operations. Also, sensors are incorporated to identify carton locations and their delivery point. Depalletizing operation is the reverse of palletizing, in whi the robot removes cartons from a pallet and plac conveyor or other location, them ontoa Q18. How palletising operation is carried out by an industrial robot? Answer : ‘Aprmay-18, (R13), Q10(0) Palletizing operation is similar to the pink-n-place ‘operation but the difference is that the placing point of every partis different. A robot performing the palletizing operation is shown in the figure. Robot picks the part from the point ‘A’ in the feed system and follows the path A-B and places the firs partat °B’. Feed system delivers the next part to point A, Then, robot picks the second part from point-A and follows the path ‘A-B-Cand places the part at C. This process continues until the Pallet isull. Thuis, in palletizing operation robot picks the part from same point in every operation cycle, but delivery point differs for part to part. PP WARNING: xeroxPnotocopying ofthis book is @ CRIMINAL act: Anyone found guilty is LIABLE to tace LEGAL proceedings o $40 23 3 ee OeCT uN! syst PI 135 Feed system, ¥ Figure” “The robot sto be programmed to perform desired motion patter in palletizing operations. Also, sensors are incorporated ions and their delivery point. Location ofthe delivery point of next pallet is calculated using the parameters to idemtfy part lati ‘ech as numberof parts part size, pallet size and location of comer pallet. ‘G1. Explain simple pick-and-place operation of the robot. [Model Papers, Q10() | Now/Dee.-17, (R13), Q10(0 « Answer + Inpckcand place operation, the robot pickups the part at ne locaton and moves ito another lation. The partis available tothe robe by mechanical feeding deve or belt conveyor in known eation and orientation simple init switch suse to ped by robot. The robot ther moves and position the part ata desied location. The Stop the component to allow the part tobe grip eration ofthe part remains unchanged during the travelling, The basic operation s shown i igure. In this ase, DOF's are areyad_ one degree of frcedom i required to lift component fom pickuppoint and pu it down atthe drop-off point and second ‘Bois neaded to move the part between these two positions. In some cases, a reorientation ofthe component is accomplished daring the move period. Inco Figure: Pick and place Operation 020, Explain in detail the requirements of robots in Material transfer applications in industrial environment, ‘OctiNow-20, (R16), 846) Answer : " ‘The primary requirement of robots in material transfer applications isto move & component from one place to another ce Palletizing and pick-and-place operations are material transfer applicstion. Requirements of Robots in Palletizing Operation For answer refer Unit-V, Q18. Requirement o Robs in Pick-and-place Operation For answer refer Unit-V, QU9. srecraun ALLW-ONE JOURNAL FOR ENGINEERING STUDENTS | ©)!" —a ee ae FUNDAMENTALS OF ROBOTICS [JNTU-HYDERABAD) O21. Discuss the use of industrial robots In die- ©asting operation, Answer: Die-cast products comprise with t manufactured by the automo bulk components te. Robots plays, with respect as Cost-eftcctiveness Improved working conditions Quick product changes ete Uses of Robot in Die-casting. Uses of robot in die-casting are as follows, (Low cost of robots leading to cost effective automation with quick return on investment Ever increasing focus on the human factor work ‘cell safety (iv) Variety of producti market for east products, Le requirements based on (%) Cycle time requirements, (1) Life cycle of manufactured product to ensure retin on investment. (ii) Product han ling requirements (viii) Maintenance requirements. (ix) Safety standards related to heat and g in die-casting operations etc exposure: Factors to be Considered for Automated Die-casting jutomated (i.¢., using robots), the For die-casting to be following factors are considered, (i) Product and die design (ii) Environmental factors (iii) End-effect design (iv) Floor space (¥) Play load and robot selection (vi) Cyele time validation (vii) Part cooling requirements (viii) Flash timing (ix) Part transfer/exit Answer : (x) Control engineering and robot progran WARNING: Xerox/Photocopying of this boo} ming, Q22. What are the desirable features of a robot for Successful machine tool load/untoad applications? Answer + The desirable features ofa robot for successful machine J load oF unload applications are as follows, allows the robot to handle the raw material and finisheg Work parts simultaneously, due to which the production cycle time reduces. (ii) Degrees af freedom To manipulate and position the part in the machine too}, robot requires more number of degrees of freedom of the arin and wrist. (ii) Good Repeatability To position the part into chuck or other work holding devices, robot requires comparatively high level at prevision. (iy) Palletizing and Depalletizing Capabilities The use of robot is to place the raw work parts on pallets (palletizing) and move it to the work cell and then remove the work parts from pallet (depalletizing). The robots controller and programming capabilities must be sullicient to accomplish the specified task () Program The use of robots allows Several programming features in machining applications. In batch production of different Parts, the change over of set up is required from batch to batch, This change over causes the change in robot program among different batches. Thus, the robot must have high storage medium like disks, tapes, ete, for storing and changing arge mumber of programs in between batches. Robot requires another programming feature for machining ie., it must be able to accept programs for tool or pallet changes. 1g Features Q23, List out the applications of robot in machine loading and unloading. ‘AprivMay-1 (R13), 14) OR What is the role of robots in loading and unloading? OR State and explain the application of robots in ‘machine loading and unloading. [Model Papers, 210(b) | Nov Dec.-16, (R13), 01001 Robots are used for loading raw materials and unloading finished products in manufacturing process. es the rate of production and minimizes the idle CRIMINAL act. Anyone found guilty is LIABLE to face LEGAL proceedings. 2system Integration and Robotic Applicatior wit plications 137 tos are highly efficient, wi ing in hazardous environments 4 ‘he pars are loaded with high accuracy thereby elfminating human errors «__ Robotsare also sed for loading of ols, special Hxtres or atachnents, et. on a micine 4 Haig of ars na work cel, containing multiple machine ol 4 Therobot used to Toad the finshed prot nto an inspection gage for quality insection {The pars are loaded on functional testers, which measures the responses of system t certain controled inputs 4, _ Use ofrobosnereases the Mexbilty of he system and reduces the material handling ost jp Theyarcelfectvely used for palleizng, loading and unloading of iregular or complex parts Gia. Explain loading and unloading of material handling in die casting process. ee. Nov iove-7, R33), a110) Die-casting is one ofthe manufacturing process in which molten metal is forced into the cavity of a mould (die) under high Generally, die consists of two halves that are opened and closed by a die casting machine, During operation, the die is dosed and molten metal is injected into the cavity by an extemal energy source like pump. When the metal gts solidified, the jis opened and the casted component i ejected by pins which push the component away from mould cavity. The part which is removed from the die casting machine is immediately heat treated (quenched). Henee, atypical die-casting manufacturing cycle ‘ons of casting, removing the part from the machine, quenching and trimming. Generally, the production rate of die-casting rors is about an average 400 openings per hour depending upon the machine capacity. Jn eference to robotics concept, the die-casting provess represents a relatively straight forward application. The limit vies are used 1 interlock the robot cyclic operation. The programming of the robot is done to operate gripper to remove part fom the dc, when die is opened. The process requires only thatthe robot unload the die-castinz machine, since the metal is in ‘te olin tate before the parts formed. ws. Explain the loading and unloading of material handling in plastic molding process. NowiDec-18, (R15), 210) Answer : Robots are used in plastic injection moulding machines for mass production. The figure below shows the plastic moulding ‘peti with incorporation of robot es ‘ou ati i le Figura: lastie Moulding Operation Phstic moulding robot is of large servo transverse type, whose applied capacity isin tonnes. They remove the runners, ind ject the products from the mould of plastic injection machine, which are inline automatically. The benefits ae reduced quirement and increased output leading to lower unit cost. ‘Therobot may be linea (cartesian) or articulated arm type. Linear robots are mounted cn cither the fixed or moving plate Pt ibe man axis ofthe robot at 90° tobe moulding machine axis (ianserse) or in ine withthe moulding machine axis ‘Mounted robots allow part removal atthe front or rear of the machine, while longitudinal robots allow parts to be Pike tend otte matne Le SPECTRUM ALL-IN-ONE JOURNAL FOR ENGINEERING STUDENTS ‘x TICS LINTU-HYDERABAn, 138 FUNDAMENTALS OF ROB‘ rocess. 226. Discuss various machine loading and unloading operation for machining P % March21, (81) oy newer | —_Foranewerfefer Units, Q24 and Q2s 27. What are the various parts joining tasks where robot is involved. Answer Mott Papers, 10°) | O¥- 16, ag, Various pars joining tasks where robot is involved are, Screwed Fastening . [her re two metho to cary ot screw fastening bythe robot. Ine ist metho, robot west des 1 nog threaded hoe, while rotates and advances simultaneously. In the second method, a power screwdriver which’ hel Special end efector of robot drives he screw. Power screwdrivers are povided with a feature o feed the Seres automatic toe bit ay shown in gue. Foret method of eew fstesing is diicult when compared fo the later. 2 Welding and Related Part Joining Tasks Common welding operations carried out xing robots are sot wekéng and continuous arc weding.theoining mths similar to welding whch canbe performed ssing robots are olering, brazing and ulasonie welding, 30° Press Fits ‘They are use to jon ape and ahole. A pg larger in itis inset ino he hole of male size. To obtain he pres onsidraby lrg amount of force required fre the pg it the hole Inmost a the cases, force applied by the iba ill not be sufficient to press the one part into another, Therefore, robot lads the parts tobe joined into a power pressin which press fitting occurs, Z 4, Snap Fits By snap fils, purpose of both the pres fs andthe retainer are Obtned. The pars undergoing the snap fit ar desined in such a way that a temporary interference exis between them only during the pressing process. Aer presing, eli ‘deformation of on or both the parts occurs o accommodate the interference, then ets hoked int the mating elem Slight interference will present between the parts after they are snapped into one another. Component 1—-f 7 Component? > Figure WARNING: XerxPhotctpying of his books « CRIMINAL ot, Amon fount guy is UABLE to face LEGAL proceedings.