Introduction to mechanical Engineering

Module 5
ROBOTICS
Robots are devices that are programmed to move parts, or to do work with a tool. Robotics is a
multidisciplinary engineering field dedicated to the development of autonomous devices,
including manipulators and mobile vehicles.

An industrial robot is a general purpose, programmable machine possessing certain

anthropomorphic characteristics. The most typical anthropomorphic or human like,
characteristics of a robot is its arm. This arm, together with the robots capacity to be
programmed, make it ideally suited to a variety of production tasks, including machine loading,
spot welding, spray painting and assembly. The robot can be programmed to perform sequence
of mechanical motions, and it can repeat that motion sequence over the over until programmed
to perform some other job.
An industrial robot is a general-purpose programmable machine that possesses certain
anthropomorphic features
• The most apparent anthropomorphic feature of an industrial robot is its mechanical arm, or
manipulator
• Robots can perform a variety of tasks such as loading and unloading machine tools, spot
welding automobile bodies, and spray painting
• Robots are typically used as substitutes for human workers in these tasks

Components of an Industrial Robot

The main components of an industrial robot are Manipulators, End Effectors, Feedback devices,
Controllers, and Locomotive devices.

1. Manipulators
To simply understand what a manipulator is, think of it as the arm of a robot and like a human
arm that has several joints. These joints or mechanical linkages are capable of movement in
various directions to perform the work of the robot.
These mechanical linkages are driven by actuators which may be pneumatic or hydraulic
cylinders, hydraulic rotary actuators, electric motors, drives, etc. The actuators may be coupled
directly to the mechanical links or joints or may drive indirectly through gears, chains, or
screws. When pneumatic or hydraulic drives are utilized, the flow of air or oil to the actuators is
often controlled by valves mounted on the manipulator.

2. End Effectors
This is a device that is attached to the end of a robotic arm to carry out its tasks. Think of it like
the palm and fingers of a human hand. The End Effector is the component that moves or orients
the product or process. It is used for specialized tasks such as welding, measuring, marking,
drilling, cutting, painting, cleaning, and so on.

3. Feedback Devices
These are a class of devices used to monitor an operation or process and then verify the
operation or process has occurred. Back to a human body analogy, they are the organs that
supply data to the brain (controller).

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Introduction to mechanical Engineering
In a robot, a feedback device could be installed to sense the positions of the various links and
joints and transmit this information to the controller. They may be simple limit switches,
actuated by the robot's arm or position-measuring devices such as encoders, potentiometers,
resolvers, and/or tachometers. Depending on the devices used, the feedback data is either digital
or analog.

4. Controllers
The robot controller is a computer, composed of hardware and software, linked to the robot and
essentially functions as its "brain”. Controllers have all of the characteristics associated with
computers and contain sophisticated decision-making and data storage capabilities. They initiate
and terminate the motion of the manipulator through interfaces with the manipulator's control
valves and feedback devices, or perform complex arithmetic functions to control path, speed,
and position, or provide two-way communications between the controller and ancillary devices.

5. Locomotive Devices
Muscles help in the movement of the arm, fingers, and palm in humans. For the robot, the
power of movement is provided by motors. pneumatic, electric, and hydraulic motors are the
three most popular types of motors used in robot movement.

Robot joints
Robot joints refer to the movable components of the robot that result in relative motions
between adjacent links. In this context, links are used to refer to the rigid members connecting
the joints for clear and adequate functioning. The robotic joints are also at times referred to as
axes.

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Linear Joints
In the linear joints, the relative motion featured by the adjacent links is meant to be parallel.
This means that the input and output links are sliding in a linear motion. This kind of movement
results in a translational motion. This kind of linear motion can be achieved in several ways
including the use of the telescoping mechanism and piston. This type of joint is also referred to
as the L- joint.

Orthogonal Joints
The orthogonal joints are also popularly referred to as the type O-joints. They feature a relative
movement taken by the input link and output link. This kind of motion involved in the
Orthogonal joints is a translational sliding motion. However unlike the linear joints
arrangement, with the Orthogonal joint, the output link is perpendicular to the input link.

Rotational Joints
When it comes to the rotational joints, you’ll find the use of rotational relative motions that
come in handy for robot manipulators working multiple workspaces. These movements are
carried out with the axis of rotation perpendicular to the axes of the input and output links.
These rotational joints are also referred to as Type R joints.

Twisting Joints
This type of joint features rotary motion that also results in some degree of rotation when in use.
The movement in these joints is relative to the axis of rotation that is perpendicular o the axes of
the input and output links. The twisting joints are also referred to as type T joints.

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Introduction to mechanical Engineering
Revolving Joints
In the revolving joints, things are a bit different compared to the others. These joints also feature
a rotational movement that comes in handy in different applications. The movement of these
joints features motion between the two links. The axis of the input link is designed to be parallel
to the axis of rotation of the joint. On the other hand, the axis of the output link is designed to be
perpendicular to the axis of rotation of the joint. This type of joint is also referred to as the Type
V joint.

ROBOT ANATOMY
• The robot has human like characterization to respond to sensory inputs, communicate
with other machines and perform a variety of useful tasks.
• The manipulator of a robot consists of series of joints and links. Robot anatomy looks
into these type of joints, its sizes and other physical construction.

Joints and Links

• A joint in a robot is similar to joint in a human body. It provides relative motion between
two parts of the body which is also called as degree of freedom of motion.
• Generally one degree of motion is associated with each joint.
• Links are the rigid component of the robot manipulator
• Joints are connective between two links
• The purpose of joints is to provide controlled relative movement between the input link
and output link
• Most of the robots are mounted on a stationary base on the floor

Robot Physical Configuration

Industrial robots come in a variety of shapes and sizes. They are capable of various arm
manipulations and they possess different motion systems.

Classification based on Physical configurations

1. Cartesian configuration: A robot which is constructed around
this configuration consists of three orthogonal slides, as shown in
fig. the three slides are parallel to the x, y, and z axes of the
Cartesian coordinate system. By appropriate movements of these
slides, the robot is capable of moving its arm at any point within its
three dimensional rectangular spaced work space.
Advantages:
• High resolution and accuracy.
• No counterbalance problem.
• 3 linear axes
Disadvantages:
• Large structural framework.
• Complex mechanical design for linear sliding motions.
• Confinement of the workspace (limited).

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Introduction to mechanical Engineering
2. Cylindrical configuration: in this configuration, the robot body is a vertical column that
swivels about a vertical axis. The arm consists of several orthogonal
slides which allow the arm to be moved up or down and in and out
with respect to the body. This is illustrated schematically in figure.
Advantages:
• Almost no counterbalance problem.
• Mechanical design is less complex than Cartesian robots.
• 2 linear axes +1 rotating can reach all around itself.
Disadvantages:
• Large structural framework.
• Lower accuracy compared with the Cartesian robots.
• Restriction of the workspace

3. Polar/Spherical configuration: this configuration also

goes by the name “spherical coordinate” because the
workspace within which it can move its arm is a partial
sphere as shown in figure. The robot has a rotary base and a
pivot that can be used to raise and lower a telescoping arm.
Advantages:
• Low weight and minimal structural complexity.
• Short joint travel for many motions.
• Good accuracy and resolution.
• 1 linear + 2 rotational axes
Disadvantages:
• Large variable torque on second joint creating counterbalance problem.
• Position error is large due to rotary joints.

4. Jointed-arm/Revolve configuration: is combination

of cylindrical and articulated configurations. This is
similar in appearance to the human arm, as shown in fig.
the arm consists of several straight members connected
by joints which are analogous to the human shoulder,
elbow, and wrist. The robot arm is mounted to a base
which can be rotated to provide the robot with the
capacity to work within a quasi-spherical space.

Advantages:
• Flexibility to reach over or under an object.
• Good workspace.
• 3 rotational axes can reach above or below obstacles.
Disadvantages:
• Counterbalance problem.
• Poor resolution and accuracy due to rotary joints.
• High moment of inertia and dynamic instability (i.e. vibrations).
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ROBOT APPLICATIONS

Need to replace human by robots:

• Work environment hazardous for human beings
• Repetitive tasks
• Boring and unpleasant tasks
• Multi shift operations
• Infrequent changeovers
• Performing at a steady pace
• Operating for long hours without rest
• Responding in automated operations
• Minimizing variation

Industrial Robot Applications:

Industrial Robot Applications can be divided into:
1. Material-handling applications:
• Involve the movement of material or parts from one location to another.
• It includes part placement, palletizing and/or de-palletizing, machine loading and
unloading.
2. Processing Operations:
• Requires the robot to manipulate a special process tool as the end effectors.
• The application include spot welding, arc welding, riveting, spray painting, machining,
metal cutting, debarring, polishing.
3. Assembly Applications:
• Involve part-handling manipulations of a special tools and other automatic tasks and
operations.
4. Inspection Operations:
• Require the robot to position a work part to an inspection device.
• Involve the robot to manipulate a device or sensor to perform the inspection.

Material Handling Applications

1. Part Placement:
• The basic operation in this category is the relatively simple pick-and-place operation.
• This application needs a low-technology robot of the cylindrical coordinate type.
• Only two, three, or four joints are required for most of the applications.
• Pneumatically powered robots are often utilized.
2. Palletizing and/or Depalletizing
• The applications require robot to stack parts one on top of the other, that is to palletize
them, or to unstack parts by removing from the top one by one, that is depalletize them.
• Example: process of taking parts from the assembly line and stacking them on a pallet or
vice versa.
3. Machine loading and/or unloading:
• Robot transfers parts into and/or from a production machine.
• There are three possible cases:

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➢ Machine loading in which the robot loads parts into a production machine, but
the parts are unloaded by some other means. Example: a press working
operation, where the robot feeds sheet blanks into the press, but the finished parts
drop out of the press by gravity.
➢ Machine loading in which the raw materials are fed into the machine without
robot assistance. The robot unloads the part from the machine assisted by vision
or no vision. Example: bin picking, die casting, and plastic moulding.
➢ Machine loading and unloading that involves both loading and unloading of the
work parts by the robot. The robot loads a raw work part into the process ad
unloads a finished part. Example: Machine operation difficulties
• Difference in cycle time between the robot and the production machine. The cycle time
of the machine may be relatively long compared to the robot’s cycle time.

4. Stacking and insertion operation:

• In the stacking process the robot places flat parts on top of each other, where the vertical
location of the drop-off position is continuously changing with cycle time.
• In the insertion process robot inserts parts into the compartments of a divided carton.
The robot must have following features to facilitate material handling:
➢ The manipulator must be able to lift the parts safely.
➢ The robot must have the reach needed.
➢ The robot must have cylindrical coordinate type.
➢ The robot’s controller must have a large enough memory to store all the programmed
points so that the robot can move from one location to another.
➢ The robot must have the speed necessary for meeting the transfer cycle of the operation.

Processing operations:
• Robot performs a processing procedure on the part.
• The robot is equipped with some type of process tooling as its end effector.
• Manipulates the tooling relative to the working part during the cycle.
• Industrial robot applications in the processing operations include:
➢ Spot welding
➢ Continuous arc welding
➢ Spray painting
➢ Metal cutting and deburring operations
➢ Various machining operations like drilling, grinding, laser and water jet cutting, and
riveting.
➢ Rotating and spindle operations
➢ Adhesives and sealant dispensing

Assembly operations:
Batch assembly: As many as one million products might be assembled.
The assembly operation has long production runs.
Low-volume: In this a sample run of ten thousand or less products might be made.
The assembly robot cell should be a modular cell.
One of the well-suited areas for robotics assembly is the insertion of odd electronic components.

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Inspection operation:
• Some inspection operation requires parts to be manipulated and other applications
require that an inspection tool be manipulated.
• Inspection work requires high precision and patience, and human judgment is often
needed to determine whether a product is within quality specifications or not.
• Inspection tasks that are performed by industrial robots can usually be divided into the
following three techniques:
➢ By using a feeler gauge or a linear displacement transducer known as a linear
variable differential transformer (LVDT), the part being measured will come in
physical contact with the instrument or by means of air pressure, which will cause it
to ride above the surface being measured.
➢ By utilizing robotic vision, matrix video cameras are used to obtain an image of the
area of interest, which is digitized and compared to a similar image with specified
tolerance.
➢ By involving the use of optics and light, usually a laser or infrared source is used to
illustrate the area of interest.
• The robot may be in active or passive role.
• In active role robot is responsible for determining whether the part is good or bad.

Industrial Robots:
An industrial robot is a general purpose programmable machine possessing certain
anthropomorphic characteristics. It is most typically used for parts handling tasks but can also
be used in conjunction with a variety of manufacturing processes. The robots can be
programmed to carry out a sequence of mechanical movements. It will perform that sequence
over and over again until reprogrammed to carry out a sequence of mechanical movements.
General Physical Configuration There is two principal robot configurations: polar and
cylindrical. The two types are illustrated in figure in the polar configuration the body of the
robot pivots either horizontally vertically or both. Attached to body pivots is the area that moves
by body motion. They are of the robot in the horizontal orientation and can be made to move up
and down and in or out with respect to the body.
Arm and body motions
1. Vertical traverse Up and down motion of the arm
2. Radial traverse Extension and retraction of the arm
3.Rotational traverse Rotation about the vertical axis Wrist Motions
4.Wrist swivel Rotation of the wrist
5.Wrist bend up or down movement of the wrist which also involves a rotational movement.
6. Wrist yaw Right or left swivel of the wrist.

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