Course Title: Introduction to Mechanical Engineering

Course Code: BMEESC104

Course In charge: Ashoka E

Module-5
Automation: Reasons for automation, fixed, programmable, and flexible automation. Basic elements of
automated system. Advantages and disadvantages of automation. Open loop and closed loop control system.
Robotics: Introduction, robot anatomy, robot configuration- Cartesian coordinate, cylindrical, polar and
spherical configuration.
Self-Study Components: Pick and place robots. (CIE only)

Control system
A control system is defined as the mechanism or a system that provides the desired response or
output by controlling the input and processing system. These days, control systems are being implementing
in every smart devices and systems such as traffic lights system, washing machine, rocket launching
systems, electrical power system, etc.

Depending on the feedback path present in the system, the control systems can be classified into
following two types

 Open Loop Control System

 Closed Loop Control System

Open Loop Control System

An open loop control system is the one in which the output signal is not fed back to the input of the
system. Therefore, an open loop control system is also referred to as a non-feedback control system.

In case of open loop control system, the output has no control on the control action of the system.
Thus, the open loop control system follows its input signals regardless of the final results. The input is
supplied to the controller which produces an actuating signal (or control signal). This actuating single is
supplied to the plant or processing system which is to be controlled.
Closed Loop Control System
A closed loop control system is the one in which the output signal is fed-back to the input of the
system. Therefore, in a closed loop control system, the control action is a function of desired output signal.

The error detector accepts input signal and feedback signal to produce an error signal which is the
difference of input and feedback signals. The feedback signal is the sample of output of the overall system.

Now, the error signal is supplied to the controller to produce an actuating signal which controls the plant or
processing system to produce desired results. Therefore, in the closed loop control system, the input of the
system is automatically adjusted to produce a desired response from the system.
Difference between Open-Loop Control System and Closed-Loop Control System

Basis of Open Loop Control System Closed Loop Control System

Difference
Definition A control system in which there is no The control system in which there is a
feedback path is provided is called feedback path present is called a closed
an open loop control system. loop control system.

feedback control Open loop control system is also called Closed loop control system is also called a
system non-feedback control system feedback control system
Control action In open loop control system, the control In closed loop control system, the control
action is independent of the output of action is dependent on the output of the
the overall system. system.
Design complexity The design and construction of an open Closed loop control system has
loop control system is quite simple. comparatively complex design and
construction.

Main The major components of an open loop The main components of a closed loop
Components control system are − controller and control system are − Controller, plant or
plant. process, feedback element and error
detector (comparator).
Response Open loop control system has fast The response of the closed loop control
response because there is no system is slow due to presence of feedback.
measurement and feedback of output.
Reliability The reliability of open loop control The closed loop control system is more
system is less. reliable.
Accuracy The accuracy of open loop control Closed loop control system is
system depends upon the system comparatively accurate because the
calibration and therefore, may be less. feedback maintains its accuracy.

Maintenance Open loop control system requires less Comparatively more maintenance is needed
maintenance. in closed loop control system.
Implementation Open loop control system is easy to The implementation of a closed loop
implement. control system is relatively difficult.
Cost Open loop control system is less The cost of the closed loop control system
expensive. is relatively high.
Noise Open loop control system has more In closed loop system, the internal noise in
internal noise. the system is less.
Examples Electric Hand Drier, Washing Machine, Air Conditioner, Water Level controller,
Bread Toaster, Light switch etc. Automatic Electric Iron, Voltage stabilizer,
etc.

INDUSTRIAL ROBOTICS
Robot Anatomy
Robot Configuration
Industrial robots are available in a wide variety of sizes, shapes, and physical configurations. These
configurations are mainly depending on the movement of joints.
Classification based on robotics configuration:

1. Cartesian Robot Configuration (3P)

2. Polar Configuration (P2R) or Spherical configuration
3. Cylindrical robot configuration
4. Jointed-arm configuration

1. Cartesian Robot Configuration (3P)

These robots are made of three linear joints that position the end effector, which is usually followed by
additional revolute joints that orientate the end effector. 3P represents three Prismatic or Linear joints used
in the robots. By moving the three slides relative to one another, the robot is capable of operating within a
rectangular work envelope.

Advantages
• Highly accurate & speed,
• Fewer costs,
• Simple operating procedures, and
• High payloads.

Disadvantages
• Less work envelope, reduced flexibility.
• Low dexterity (not able to move quickly and easily)
• Limited manipulability
2. Polar Configuration (P2R)
The polar configuration uses a telescopic arm that can be moved up or down about a horizontal pivot. The
pivot is mounted on a rotating base. A rotating base supports the two links. These various joints can move
the arm endpoint within a partial spherical space. It is also called a spherical co-ordinate‖ configuration,
which allows manipulation of objects on the floor. This system has one Prismatic and two revolute joints
that denote the P2R.

Advantages
• Long reach capability in the horizontal position.

Disadvantages
• Vertical reach is low
• Low mechanical stiffness
• Complex construction
• Accuracy decreases with the increasing radial stroke.

3. Cylindrical Robot Configuration (PRP)

The cylindrical configuration uses a vertical column and a slide that can be moved up or down along the
column. The robot arm is attached to the slide so that it can be moved radially with respect to the column.
By rotating the column, the robot is capable of achieving a workspace that approximates a cylinder. This
cylindrical configuration has two Prismatic or Linear joints and one revolute joint, (PRP) denotes this only.
Advantages
• Increased rigidity, and
• Capacity to carry high payloads

Disadvantages
• Floor space required is more, and
• Less work volume.
• Accuracy decreases as the horizontal stroke increases.

4. Spherical Configuration /Jointed Arm Configuration

The jointed Arm configuration is made up of rotating joints. This robot configuration is also sometimes
called anthropomorphic as its anatomy is similar to the Human arm. These configuration joints are all
revolute (3R). They are the most common configuration for industrial robots.

Advantages
• Increased flexibility,
• Huge work volume, and
• Quick operation.

Disadvantages
• Very expensive,
• Difficult operating procedures, and
• Plenty of components.
Advantages and Disadvantages of Robots
Applications of Robots
 Automation
Automation could be defined as the technology dealing with design of machine tools and systems
utilising electronics and computer systems to produce the final product at minimum cost, involving
minimum labour intervention, producing components of high accuracy repeatedly without causing
rejections.

The Advantages of automation are:

 Reduced human labour required
 Consistency in quality
 Fewer risks of human error
 Improved health & safety
 Improved efficiency

The Disadvantages of automation are:

 Initial investment is high
 Require some manual labour: observation and programming
 Failures could lead to temporary downtime in production
Types of Manufacturing Automation
1) Fixed Automation
2) Programmable Automation
3) Flexible Automation

1) Fixed Automation
In fixed automation, the sequence of processing is fixed for one particular product. Such a system
can be used for mass production of a product. Its initial cost is high and any changes in product
design can be incorporated with difficulty.
If product has to be changed, then lot of modifications, new additions, etc. may be required and to
accommodate same would be very costly and time consuming. But it provides high production
rates. This type of automation is best suited for: High demand and general products that require no
change.
This is relatively useful for many companies who use automation to create food products of one type
and variant. It allows them to effectively produce that item and package it in bulk.

Advantages of fixed automation include:

 High levels of production
 Consistent quality in production
 Low cost per unit produced
Disadvantages of fixed automation include:
 High initial cost
 Difficult to accommodate change

2. Programmable Automation
In programmable automation (as with numerically controlled machines and robots), it is
possible to accommodate the change in sequence of operations for new product by changing the
program (set of instructions). Such a system is thus suited for batch production. For new product, not
only programs have to be changed, but new tools and fixtures may have to be loaded, and machine
settings changed.
Programmable automation will often be used by factories who make different variants of
foods. This allows them to make batches, from a few dozen to potentially thousands at a time, of one
product. If the product needs changing, it simply needs to be reprogrammed.
This type of automation is well suited for: Low/Medium demand and occasional changes in products.

Advantages of Programmable automation:

 Flexibility to change products if needed
 Suitable if batch production is required

Disadvantages of Programmable automation:

 Expensive for equipment
 Lower production levels
 Often time-consuming to change products

3. Flexible Automation
Flexible automation, also known as “soft automation”, is similar to programmable
automation, although a little more complicated. Essentially, flexible automation enables the
production of different types of products without losing time when reprogramming.
A flexible automation system can produce various combinations of products efficiently without
having to separate them into different batches, as required in batch production. No time is lost for
production of one product and changing over to new product. Complete information and programs
for the products desired to be produced are available in computer system
Altering the part programme is usually done by coding the program offline on a computer
and then transferring it to the automated system. Such systems are best suited for production of
large variety of spare parts for large industrial plant/process/complex.
 Advantages of automation:
 Flexibility of products
 No time lost with new changes to production

Disadvantages include:
 High custom machinery/automation cost
 Higher cost per unit

Course In charge: Ashoka