INDUSTRIAL ROBOTICS :

THEORIES FOR
IMPLEMENTATION

By

Dr T Elango/Prof/MECH

08/10/2024 05:50 AM
ASIST
A S I S T- MECH 1
 INDUSTRIAL ROBOTICS : THEORIES
FOR IMPLEMENTATION
WEEK 1: Introduction: Robot definition, applications,
Industrial robot anatomy, robot classifications,
Understanding its technical specifications, serial robots and
parallel robots.
WEEK 2: Electrical Actuators and Drives: DC Motors, Stepper
motors, BLDC Motor, and Synchronous AC servo motors,
Industrial Servo drives, hardware controllers and interfaces,
Selection of motors. Understanding Manufacturer's
Technical datasheet.
WEEK 3: Robot sensors and its interfaces: Contact and non-
contact Online sensors; position, velocity, acceleration,
proximity, and force sensors. Characteristics of Sensors.
Understanding Manufacturer's Technical datasheet.
WEEK 4: Grubler-Kutzbach Criterion; DOF of a Robot
Manipulator. Kinematic Transformations: Homogeneous
Transformation, Denavit-Hartenberg (DH) Parameters;
Forward Kinematics.
WEEK 5: Inverse Kinematics. Differential Motion: link velocity
and Acceleration analysis, Jacobian matrix and Singularity.
WEEK 6: Industrial Robot Installation and Commissioning,
Mastering a Robot, Tool Center Point Calibration: 4-Point
method, External reference method, Orientation calibration:
WEEK 7: Calibration of Industrial Robot system: External fixed tool,
Workpiece calibration: Direct and Indirect methods, Work Surface
calibration: 3-Point method and Indirect method, Linear rail robot
mounts and external rotary turn-table.
WEEK 8: Statics: Link forces and moments; Recursive formulation,
Gravity Compensation, Role of Jacobian: Force and Velocity ellipsoid.
WEEK 9: Robot Dynamics: Euler-Lagrange formulation, Newton-Euler
formulation.
WEEK 10: Load data calibration: For payload and any supplementary
loads. Identification experiments. Repeatability tests and ISO
9283:1998
WEEK 11: Robot Control: Transfer function and state-space
representation of a robotic joint, feedback control system,
Proportional, Derivative and Integral (PID) control. Gain tuning.
WEEK 12: Workspace and Operator Safety, Safety triggers and
 ROBOTICS
“Robotics is an APPLIED ENGINEERING SCIENCE that has been referred to as a
combination of MACHINE TOOL TECHNOLOGY and COMPUTER SCIENCE.
"Robotics" is defined as the science of designing and building Robots which
are suitable for real life application in automated manufacturing and other
non-manufacturing environments .
It includes Machine Design, Production Theory, Micro Electronics,
COMPUTER PROGRAMMING & ARTIFICIAL INTELLIGENCE”.

Robots motion must be Modelled, Planned, Sensed, Actuated and

Controlled, and whose motion behaviour can be influenced by “COMPUTER
PROGRAMMING”.
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 ROBOTS

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 An IR is one that has been developed to automate intensive production
tasks such as those required by a constantly moving assembly line.
 They are used in replacement of humans as they can perform repetitive
or dangerous tasks with extreme accuracy.
 As large, heavy robots, they are placed in fixed positions within an
industrial plant and all other worker tasks and processes revolve around
them.
 Many parts are used to making industrial robotics. Like cables, small
parts, grippers, guarding, and many other components are used to make
these robots.
 Industrial Robots are called “INTELLIGENT” if they succeed in moving in
safe interaction with an unstructured environment, while autonomously
achieving their specified tasks
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• 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.
• Typical applications of robots include welding, painting, assembly, pick
and place (such as packaging, palletizing and Surface Mount
Technology), product inspection, and testing; all accomplished with
high endurance, speed, and precision.
It has the following objectives,
1.To increase productivity
2. Reduce production time
3. Minimize labour requirement
4. Enhanced quality of the products
5. Minimize loss of man hours, on account of accidents.
6. Make reliable and high speed
08/10/2024 05:50 AM
production.
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Evolution of robot illustration, BEST Robotics Technology
Industrial robot, Robotics, monochrome, human, humanoid
Robot.
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 AUTOMATION AND ROBOTICS
• Automation and robotics are two closely related technologies.
• In an industrial context, Automation as a technology that is
concerned with the use of mechanical, electronic, and computer-
based systems in the operation and control of production.
• Examples of this technology include,
Transfer lines. Mechanized assembly machines, feedback
control systems (applied to industrial processes), numerically
controlled machine tools, and robots.
• Accordingly, robotics is a form of industrial automation.
Ex:- Robotics, CAD/CAM, FMS, CIMS
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 FLEXIBLE AUTOMATION
• A computer integrated manufacturing system which is an extension
of programmable automation is referred as FLEXIBLE AUTOMATION.
• It is developed to minimize the time loss between the changeover of
the batch production from one product to another while reloading.
• The program to produce new products and changing the physical
setup. i.e., it produces different products with no loss of time.
• This automation is more flexible in interconnecting work stations with
material handling and storage system.
• Advantages:-
1.High Production rates 2. Lead time decreases
3. Storing capacity decreases 4. Human errors are eliminated.
5. Labour
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05:50 AMis decreases. ASIST MECH; ROBOTICS-II EEE 12
• Disadvantages:-
Initial cost of raw material is very high,
Maintenance cost is high,
Required high skilled Labour.
Indirect cost for research development & programming increases.
Reasons for implementation of automated systems in manufacture
industries:-
To Increase the Productivity Rate of Labour
To Decrease the Cost of Labour
To Minimize the Effect of Shortage of Labour
To Obtain High Quality of Products
To Decrease the Manufacturing Lead Time
To upgrade the Safety of Workers.
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 APPLICATIONS
 Any industry that makes something or moves something at scale has a potential use
for industrial robots.
 In manufacturing industries, robotics are generally used for the fabrication, finishing,
transfer and assembly of parts.
 In material handling industries where finished products are prepared for distribution,
robotics are used for picking, sorting, packaging and palletizing of products.
 Other industries that commonly use robotics include clinical laboratories, agriculture
and education.
 Several retail and service industries are also starting to apply collaborative robots in
various public-facing settings.
SECURITY
Robotics companies are working on pairing robot guards with
human security consultants.
SPACE EXPLORATION
Mars Rover is an autonomous robot that travels on Mars and
takes pictures of Martian rock formations that are interesting or
important and then sends them back on Earth for the NASA
scientists to study.
ENTERTAINMENT
Robots can also be used to provide special effects, to do stunt
work that is very dangerous for humans but looks pretty cool in an
action movie.
AGRICULTURE
Agriculture is also a seasonal sector that is dependent on ideal
• AGRICULTURE
 The objective of agricultural robotics is to help the sector in its efficiency and in
the profitability of the processes
 Mobile robotics works in the agricultural sector to improve productivity,
specialization and environmental sustainability.
 Labor shortages, increased consumer demand and high production costs are some
of the factors that have accelerated automation in this sector, with the aim of
reducing costs and optimizing harvests
 Agriculture is also a seasonal sector that is dependent on ideal weather conditions
optimal soil, etc.
 Moreover, there are many repetitive tasks in agriculture that are just a waste of
farmer’s time and can be performed more suitable by robots.
 These include seeding, weed control, harvesting, etc. Robots are usually used for
harvesting the crops which allow farmers to be more efficient.
 BACCHUS intelligent mobile robotic Platforms for Active Inspection and Harvesting
in Agricultural Areas.
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nmanned tractor "Uralets-224"
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 An agricultural robot is a robot deployed for agricultural purposes. The main area of application of robots in

agriculture today is at the harvesting stage. Emerging applications of robots or drones in agriculture include

weed control, cloud seeding, planting seeds, harvesting, environmental monitoring and soil analysis.

 Fruit picking robots, driverless tractor / sprayers, and sheep shearing robots are designed to replace human labor.

 Robots can be used for other horticultural tasks such as pruning, weeding, spraying and monitoring.

 Robots can also be used in livestock applications (livestock robotics) such as automatic milking, washing and

castrating.

 They can also be used to automate manual tasks, such as weed or bracken spraying, where the use of tractors and

other human-operated vehicles is too dangerous for the operators.

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Robots have many fields of application in agriculture. Some examples and prototypes of robots include the Merlin

Robot Milker, Rosphere,[clarification needed] Harvest Automation,[clarification needed] Orange Harvester, lettuce bot,[clarification needed][17] and

weeder.

Small Robot Company developed a range of small agricultural robots, each one being focused on a particular task

(weeding, spraying, drilling holes, ...) and controlled by an AI system

• Agricultural robots automate slow, repetitive and dull tasks for farmers, allowing them to focus more on improving
overall production yields. Some of the most common robots in agriculture are used for:
• Harvesting and picking
• Weed control
• Autonomous mowing, pruning, seeding, spraying and thinning
• Sorting and packing
• Utility platforms
• Harvesting and picking is one of the most popular robotic applications in agriculture due to the accuracy and speed that robots can achieve to improve the size of yields and reduce waste from
crops being left in the field.

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MEDICAL /HEALTHCARE APPLICATIONS
Medical robotics is a growing field and regulatory approval has been
granted for the use of robots in minimally invasive procedures.
Robots are being used in performing autonomously in surgery, highly
delicate, accurate surgery, or to allow a surgeon who is located
remotely from their patient to perform a procedure using a robot
controlled remotely.
One example of this is the da Vinci robot that can help surgeons in
performing complex surgeries relating to the heart, head, neck, and
other sensitive areas. Also provide therapy to patients, etc.
• MEDICAL /HEALTHCARE APPLICATIONS
• AI robotics is increasingly disrupting and transforming the healthcare market. ML-driven robotics is already
a massive part of the healthcare chain, including function testing, surgery, research, data integration, etc.

• AI robotics is widely used to track patients’ health status, form a continuous supply chain of medication
and other essentials around the hospital, and design custom health tasks for patients.

• AI and robotics are aiding the healthcare sector by providing assisting robots, precise diagnosis, and
remote treatment. Robots’ proactive analysis allows them to detect minute and complex patterns in a
patient’s health graph.

• Robots driven by machine learning are actively used in hospitals for micro-surgeries such as unclogging
blood vessels. One of the biggest gifts of AI robotics to the healthcare industry is its operation in remote
areas.

• Treatment in remote areas has been a major loophole in the medical sector for a long time. Robots can
solitarily undergo several clinical tasks. Technology like bot-pill is a marvel of AI robotics.
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UNDERWATER EXPLORATION
Robots are a great option for exploring places that humans cannot
reach easily, like the depths of the ocean!
There is a lot of water pressure deep in the ocean which means
humans cannot go that down and machines such as submarines can
only go to a certain depth as well.
A deep underwater is a mysterious place that can finally be explored
using specially designed robots.
These robots are remote-controlled, and they can go into depths of
the ocean to collect data and images about the aquatic plant and
animal life.
FOOD PREPARATION
The robot can then cook the food on its own.
 Moley Robotics is one such robotics company that has created a
APPLYING MACHINE LEARNING AND ARTIFICIAL INTELLIGENCE IN ROBOTICS IN VARIOUS SECTORS-
As highlighted above, AI and ML improve the efficacy of robotics, and in the current global scenario, it has left no sector
untouched. Here is a glance at some sectors where robotics is deriving assistance from AI and ML.
WAREHOUSES
Big companies with even larger warehouses are big consumers of robotics as it cuts operational time and intermediate
costs. High-tech sensors allow these automated devices to operate independently in these huge warehouses. The
sensors include visual, auditory, thermal, and haptic sensors. The introduction of the latter two in robotization is a gift of
AI that ensures safety through a better perception of the surrounding. In a nutshell, these sensors are the decision-
making body of the robots. Automated guided vehicles (AGVs) or automated guided carts (AGCs) are utilized for
transporting stock from one place to another in a warehouse. The corporate world today works day and night, and
therefore the presence of systems like AGSs or AGCs sustains 24*7 working with similar costs. Aerial drones are another
innovation used in warehouses that sustain quick scanning and optimization of the current inventory within no time and
with minimal effort. There are some clear benefits of adopting robotics- minimal errors, adaptability, safety, etc. robots
are trained human-like figures which operate on acquired algorithms, thus, avoiding mistakes. Safety is a major
advantage of robotics as it prevents workers from undergoing dangerous tasks such as pulling stocks from a height.
Hence, robots take away mundane and risky tasks from workers.
08/10/2024 A S I ST - MECH 23
• MEDICAL /HEALTHCARE APPLICATIONS
• AI robotics is increasingly disrupting and transforming the healthcare market. ML-driven robotics is already
a massive part of the healthcare chain, including function testing, surgery, research, data integration, etc.

• AI robotics is widely used to track patients’ health status, form a continuous supply chain of medication
and other essentials around the hospital, and design custom health tasks for patients.

• AI and robotics are aiding the healthcare sector by providing assisting robots, precise diagnosis, and
remote treatment. Robots’ proactive analysis allows them to detect minute and complex patterns in a
patient’s health graph.

• Robots driven by machine learning are actively used in hospitals for micro-surgeries such as unclogging
blood vessels. One of the biggest gifts of AI robotics to the healthcare industry is its operation in remote
areas.

• Treatment in remote areas has been a major loophole in the medical sector for a long time. Robots can
solitarily undergo several clinical tasks. Technology like bot-pill is a marvel of AI robotics.
08/10/2024 A S I ST - MECH 24
AGRICULTURE

Integrating AI, ML, and Robotics provide agronomists with useful and actionable insights to help improve their
farm productivity. By attaining this information, farmers ensure high yields and low operational costs, thus,
stepping towards farm success.

The primary fundamental of introducing robotics in farms is cutting down back-breaking labor efforts by
automating farm activities like irrigation, seed distribution, pest control, and harvesting; you name it, and you
have it. This renders the growers with much more time to focus on productive tasks.

Emphasizing a major advantage of robotics of ensuring precision, it helps mitigate wastage of land potential, thus
making a place for effective land use. Robotization of the green economy can help monitor quality enhancement,
environmental conservation, and so on.

The agricultural colony is gradually shifting towards these technologies, ensuring huge farm success in the wider
picture. This creates a need for constant growth in AI-generated robots to improve the global agriculture scenario.

The seeding of AI and robotics will result in sustainable development, which is also the focus of the UN and the
world.08/10/2024 A S I ST - MECH 25
AUTOMOBILES
• The role of robotics has a whole network of applications in the automotive industry ranging from
designing, supply chain, and production activities to an entire set of management activities. Systems
like driver assistance, autonomous driving, and driver risk assistance are being implemented in
transportation for automobile industries. The automobile industry has been using robotic intelligence
for more than 50 years. The only change from then to now is the advancement of AI and ML in this
branch, which is a drastic one. The advantages of robotics in automobiles are widespread-

• Robotics provides an accurate vision for locating the required items. Basic errands like installing door
panels, fenders, etc., can be easily carried out by robots.

• Assembling machine devices like motors, screws, pumps, etc.

• Robotic arms can be deployed in painting and coating.

• Along with assembling segregated parts, robots can also transfer these parts, including loading and
unloading.
08/10/2024 A S I ST - MECH 26
• APPLYING MACHINE LEARNING AND ARTIFICIAL INTELLIGENCE IN ROBOTICS IN VARIOUS SECTORS-
• As highlighted above, AI and ML improve the efficacy of robotics, and in the current global scenario, it has left no sector
untouched. Here is a glance at some sectors where robotics is deriving assistance from AI and ML.
WAREHOUSES
Big companies with even larger warehouses are big consumers of robotics as it cuts operational time and intermediate
costs. High-tech sensors allow these automated devices to operate independently in these huge warehouses. The
sensors include visual, auditory, thermal, and haptic sensors. The introduction of the latter two in robotization is a gift of
AI that ensures safety through a better perception of the surrounding. In a nutshell, these sensors are the decision-
making body of the robots. Automated guided vehicles (AGVs) or automated guided carts (AGCs) are utilized for
transporting stock from one place to another in a warehouse. The corporate world today works day and night, and
therefore the presence of systems like AGSs or AGCs sustains 24*7 working with similar costs. Aerial drones are another
innovation used in warehouses that sustain quick scanning and optimization of the current inventory within no time and
with minimal effort. There are some clear benefits of adopting robotics- minimal errors, adaptability, safety, etc. robots
are trained human-like figures which operate on acquired algorithms, thus, avoiding mistakes. Safety is a major
advantage of robotics as it prevents workers from undergoing dangerous tasks such as pulling stocks from a height.
Hence, robots take away mundane and risky tasks from workers.
08/10/2024 05:50 AM A S I S T- MECH 27
AGRICULTURE

Integrating AI, ML, and Robotics provide agronomists with useful and actionable insights to help improve their
farm productivity. By attaining this information, farmers ensure high yields and low operational costs, thus,
stepping towards farm success.

The primary fundamental of introducing robotics in farms is cutting down back-breaking labor efforts by
automating farm activities like irrigation, seed distribution, pest control, and harvesting; you name it, and you
have it. This renders the growers with much more time to focus on productive tasks.

Emphasizing a major advantage of robotics of ensuring precision, it helps mitigate wastage of land potential, thus
making a place for effective land use. Robotization of the green economy can help monitor quality enhancement,
environmental conservation, and so on.

The agricultural colony is gradually shifting towards these technologies, ensuring huge farm success in the wider
picture. This creates a need for constant growth in AI-generated robots to improve the global agriculture scenario.

The seeding of AI and robotics will result in sustainable development, which is also the focus of the UN and the
world.08/10/2024 05:50 AM A S I S T- MECH 28
AUTOMOBILES
• The role of robotics has a whole network of applications in the automotive industry ranging from
designing, supply chain, and production activities to an entire set of management activities. Systems
like driver assistance, autonomous driving, and driver risk assistance are being implemented in
transportation for automobile industries. The automobile industry has been using robotic intelligence
for more than 50 years. The only change from then to now is the advancement of AI and ML in this
branch, which is a drastic one. The advantages of robotics in automobiles are widespread-

• Robotics provides an accurate vision for locating the required items. Basic errands like installing door
panels, fenders, etc., can be easily carried out by robots.

• Assembling machine devices like motors, screws, pumps, etc.

• Robotic arms can be deployed in painting and coating.

• Along with assembling segregated parts, robots can also transfer these parts, including loading and
unloading.
08/10/2024 05:50 AM A S I S T- MECH 29
Material Transfer, Machine Loading And Unloading
Material transfer applications are defined as operations in which the
primary objective is to move a part from one location to another
location.
The most basic of these applications is where the robot picks the part
up from one position and transfers it to another position.
In other applications, the robot is used to load and/or unload a
production machine of some type.
As the assembly of the machine parts is a repetitive task to be
performed, the robots are conveniently used instead of using mankind

08/10/2024 05:50 AM ASIST MECH; ROBOTICS-II EEE 30

Military,
Customer Service

08/10/2024 05:50 AM A S I S T- MECH 31

Industrial Robot Applications

• Product Assembly: Industrial robots are widely used as assembly

machines. They are suitable for highly repetitive but precise tasks
that are tedious for a human operator. Their EOAT is usually
mechanical grippers that pick, place, and orient small or large
parts in quick succession. Sensors are optional and are typically
used for recalibrating the accuracy of the robot‘s
movements.Modern end effectors are usually equipped with
sensors to ensure that they have the correct part and the part is in
the correct orientation for the assembly process. In addition, some
robots can use a machine vision camera attached to the end
effector to perform dynamic positioning based on the actual
location of an assembly that may vary during production.
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• Non-Conventional Machining: Common non-conventional methods of
machining include waterjet cutting, laser cutting, abrasive jet
machining, electric discharge machining (EDM), and plasma cutting.
These non-contact machining processes perform material removal by
using highly concentrated streams of water, light, electric charge, or
another physical entity. The concentrated stream erodes, vaporizes, or
melts the material.High amounts of energy are involved in these
processes, potentially damaging the product or the machine itself if not
controlled properly. Industrial robots are used to control the cutting
path of the machine accurately. The right cutting speed, stream
stability, and accurate control of machine parameters such as power,
pressure, and flow rate are properly maintained using digital industrial
robots.
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• Palletizing and Depalletizing: Palletizing is the process of
combining several individual products into a single load for
more efficient product handling, storage, and distribution.
On the other hand, depalletizing is the opposite: it‘s the
disassembly of a palletized load. Both of these processes are
labor-intensive and can quickly become process bottlenecks.
Robotic palletizers are used for their better product
handling and cost-efficiency. EOATs integrated into robotic
palletizers are mechanical, pneumatic, and vacuum grippers
that operate by picking, orienting, and stacking items,
similar to the operation of assembly machines.
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• Welding: Robotic welding systems are commonly seen in automotive
manufacturing plants, but they are also widely used in many high-volume
metal fabrication processes. Increased market competitiveness created the
need for better product quality and higher operating rates. This, in turn,
requires more accurate and precise welding processes. The main advantage of
using industrial robots in welding is better control of different parameters such
as current, voltage, arc length, filler feed rate, weld rate, and arc travel speed.
• Painting and Coating: Painting and coating is a sensitive operation that requires
highly accurate and repeatable movements to create a layer with uniform
thickness. On top of the required accuracy and precision, painting involves
working with potentially hazardous chemicals. Many pigments and solvents are
poisonous, and some can even create an explosive atmosphere. All these
hazards are mitigated by using industrial robots.

08/10/2024 05:50 AM A S I S T- MECH 39

INDUSTRIAL APPLICATIONS
The auto industry is the largest users of robots, which automate the production
of various components and then help, assemble them on the finished vehicle.

Car production is the primary example of the employment of large and

complex robots for producing products.

Die casting , Plastic moulding, Forging and related operations, Machining

operations, Stamping press operations

The other industrial applications of robotics include processing operations such

as spot welding, continuous arc welding; painting, spray coating, also in
assembly of machine parts and their inspection.
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 APPLICATIONS OF ROBOTS-
Present Applications of Robots:-
(i) Material transfer applications
(ii) Machine loading and unloading
(iii) Processing operations like,
(a) Spot welding
(b) Continuous arc welding
(c) Spray coating
(d) Drilling, routing, machining operations
(e) Grinding, polishing debarring wire brushing
(g) Laser drilling and cutting etc.
(iv) Assembly tasks, assembly cell designs, parts mating.
(v) Inspection, automation.

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• Grinding, Polishing, and Buffing: Grinding, polishing, and buffing are
common secondary fabrication processes used to improve the product's
final appearance and surface properties. These processes involve
repetitive, oscillating motions of the abrasive or polishing material. A
robotic arm can easily mimic this simple movement of the tool.
• Deburring: Another capability of modern industrial robots is deburring.
This is a process where the robot holds a rotating tool, usually a sanding
drum, wire wheel, or carbide deburr tool, and follows a pre-programmed
path to deburr and smooth parts from casting or injection molding. The
advantage of using a robot for deburring is that there is usually debris or
dust that the operator would be exposed to during the deburring
process. Since a robot's path is repeatable, there is better consistency in
smoothing between parts.
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• Machine Loading and Unloading: Machine loading and unloading take advantage of
robotic systems' high load capacity and mechanical advantage. Specific machine loading
and unloading applications include transferring large metal or plastic parts from casting,
molding, and forging processes to conveyor systems, secondary processing stations, or
loading machining centers with blanks for machining.
• Inspection: Robotic inspection systems can use measuring devices such as optical sensors,
proximity sensors, force transducers, ultrasonic probes, and even complete machine
vision systems to perform inspection tasks on parts or assemblies. These machines are
typically used to precisely measure the dimensions of a product to maintain quality and
consistency. Other inspection applications include non-destructive testing (NDT) of welds,
wherein a robotic system automatically moves and controls ultrasonic probes or arrays.
• Sorting: Sorting processes utilize the simple pick and place capability and high-speed
monitoring of robotic systems. Visual sensors detect variations in size, color, or shape.
Upon detection of an odd item, a robot is used to pick and reject the item. Common
industries using robotic sorting systems are pharmaceuticals and electronics.

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 FUTURE APPLICATIONS OF ROBOTS
The profile of the future robot based on the research activities will include the following,
(i) Intelligence
(ii) Sensor capabilities
(iii) Telepresence
(iv) Mechanical design
(v) Mobility and navigation (walking machines)
(vi) Universal gripper
(vii) Systems and integration and networking
(viii) FMS (Flexible Manufacturing Systems)
(Ix) Hazardous and inaccessible non-manufacturing environments
(x) Underground coal mining
(xi) Fire fighting operations
(xii) Robots in space
(xiii) Security guards
(xiv) Garbage collection and waste disposal operations
(xv) Household robots
08/10/2024 05:50 AM ASIST MECH; ROBOTICS-II EEE 47
What is anatomy in robotics?
• Robot anatomy deals with the study of different joints and links and other. aspects of the
manipulator's physical construction. • A robotic joint provides relative motion between two
links of the robot. • Each joint, or axis, provides a certain degree-of-freedom (dof) of
motion.
Robot Anatomy: Four Configurations
Robot Anatomy
The anatomy of robot is also known as structure of robot. The basic components or sections in anatomy of robots are as follows.
The anatomy of the robot is concerned with the physical construction of the body, arm, and wrist of the machine.
Nowadays, most robots used in industries are mounted on a base that is fastened to the floor. The whole body of the robot was attached to the base
and the arm assembly is attached to the body. At the end of the arm is the wrist.
The RIA (Robotics Industries Association) has officially given the definition for Industrial
Robots An .Industrial According Robot is are programmable, to RIA, multifunctional “ manipulator designed to move materials, parts,
tools, or special devices through variable programmed motions for the performance of a
The Anatomy of Industrial Robots deals with the assembling of outer components of a robot such as wrist, arm, and body. Before jumping into Robot
Configurations, here are some of the key facts about robot anatomy.
·The wrist consists of a number of components that allow it to be oriented in a variety of positions. The movement between various components of
the body, arm, and wrist is provided by a series of joints.
End Effectors: A hand of a robot is considered as end effectors. The grippers and tools are the two
significant types of end effectors. The grippers are used to pick and place an object, while the tools
are used to carry out operations like spray painting, spot welding, etc. on a work piece.
The tool or hand attached to the robot’s wrist is known as the end effector.
·Robot Joints: The joints in an industrial robot are helpful to perform sliding and rotating movements
of a component.
·Manipulator: The manipulators in a robot are developed by the integration of links and
joints. In the body and arm, it is applied for moving the tools in the work volume. It is also
used in the wrist to adjust the tools.
These joints may be in either rotating or sliding motions. The body, arm, and wrist assembly combinedly are known as manipulators.
·Kinematics: It concerns with the assembling of robot links and joints. It is also used to
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illustrate the robot motions.
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he anatomy or the structure of a robot depends on the basic components such as the wrist, arm, and body used to build
it for a specific operation. An industrial robot comprises a mechanical manipulator and a controller that allows it to move
and perform other tasks.
The mechanical manipulator comprises joints and links that allow the manipulator’s end to be positioned and oriented
relative to its base. The controller operates the joints in a coordinated manner at the same time to complete a
programmed work cycle.
A robot joint is similar to a joint in the human body. It allows for relative movement between two body parts. Industrial
robots typically have five or six linear or rotating joints.
Robots are mostly divided into four major configurations based on their appearances, sizes, etc., including cylindrical
configuration, polar configuration, jointed arm configuration, and cartesian coordinate configuration.
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ROBOT CLASSIFICATION
1) Based on physical configuration

1. Cartesian configuration
2. Cylindrical configuration
3. Polar configuration
4. Joint-arm configuration
2) Depending on Robot Base
1.Fixed
2.Mobile
3) Based on control systems

1. Point-to-point (PTP) control robot

2. Continuous-path
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(CP) control
A S I S T- MECH
robot 54
 ROBOT CONFIGURATIONS and its TYPES
Industrial robots are available in a wide variety of sizes, shapes, and physical configurations. These
configurations are mainly depending on the movement of joints.
Those joints are known as Prismatic joints or Linear joints denoted by P, revolute joints denoted by R,
and spherical joints denoted by S.
• A coordinate system defines a plane or space by axes from a fixed point called the origin. Robot
targets and positions are located by measurements along the axes of coordinate systems.
• A robot uses several coordinate systems, each suitable for specific types of jogging or programming.
The Robots are mostly divided into four major configurations based on their appearances, sizes, etc.
such as:
1) Cylindrical Configuration,
2) Polar Configuration [Spherical],
3) Jointed Arm Configuration, and
4) Cartesian Co-ordinate Configuration.
 1. CYLINDRICAL CONFIGURATION(PRP)
 The cylindrical configuration has two perpendicular prismatic joints and a revolute
joint.
 A vertical column and a slide that moves up and down the column are used in this setup.
 The robot arm is connected to the slide and can move radially around the column.
 By rotating the column, the robot can achieve a workspace that approximates a cylinder.
 The cylindrical configuration offers good mechanical stiffness.
• Example: GMF Model M1A Robot.
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.
 2. POLAR/SPHERICAL CONFIGURATION (P2R)
 A prismatic joint can be raised or lowered about a horizontal
revolute joint in the polar configuration.
 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.
 Example: Unimate 2000 Series Robot.
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. JOINTED ARM CONFIGURATION(3R)
 Widely-used jointed arm configuration is similar to that of a
human arm.
 It comprises two straight links representing the human forearm
and upper arm and two rotary joints representing the elbow and
shoulder joints, which are mounted on a vertical rotary table
corresponding to the human waist joint.
 As a result, it can be controlled at any adjustments in the
workspace.
 These types of robots perform several operations like spray
painting, spot welding, arc welding, and more.
 Example: Cincinnati Milacron T3 776 Robot
Advantages
• Increased flexibility,
• Huge work volume, and
• Quick operation.
Disadvantages
• Very expensive,
 4. CARTESIAN CO-ORDINATE CONFIGURATION [Gantry
Robot] (3P)
 Cartesian or rectangular coordinate configuration is constructed by
three perpendicular prismatic joints slides, giving only linear
motions along the three principal axes.
 These robots are also called XYZ robots because they are equipped
with three rotary joints to assemble XYZ axes.
 The robots will process in a rectangular workspace and it can carry
high payloads with the help of its rigid structure.
 It is mainly integrated with pick and place, material handling,
loading, unloading, etc. Example: IBM 7565 Robot.
Advantages
• Highly accurate & speed,
• Fewer costs,
• Simple operating procedures, and
• High payloads.
Disadvantages
 Less work envelope
• Selective Compliant Articulated Robot Arm (SCARA): A
SCARA is a type of robot with an arm that is compliant or
flexible in the horizontal or XY-plane but rigid in the vertical
direction or Z-axis. Its translational movement on a single
plane describes its “Selective Compliant” characteristic. A
SCARA has two links, two revolute joints, and a single
prismatic joint. The links and the base are connected by the
revolute joints oriented at the same axis. The prismatic joint
is only for raising or lowering the EOAT. The resulting work
envelope of a SCARA is a torus. Its application is similar to
that of a cylindrical robot.
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• Delta Robot: A delta robot consists of at least three links
connected to an EOAT and a common base. The EOAT is
connected to the links by three undriven universal joints. On
the other hand, the base is connected by either three
prismatic or revolute-driven joints. The driven joints work
together to allow the EOAT to have four degrees of
freedom. For designs using prismatic joints, a fourth link or
shaft is usually connected to the EOAT to enable rotation.
The EOAT of a delta robot can move along all Cartesian axes
and rotate around the vertical axis, resulting in a dome-
shaped work envelope. The simultaneous action of the
three
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AM joints makes delta robots suitable for high-
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• Articulated Robot or Anthropomorphic Robot: Articulated
robots are the most common robots used in manufacturing
processes. They perform more complex operations such as
welding, product assembly, and machining. EOATs mounted
on articulated robots are designed to have a full six degrees
of freedom. The robot arm consists of at least three
revolute joints. A fourth revolute joint can be added to the
wrist of the arm for rotating the EOAT. Its work envelope is
also spherical, similar to that of the polar robot type.

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2) Depending on Robot Base
1. Fixed-
Robots used in manufacturing are
examples of fixed robots. They can not
move their base away from the work being
done.

08/10/2024 05:50 AM Fig. Example of FixedArobot

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2. Mobile- Mobile bases are typically platforms with wheels or tracks attached.

Fig. Example of mobile type robots

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3) Based on control systems

1. Point-to-point (PTP) control robot

The PTP robot is capable of moving from one point to another point. The
locations are recorded in the control memory. PTP robots do not control the path
to get from one point to the next point.
Common applications include:
•Component insertion
•Spot welding
•Hole drilling
•Machine loading and unloading
•Assembly operations

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2. Continuous-path (CP) control robot

The CP robot is capable of performing movements along the

controlled path. With CP from one control, the robot can stop at
any specified point along the controlled path.
All the points along the path must be stored explicitly in the
robot’s control memory. Applications Straight-line motion is the
simplest example for this type of robot. Some continuous-path
controlled robots also have the capability to follow a smooth
curve path that has been defined by the programmer. In such
cases the programmer manually moves the robot arm through
the desired path and the controller unit stores a large number of
individual point locations along the path in memory (teach-in).
Typical applications include:
•Spray painting
•Finishing
•Gluing
•Arc welding operations

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 3. Controlled-path robot
In controlled-path robots, the control equipment can generate paths of different
geometry such as straight lines, circles, and interpolated curves with a high degree of
accuracy. Good accuracy can be obtained at any point along the specified path.
Only the start and finish points and the path definition function must be stored in the
robot’s control memory. It is important to mention that all controlled-path robots have
a servo capability to correct their path.

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SCARA Configuration
SCARA stands for Selective Compliance Assembly Robot Arm. SCARA robots have two or three revolute joints that are parallel and
allow the robot to move in a horizontal plane, plus a linear joint that moves vertically.
SCARA robots are very common in assembly operations.