MODULE-5

Automation
&
Robotics
By,
Prof. Akshay S Bhat
Dept. Of M.E
VVCE, Mysore
 MODULE 5: Automation

Syllabus-

Automation: Definition, types – fixed, programmable, and flexible

automation. Reasons for automation, automation strategies.
Robotics: Introduction, robot joints & links, robot configuration- polar,
cylindrical, cartesian and spherical, application, advantages and
disadvantages.
Self-Study Components: Advantages and disadvantages of automation.
MODULE - 5
Chapter – 1

Automation
AUTOMATION
 An automated system is one in which a process is performed by a machine without
the direct participation of a human worker.

 Automation is implemented using a program of instructions combined with a control

system that executes the instructions.

 Power is required to drive the process and to operate the program and control system.
Types of Automation
 Advantages of Automation
1. Increase in Productivity
2. Improvement in Product Quality
3. Increase in Accuracy and Repeatability
4. Improved Safety at the workplace
5. Reduction in manufacturing Lead times
6. Reduced direct human labor costs and expenses
7. Mitigation of Potential labor shortages
8. Can do jobs which cannot be done by Humans
 Disadvantages of Automation
• High initial cost
• Security threats with limited level of intelligence
• High maintenance, development and research costs
• More dependency
• Increased unemployment
Reasons for Automation
 Automation Strategies
Automation strategies are plans or approaches that organizations use to adopt and implement
automation technologies to improve their business processes, operations, and overall performance.
Some examples of automation strategies are;
1.Process Automation (Data entry, Customer service, etc.)
2.IT Automation (Software deployment, Infrastructure provisioning, etc.)
3.Intelligent Automation (Use of advanced technologies such as AI & ML – Predictive maintenance,
demand forecasting, etc.)
4.Industrial Automation (Increased productivity by using PLC, Industrial robots, etc.)
5.Service Automation (Ticketing, Self service portals, etc.)
Overall, automation strategies are designed to help organizations achieve their goals, whether it's
reducing costs, improving productivity, or enhancing the customer experience. The specific strategy
chosen depends on the organization's needs, capabilities, and goals.
MODULE - 5
Chapter – 2

Robotics
 MODULE 5: Automation
Syllabus-

Automation: Definition, types – fixed, programmable, and flexible

automation. Reasons for automation, automation strategies.
Robotics: Introduction, robot joints & links, robot configuration- polar,
cylindrical, cartesian and spherical, application, advantages and
disadvantages.
Self-Study Components: Advantages and disadvantages of automation.
History
The word “Robot” was first coined by the Czech novelist Karel Capek in his
1920s play called “Rassum’s Universal Robots (RUR)".

In Czech, the word Robot means a servant or a worker

The first Robot (Unimate) was made and sold to General Motors in 1961
to perform repetitive tasks and unloading a die casting machine.

The German company KUKA developed first robot with six

electromechanically driven axes in the 1970s

In 1981, Takeo Kanade, a Japanese scientist built the "direct drive arm"
which used motors and was faster than the earlier robots.
 ROBOTS
Robot definition:

“A Robot is a reprogrammable, multifunctional manipulator designed to move

material, parts, tools or specialized devices through variable programmed
motions and perform a variety of tasks”.

Robotics can be defined "as a field of technology that deals with the

conception, design, construction, operation and application of robots".

• A Robot possess anthropomorphic characteristics (meaning
human-like characteristics) such as mechanical arm (resembling
human arm) to perform variety of tasks, capability to respond to
sensory inputs, communication, interaction and taking decisions.

• But why a robot is required when a human can perform

the tasks?
But why a robot is required when a human can perform the tasks?
That is because of the following qualities:
•Robots can work in hazardous or dangerous environments such as a nuclear
reactor, behind enemy lines, outside earth's atmosphere, etc. They can substitute
humans in such environment.
•Robots can consistently work as per the program with great repeatability and
accuracy that is unmatched by the humans.
•At the end of a task, robots can be reprogrammed to take up different task
altogether.
•Robot parts can be replaced when damaged.
•In industries, Computer Integrated Manufacturing can be realized by connecting
robots to computer system and carrying out the different tasks.
Robot anatomy
 Robot anatomy
• Manipulator: Manipulator is an arm-like mechanism which is designed to
manipulate or move materials, parts or tools without direct human contact.

• Joint: A joint is the one that integrates two or more links to provide
controlled relative movement between input link and the output link.

• Link: The link is a rigid member that connects the joints. Link can be an input
link and an output link. The movement of the input link causes various
motions of the output link.
 Robot anatomy
• Degrees of freedom (d.o.f): The degrees of freedom describes a robot's
freedom of motion in the three-dimensional space.

• End effector: End effector or end-of-arm tool is the device at the end of the
robotic arm which is shaped like a hand or as a special tool depending upon
the application.

• Base: The support for the robot arm is called as the base.
 Elements of a Robotic System
The Robot: This consists of
•The Manipulator which includes the base and the arm assembly.

•End-of-the-arm tooling which is the end-effector.

•Actuators which convert stored energy into movement. Common

actuators include electric motors and linear actuators.
•Transmission elements such as ball screws, pulleys, belts, gears, etc.
 Elements of a Robotic System
Control System: The control system generates the required signals to co-
ordinate and execute the robot movements. The Control System comprises of:

•Controls such as Mechanical control, hydraulic control, pneumatic control,

electrical or electronic control. The control techniques can be an open-loop
(non-servo) control, feedback control, feed forward control and adaptive
control.

•Sensors that allows robots to collect information about a certain measurement

of the environment or internal components. The sensors can be touch sensors
or vision sensors.

•Equipment Interfaces.
Elements of a Robotic System
Computer System:
The Computer system is used to program the robots according to the tasks
required to be performed. The necessary software must be installed in the
computer to develop robot programs.

Power Source:
Power source supplies electrical energy for the robot. The commonly used
power source is the battery which can be a lead-acid battery or a silver-
cadmium battery.
 Types of End Effectors
There are broadly two types of end-effectors:

•Grippers

•Tools

Gripper is a component of a robot that is used to grasp the object/s to be

manipulated.

•Grippers are either actuated pneumatically or by using servomotors.

• The design of a gripper depends on the shape, size and weight of the part to
be gripped
 Types of End Effectors
Mechanical Grippers:
A mechanical gripper consists
of two fingers that can open and
close to pick up and let go of the
parts.

The Robot uses hydraulic, electric or

pneumatic drive system to produce
the input power which is transmitted
to the gripper to make the fingers
react.

Vacuum Grippers: These grippers

are used to hold objects that are flat.
 Types of End Effectors
Tools:
•Tools for processing operations such as spot welding, spray painting,
drilling, milling, etc can be used as end-effectors to move relative to
the workpiece and perform the required operations.
•Example: A spray painting gun can be an end-effector that is used by
the robot to perform spray painting on the work surface.
•Other examples of tools include spot welding gun, plasma torch, a
rotating spindle on which various tools such as drill bits, milling
cutters, etc can be mounted and so on.
Joints and Links
 Types of Robot joints
Rotational joint or the R-joint:
•This type of joint allows rotary relative motion where the axis of the rotation
is perpendicular to the axes of the input link and the output link.

Linear joint or the L-Joint:

•This type of joint allows a translational sliding motion between the input and
the output links with the axes of the links being parallel. They are also called
Prismatic joints.

Orthogonal joint or the 0-joint:

•This type of joint allows a translational sliding motion between the input link
and the output link with the axis of the output link perpendicular to the input
link.
 Types of Robot joints
Twisting joint or the T-joint:

•This type of joint allows rotary motion where the axis of rotation is parallel to
the axes of the input and output links.

Revolving joint or the V-joint:

•In this type of joint, the input link axis is parallel to the rotational axis of the
joint whereas the output link axis is perpendicular to the rotational axis of the
joint.
 Robot Configuration
1. Polar Configuration (Spherical Configuration):
 1. Polar Configuration (Spherical Configuration):
• It consists of a sliding arm (L-joint) that is actuated relative to the body and a
rotational base along with a pivot, which can rotate about a horizontal axis (R
joint) and the vertical axis (T Joint).
• The one linear and the two rotary joints creates a spherical work volume in which
the robot operates.
Advantage:
– Long reach capability is realized in the horizontal position
Disadvantage:
– The vertical reach is low.
Applications:
– Die casting, forging, injection moulding, dip coating etc.
2. Cylindrical Configuration
 2. Cylindrical Configuration
• It consists of a slide in the horizontal position and a column in the vertical position.
• The arm assembly moves up or down relative to the column using as L-joint. The
column is rotated about its axis using the T-joint. The radial movement of the arm
is achieved using the O-joint.
Advantage:
– Rigidity is increased and is quite robust. - Has the capacity to carry high payloads
Disadvantage:
– Work volume is less. -Occupies more floor space
Applications:
– Foundry & forging applications, investment casting, conveyor pallet transfers,
machine loading and unloading.
3. Cartesian Co-ordinate Robot
 3. Cartesian Co-ordinate Robot
• It is also called as a rectilinear robot or a XYZ Robot. It consists of three sliding
joints along the X, Y and Z directions joints in three dimensional space.
• There are two orthogonal joints. Since movement can stop and start simultaneously
along the X, Y and Z axes, the motion of the tool tip is smoother.
Advantage:
– Allows for simpler controls. - They can carry heavy loads.
– Possess a high degree of mechanical rigidity, accuracy and repeatability.
Disadvantage:
– Limited in their movement to a small rectangular work space. - Reduced flexibility.
Applications:
– Pick and place tasks, material handling, loading/unloading and machining operations.
4. Jointed-arm Configuration Robot
 4. Jointed-arm Configuration Robot
• It resembles the human arm where the column swivels about a base. This configuration
has the capability to be controlled at any adjustments in the workspace
• The column and the base forms a T-joint, the column top connects to the shoulder
through a shoulder joint (R-joint) and the shoulder connecting to the elbow through an
elbow joint (R-joint).
Advantage:
– The work volume available is large. - Operation is quick. - Flexibility is increased.
Disadvantage:
– Operating procedures are difficult. - Quite expensive as Number of components involved are
more.
Applications:
– Perform arc welding, spot welding and spray painting operations.
ROBOTS
 APPLICATIONS
 Material Handling: used to transfer material from one location to another or
from conveyor to machine.

 Processing: holds the part in machining position, it works directly with processing
equipment such as welding spray painting drilling riveting etc.

 Assembly: it is highly repetitive job which leads to human fatigue so its use
improves the product quality and reliability.

 Inspection: inspection job is labour intensive activity, robots are equipped with
probes optical sensors or measuring devices to carry out inspection function on
100% basis.
 Application of Robots

I. Material / Part Handling applications

a. Transfer materials from one location to another location.

Typical applications are as given below:

i).Pick-and-place application: The most common and simplest

application here is the pick-and-place application where
objects are picked from one location and placed to another
location.
ii. Palletizing application: Another application that is slightly complex is the
"Palletizing application" where the robot stacks products or carton boxes
onto a pallet at various positions on the pallet to the required height

iii. Depalletizing application: Here the robot picks parts from an orderly
stacked pallet to another location.

iv. Stacking application: Here, the robots are used to stack parts one upon
another. After each placement, the vertical position is re-calculated and the
new stacking height is determined.

v. Insertion operation: Here, the robots are used to insert parts into the
compartments or spaces provided in a carton.
 b. Machine loading/unloading:
• In the machine loading/unloading application, a robot is used to
move the work parts to or/and from the production machine.

Following industrial applications of robots used for machine

loading/unloading:

1. Die casting: Here the robot is used to safely unload the parts
from a die-casting machine with the safety gates closed.
2. Forging: Forging is one of the toughest environments considering the extreme heat,
pollution and noise. The use of a robot immensely helps to face the environment of
forging. Here the robot loads the red hot billet on to the die of the forging hammer, holds
it during the blows and unloads to a safe place away from the hammer.

3. Plastic injection moulding: Here a robot unloads parts from the injection moulding
machine, cuts the runner and drops runner to scrap area.

4. Sheet metal press operation (Press working): Here a robot loads a blank into the press,
and then after the press stamping operation is performed the robot unloads the scrap
and throws it into the scrap area. The stamped parts from the blank falls in the container
placed at the back of the machine.

5. Machining operations: Here the robot loads the raw blanks on to the machine tool and
unloads the finished parts.

6. Heat treating: Here the robot loads/unloads parts to/from a furnace.

 II. Processing operations
• Robots are used to carry out the processing operations such as
spray painting, spot welding, etc by using a tool at its end-
effectors.
• The tools can be a spray painting gun for spray painting operation,
a spot welding gun for spot welding operation, etc.
• In processing operations, the robot manipulates a tool to perform
a process on the work part.
a. Spot Welding: The end effectors of the robot here is the spot welding gun that applies
the approximate pressure and current to the sheet parts to be welded. The spot welding
robots have enough number of axes of motion to approach points in the work envelope
at any angle. This was difficult to realize in a manned environment in the absence of
robots. Spot welding is used largely in the automobile industry to weld automobile
bodies such as car panels.
b. Arc Welding: The welding here is continuous unlike spot welding. When arc welding is
manually carried out, the conditions are difficult for the operators since they require
Personal Protective Equipment like welding shield with special glass to avoid UV rays are
under the danger of operating at high temperatures involving high amount of heat and
moreover they must be accurate in following the welding path. These problems are now
overcome with the use of arc welding robots.
c. Spray Coating: Spray coating is a process where parts are coated by a spray gun
spraying the fluid on to the surface of the part. The fluid passes through the nozzle of
the spray gun and is dispersed at high velocity to the surface to be coated. Common
examples are powder coating and spray painting.
 III. Assembly
• The combination of two or more parts to form a new object is called as
an assembly.

• The parts that join to form a new entity are securely held together
either by fastening or joining processes.

• Assembly automation using robots will ensure higher productivity,

consistency in quality and cost savings when compared to manual
assembly. Robots have saved the assembly workers from the tedious,
dull and repetitive jobs which were quite labour-intensive.
 IV. Inspection:
• The robot arm manipulates an inspection probe that moves relative to the product to be
inspected. The end-effectors here are the inspection probe. Here care must be taken to
present the part at the inspection workstation at the right position and the right
orientation so that the part is inspected accurately.

• Robots can inspect whether the part is present on an assembly or not. Inspection
systems for instance look at an engine to find out if it is completely assembled or not.

• The robot picks part at the cell entry point, loads to the inspection machine and after
inspection unloads the part and then places to the cell exit point. Few cases may also
involve robot taking additional responsibility of segregating parts based on inspection
result.

• Robots are used to detect flaws by comparing the good part with the bad part. This
requires the end users to define what a good part is and what a bad part is.