Unit-I

Introduction to Robotics &

Automation
 Course Description
Robotics and automation is a branch of Engineering that
involves the design, manufacturing, and operation of robots.
It overlaps many fields of Engineering including Electronics,
Computer Science, Artificial Intelligence, Automation and
Nanotechnology. This course has its applications in industries
related to Aerospace, Defense contractors, Entertainment,
Manufacturing, Medical research (development of prosthetic
parts)
Course Educational Objectives:
• To be familiar with history of robotics, technological
advances and to gain insight on different types of End
Effectors.
• To learn about different robotic drive systems, actuators
and their control.
• To analyze the robotic Kinematics in different degrees of
freedom
• To study the principles of various Sensors used in robotics.
• To explore industrial applications of Robotics
 Course Outcomes
1. Get acquainted with history of robotics, technological advances and many types
of End Effectors (L2).
2. Gain knowledge on different robotic drive systems, actuators and their control
(L2).
3. Understand the robotic Kinematics (Robotic movements, Position and
Orientation) (L2).
4. Select the Sensors based on different applications (L4).
5. Understand industrial applications of Robotics (L2)
 Historical robots
UNIT 1 -Contents
 Robots in science fiction
 Future trends of robots
 Definitions of robots
 Present application status.
 Robot End Effectors: Classification of end effectors
 Drive systems for grippers
 Mechanical grippers
 Magnetic grippers
 Vacuum grippers
 Adhesive grippers
 Hooks
 Scoops and other miscellaneous devices
 Active and passive grippers
UNIT 2 Robot Drives, Actuators and Control
Functions of drive systems, general types of control, pump classification,
introduction to pneumatic systems, electrical drives, dc motors and transfer
functions, stepper motor, drive mechanisms.
UNIT 3 Robot Kinematics
Forward and reverse kinematics of 3 degrees of freedom robot arm, forward and
reverse kinematics of a 4 degree of freedom, arm manipulator in 3-D,
homogeneous transformations.
UNIT 4 Robot Sensors
Need for sensors, types of sensors, robot vision systems, robot tactile systems,
robot proximity sensors, robot speech and hearing, speech synthesis, noise
command systems, speech recognition systems
UNIT 5 Robot Intelligence & Programming the Robots
Robot Intelligence & Programming the Robots: AI and Robotics, Expert Systems,
Interpreting Sensory Inputs, Intelligent Tutoring Systems. Robot Languages,
Robot Operating System, Robot Application Programming, Teaching Robots
Textbooks:
1.S.R. Deb, Robotics Technology and Flexible Automation,
TMH, 2010.
References:
1.SatyaRanjan, Robotics Technology and Flexible Automation,
TMH, 2001.
2.James L.Fuller, Robotics: Introduction, Programming and Projects,
Maxwell Macmillan, 2000
Lecture-2 of Unit-I robots in
science fiction
History of robots
History of robots
History of robots Cont….
History of robots Cont….
History of robots Cont….
History of robots Cont….
 History of Robotics: I
The first industrial robot: UNIMATE

1954: The first programmable robot was

designed by George Devol, who coins the
term Universal Automation.

 He later shortens this to Unimation,

which becomes the name of the first
robot company (1962).

They are the first servo-controlled

industrial robots.

UNIMATE originally automated the

manufacture of TV picture tubes.
 History of Robotics: II

1978: The PUMA (Programmable

Universal Machine for Assembly)
robot was developed by Unimation
with a General Motors design
support

PUMA 560 Manipulator

 History of Robotics: III
1980s: The robot industry enters a phase of rapid growth. Many
institutions introduce programs and courses in robotics. Robotics
courses are spread across mechanical engineering, electrical
engineering, and computer science departments.

Adept's SCARA robots Cognex In-Sight Robot Barrett Technology Manipulator

 History of Robotics: IV
2003: NASA’s Mars Exploration Rovers launched toward
Mars in search of answers about the history of water on Mars

1995-2011: Emerging
applications in small robotics
and mobile robots drive a
second growth of start-up
companies and research
 Robotics History
• 1922 Czech author Karel Capek wrote a story called
Rossum’s Universal Robots and introduced the word
“Rabota”(meaning worker)
• 1954 George Devol developed the first programmable
Robot.
• 1955 Denavit and Hartenberg developed the homogenous
transformation matrices
• 1962 Unimation was formed, first industrial Robots
appeared.
• 1973 Cincinnati Milacron introduced the T3 model robot,
which became very popular in industry.
• 1990 Cincinnati Milacron was acquired by ABB
Historical robots
 Robotics in Science Fiction
1817: Humanoid Monster-Dr.Frankenstein
1920: RURs-Karle Capak
1939:Isaac Asimov –Contributed many stories
about robotics
1951:Movie-The Day the Earth stood Still
1968:Movie-2001:A space Odyssey
1980:The star war series pictured robots as
friendly and harmless machines
[https://www.youtube.com/watch?v=-
evyusrGnH8]
 Future Trends of Robots: I
• Intelligent Robots are now in
demand for running automated
unmanned systems or factories Artificial Intelligence

Cog Kismet
 Future Trends of Robots : II
Autonomy

Robot Work Crews Garbage Collection Cart

The Robotic Work Crew
behaves a lot like its human
counterpart might during a
home construction project
Future Trends of Robots : III
Humanoids

HONDA Humanoid Robot

 Robotics -Robots

Remote Robot Arm Manipulation

Smart Irrigation System

Smart Cane
Remote Emergency
Notification System
 Robotics

Type-X
RoboDry

Local Navigation System Safe N Sound Driver

 Robotics –Various Robots

Four Legged Hexapod

Metal Mine Surveyor

Audio Enabled Hexapod

RoboVac
 What is Robotics?
• Robotics is the science of designing and
building robots suitable for real-life
applications in automated manufacturing and
other non-manufacturing environments.
• Robotics is the interdisciplinary subject that
benefits from mechanical engineering,
electrical and electronic engineering, computer
science, biology and many other disciplines
 What is Automation?
 Definition: It is a technology that is concerned with
the use of mechanical, electronic and computer based
systems in the operation and control of production.

 Examples: Transfer Lines, Mechanized Assembly

Machines, Feedback Control Systems, Numerically
Controlled Machine tools and ROBOTICS

 Types-1) Fixed Automation

2) Programmable Automation
3) Flexible Automation
 Automation and Programmable
Automation
• To make a process in an industry or office operate
by machines or computers, in order to reduce the
amount of work done by humans and time taken to
do work
• Adjustable, adaptable and flexible enough not
only to the change in design of the products but
also to the change in the process of manufacture of
the products.
• Example: Programmable Automation Technology-
Robot
Important Programmable Automation
technologies
 PRESENT APPLICATION
STATUS
 In initial stages, major applications of
robots have been in unpleasant and
hazardous tasks.
 Robots have found wide applications in
doing repetitive and monotonous jobs
where consistency and product quality are
important.
 Usually, robots are most suitable for
automated tasks which require sensing
capability,
• where now-a-days intelligent robots are
used in factories for performing
automated tasks.
• [https://www.youtube.com/watch?
v=nmuGlM3fC84]
 Flexible manufacturing system
(FMS)
 A flexible manufacturing system is a
manufacturing concept that allows
production to adapt when facing changes
in its requirements. The required
changes could involve the amount of
product being produced or a new product
part that is needed. The changes could be
either predictable or unpredictable.
 The systems’ flexibility allows
companies to enhance their efficiency
and lower the costs typically associated
with manufacturing.
 In short, an FMS system improves a
manufacturer’s overall agility in
production.
Flexible- Fabrication- machining-
Assembly Systems (FFMAS)
• In Flexible- Fabrication-
machining- Assembly
Systems (FFMAS) , the
basic module may include
different kinds of FMS
subsystems.
• AGV-Automated Guided
Vehicle
 FMM(Flexible Manufacturing
Module)
 In Flexible Manufacturing
Module (FMM), a robot may be
employed to load and unload
parts or tools to a single
computer numerically
controlled(CNC) machine.
 Flexible Manufacturing Cell
(FMC)

 In Flexible Manufacturing
Cell (FMC), a single robot
may be busy loading several
CNC machine units.
 Flexible Manufacturing Group
(FMG)
• Flexible Manufacturing Group
(FMG) comprises the
combination of FMM and
FMC of same kind to do all
jobs of fabrication or
machining or assembly
operations
What is a Robot: I
Manipulator
 What is a Robot: II

Legged Robot Wheeled Robot

 What is a Robot: III
Autonomous Underwater Vehicle Unmanned Aerial Vehicle
 What Can Robots Do: I

Jobs that are dangerous

for humans

Decontaminating Robot
Cleaning the main circulating pump
housing in the nuclear power plant
 What Can Robots Do: II

Repetitive jobs that are

boring, stressful, or labor-
intensive for humans

Welding Robot
 What Can Robots Do: III

Menial tasks that human

don’t want to do

The SCRUBMATE Robot

 Robot Definitions
• Word robot was coined by a
Czech novelist Karle Capek in a
1920 play titled Rossum’s
Universal Robots (RUR)
• Robota in Czech is a word for
worker or servant Karel Capek
Definition of robot:
–According to Robotics Institute of America (RIA)
–A robot is a reprogrammable, multifunctional manipulator
designed to move material, parts, tools or specialized devices
through variable programmed motions for the performance of
a variety of tasks: Robotics Institute of America, 1979
 Definitions of Robots Contd…
• Webster’s dictionary defines a robot as ‘a
machine that looks like a human being and
performs various complex acts (as walking
or talking) of a human being’.
• Defined by International Standards Organization (ISO):
“An industrial robot is an automatic, servo-controlled, freely
programmable, multipurpose manipulator, with several
areas, for the handling of work pieces, tools, or special
devices. Variably programmed operations make the
execution of a multiplicity of tasks possible” (ISO 8373).
Laws of Robotics
• Sir Isaac Asimov proposed
three “Laws of Robotics”

• Law 1: A robot must not harm

a human being or through
inaction, allow a human being
to come to harm.

• Law 2: A robot must always

obey human beings unless it is
in conflict with first law.

• Law 3: A robot must protect

itself from harm unless that is
in conflict with the first and/or
the second laws.
 Industries Using Robots
•Agriculture
•Automobile
•Construction
•Entertainment
•Health care: hospitals, patient-care, surgery , research, etc.
•Laboratories: science, engineering , etc.
•Law enforcement: surveillance, patrol, etc.
•Manufacturing
•Military: demining, surveillance, attack, etc.
•Mining, excavation, and exploration
•Transportation: air, ground, rail, space, etc.
•Utilities: gas, water, and electric
•Warehouses
 What Can Robots Do?
Industrial Robots
•Material handling
•Material transfer
•Machine loading and/or
unloading Material Handling Manipulator

•Spot welding
•Continuous arc welding
•Spray coating
•Assembly
•Inspection Assembly Manipulator

Spot Welding Manipulator

 Present Application Status of Robots ----in Space

• Robots have found applications in

doing repetitive and monotonous jobs
where consistency and product quality
are of prime importance.

NASA Space Station

Robots in Hazardous Environments

TROV in Antarctica HAZBOT operating in

atmospheres containing
operating under water
combustible gases
 Medical Robots

Robotic assistant for

micro surgery
 Robots at Home

Sony SDR-3X Entertainment Robot Sony Aido

 Knowledgebase for Robotics
•Typical knowledgebase for the design and operation of robotic
systems
–Dynamic system modeling and analysis
–Feedback control
–Sensors and signal conditioning
–Actuators and power electronics
–Hardware/computer interfacing
–Computer programming
Disciplines: mathematics, physics, biology,
mechanical engineering, electrical engineering,
computer engineering, and computer science
 Key Components
Power conversion
unit
Sensors Actuators
Controller
User interface

Manipulator
linkage
Base
A Robotic System
 Robot is a system as it combines many subsystems that
interact among themselves as well as with the environment
in which the robot works
 The main components –
1) A base-fixed or mobile
2) A manipulator arm with several DOF
3) An end-effector or gripper holding a part or a tool
4) Drivers or actuators causing the manipulator arm or end-
effector to move in a space
5) Controller with H/W & S/W for giving commands to the
drivers
6) Sensors to feedback the information
7) Interfaces connecting the robotic subsystems to the
external world.
 Robot Base: Fixed v/s Mobile
Robotic manipulators used in Mobile bases are typically platforms
manufacturing are examples of with wheels or tracks attached.
fixed robots. They can not Instead of wheels or tracks, some
move their base away from the robots employ legs in order to move
work being done. about.
 Robot Mechanism: Mechanical Elements
Gear, rack, pinion, etc.

Cam and Follower

Inclined plane wedge Chain and sprocket

Lever
Slider-Crank

Linkage
END Effector Principle

A human
being decides global
position of his hand
based on analysis of
his eye and memory
and then determines
his choice of grip and
the necessary
manipulation with
the aid of sensors on
his skin, arm and
wrist.
 Robot End Effectors
• A robot end- effector which is attached to the wrist of
the robot arm is a device that enables the general
purpose robot to grip materials, parts and tools to
perform a specific task.
• The robot end effector or end of arm tooling is the
bridge between the robot arm and the environment
around it
• Depending on the task, the actions of the gripper vary.
• End effectors are also called as Grippers
 Classification of grippers
1. Mechanical Grippers
2. Hooking or lifting grippers
3. Grippers for scooping or ladling powders
or molten metals or plastics
4. Vacuum Grippers or cups
5. Magnetic Grippers
6. Adhesive or Electrostatic Grippers
The grippers may also be Classified
in to
1. Part Handling Grippers-used to grasp and
hold objects that are required to be
transported from one point to another.
2. Tools Handling Grippers-used to hold tools
like welding gun or spray painting gun to
perform a specific task.
3. Special Grippers-these are devices like
Remote Centre Compliance to insert external
to internal component like inserting plug in to
hole.
 Classification of End-Effectors
 According to the type of grasping modality
• Mechanical Fingers-have 1 or 2 fingers
• Special tools-uses electromagnetic action or action of
vacuum
• Universal fingers-have more than 3 fingers
 According to finger classification
 Two-,Three- and Five-finger grippers
 Based on mode of gripping
 Internal and External grippers
 Based on number of DOF
 1 DOF ,2DOF grippers
Multiple Grippers
Mechanical fingers are used to perform some
special tasks.Gripping by mechanical type
fingers is less versatile and less dexterous than
holding by universal fingers as the grippers
with mechanical fingers have fewer number of
joints and lesser flexibility.The grippers can be
sub grouped according to finger classification,
like the number of fingers typically 2 or 3 or
five finger types.Another classification is
according top the single gripper and multiple
grippers mounted on wrist. The multiple
gripper system enable effective execution of
more than two different jobs.
Internal and External Grippers

Robot end effectors can be classified

on the basis of the mode griping as
external and internal gripping. The
internal gripping grips the internal
surface from the inside whereas
external gripper holds from the
outside.
Drive Systems for Grippers
 Drive Systems for Grippers
 Capacity to move robots’ body arm and wrist.
 Determine speed of the arm movements, strength
of the robot & dynamic performance.
• In typical Robot gripper systems, there are 3 kinds
of drive methods
1. Electrical
2. Pneumatic
3. Hydraulic
• In electric drive system, there are typically two kinds of actuators, dc motors and
stepper motors. In general, each motor requires Appropriate reduction gear
systems to provide proper output force or torque .In the electric system , a servo
power amplifier is also needed to provide a complete actuation system .
• The pneumatic system has the merit of being less expensive than others methods,
which is the main reason for it being used in most of the industrial robots.
Another advantage of the pneumatic is the low degree of stiffness of the air-
drive system .This feature of the pneumatic system can be used effectively to
achieve compliant grasping which is necessary for one of the most important
functions of grippers; to grasp objects with delicate surfaces carefully.
• Hydraulic drives used in robot gripping system are usually electro hydraulic drive
systems. They have almost the same configuration as pneumatic systems, though
their life features are different from each other. A typical hydraulic drive system
consists of actuators, control valves and power units. There are three kinds of
actuators in the system: piston cylinder swing motor, and hydraulic motor. To
achieve positional control using electric signals electrohydraulic conversion
drives are used.
DESIGNING PISTON-CYLINDER IN
THE PNEUMATIC GRIPPER

• A piston which can supply the actuating

force F may be chosen. It is logical to
orient the piston device in the gripper
such that this force is supplied on the
extension stroke of the piston.
• Suppose the factory air pressure is
Pa. It is necessary to determine the
required diameter of the piston in
order to provide the desired
actuating force, F.
Mechanical gripper

A mechanical gripper is an end-

effector that uses mechanical fingers
actuated by a mechanism to grip an
object . The fingers are the appendages of
the gripper that actually makes contact
with the object. The fingers are either
attached to the mechanism or are an
integral part of the mechanism. The use
of replaceable fingers allow for wear and
interchangeability. Different sets of
fingers for use with same gripper
mechanism can be designed to
accommodate different parts models.
Various mechanisms used in Mechanical Grippers
Gear, rack, pinion, etc.
Linkage, Gear and
Rack, Cam, Screw,
Cable and Pulley

Cam and Follower

Linkage Chain and sprocket

Lever
Slider-Crank
 Various mechanisms used in
Mechanical Grippers

• Mechanisms used for Pivoting or Swinging

movement
• Mechanisms used for Linear or translational
movement
Pivoting or Swinging Gripper
Mechanisms
 Pivoting or Swinging Gripper
Mechanisms
• This is the most popular mechanical gripper for industrial robots. It can be
designed for limited shapes of an object, especially cylindrical workpiece. If
actuators that produce linear movement are used, like pneumatic piston-
cylinders, the device contains a pair of slider-crank mechanisms.
• In the slider crank mechanism shown in the fig 4.6 when the piston 1 is
pushed by pneumatic pressure to the right, the elements in the crank 2 and 3,
rotate counter clockwise with the fulcrum F1 and clockwise with the fulcrum
F2 respectively, when ϴ< 180°. These rotations make the grasping action can
be obtained by moving the piston to the left. An angle ϴ ranging from 160° to
170° is commonly used.
 Swing Block Mechanism
Fig 4.7 is another example of swinging gripper that uses the piston-
cylinder. This is the swing-block mechanism. The sliding rod 1
Actuated by the pneumatic piston transmits motion by way of the two
symmetrically arranged swing-block linkages 1-2-3-4 and 1-2-3’-4’ to
grasp or release the object by means of the subsequent swinging
motions of links 4 and 4’ at their pivots F1 and F2.
Rotary Actuator
• Figure 4.8 illustrates a typical
example of a gripper using a rotary
actuator in which the actuator is
placed at the cross point of the two
fingers. Each finger is connected to
the rotor and the housing of the
actuator, respectively. The actuator
movement directly produces
grasping and releasing actions.
 Cam Actuated gripper
• The cam actuated gripper includes a variety of possible designs, one of which
is shown in Fig. 4.9. A cam and follower arrangement, often using a spring-
loaded follower, can provide the opening and closing action of the gripper.
The advantage of this arrangement is that the spring action would
accommodate different sized objects.
 Screw-type Gripper
• Figure 4.10 indicates an example of screw-type actuation used in the gripper
design. The screw is turned by a motor , usually accompanied by a speed
reduction mechanism. Due to the rotation of the screw, the threaded block
moves, causing the opening and closing of the fingers depending on the
direction of the rotation of the screw.
Translation Gripper Mechanisms
Gripper using three point chuck
mechanism
 Magnetic grippers
• Magnetic grippers are used extensively on ferrous
materials.
 Advantages
1. Variations in part size can be tolerated
2. Pickup times are very fast
3. They have ability to handle metal parts with holes
4. Only one surface is required for gripping
 Disadvantage:
1. Problem of picking up one sheet at a time from stack
• Magnetic Grippers mostly uses either permanent
magnet or electromagnet for holding objects.

• Electromagnetic grippers are easier to control

but requires a source of dc power and an
appropriate controller
• Permanent magnet grippers do not require an
external power and hence they can be used in
hazardous and explosive environments.
 Electromagnets:
• Electromagnetic grippers include a controller unit and a DC power for handling the
materials.
• This type of grippers is easy to control, and very effective in releasing the part at
the end of the operation than the permanent magnets.
• If the work part gripped is to be released, the polarity level is minimized by the
controller unit before the electromagnet is turned off.
• This process will certainly help in removing the magnetism on the work parts. As a
result, a best way of releasing the materials is possible in this gripper.

Permanent magnets :
• The permanent magnets do not require any sort of external power as like the
electromagnets for handling the materials.
• After this gripper grasps a work part, an additional device called as stripper push –
off pin will be required to separate the work part from the magnet. This device is
incorporated at the sides of the gripper.
• The advantage of this permanent magnet gripper is that it can be used in hazardous
applications like explosion-proof.
Magnetic Grippers-Permanent
Magnet Gripper
 Electromagnet Type Magnetic
Gripper

• Electromagnetic grippers are easier to control

but requires a source of dc power and an
appropriate controller. When the part is to be
released, the control unit reverses the polarity.
 Vacuum Grippers
• These are used for picking up large flat objects
like metal plates, pans of glass and large light
weight boxes.
• Vacuum cups are made up of elastic materials.
• The lifting capacity of suction cup depends on the
effective area of cup and the negative air pressure
b/w the inside and outside of the vacuum cup
• https://www.youtube.com/watch?
v=h7MpTfmNCAo
• VACUUM GRIPPERS
– Large flat objects are often difficult to grasp. One solution
to this problem is the use of vacuum gripper.
– Vacuum grippers are used for picking up metal plates,
pans of glass, or large lightweight boxes.
– Since the vacuum cups are made of elastic materials, they
are complaint.
– The gripper is tolerant of errors in the orientation of the
part and is especially suited for pick-and-place work.
– For handling softer materials, cups made of harder
material are used.
– A compressed air supply and a venturi are used to create a
gentle vacuum that lifts the part
• Two different devices are used in the
suction cups for creating the vacuum. They
are
.Venturi
.Vacuum pump
• Vacuum grippers are highly useful in the
heavy industries, automobiles, compact
disc manufacturing and more for material
handling purposes.
• It is also used in the tray & box
manufacturing, labeling, sealing, bottling
and for packaging purposes.
 Vacuum Grippers-Gripper used for
lifting fragile materials

A compressed air supply and venturi are used to create a

gentle vacuum that lifts the part
Vacuum Grippers-For Contoured surface
 Adhesive Grippers
• It uses an adhesive substance for grasping
action.
• The objects that are to be gripped only on
one side.
• The reliability of adhesive gripper depends
on tackiness of the adhesive substance.
ADHESIVE GRIPPERS :
An adhesive substance can be used for grasping action
in gripper design.
Ex:Handle fabric and lightweight materials.
The requirement on the items to be handled are that
they must be gripped on one side only.
The reliability of this gripping device is diminished
with each successive operation cycle as the adhesive
substance loses its tackiness on repeated use.
 To overcome this limitation, the adhesive material
can be loaded in the form of a continuous ribbon into a
feeding mechanism attached to the robot wrist.
 Hooks, Scoops and Other
Miscellaneous Devices
• Hooks can be used as end-
effectors to handle containers and
to load and unload parts hanging
from overhead conveyors
• The item to be handled by a hook
must have some sort of handle to
enable the hook to hold it.
• Ladles and Scoops can be used to
handle certain materials in liquid
or powder form.
 Miscellaneous Devices
• Miscellaneous grippers include inflatable
devices in which an inflatable bladder is
expanded to grasp the object.
• An inflatable bladder is made up of some
elastic materials like rubber which makes it
appropriate for gripping fragile objects.
Expanding bladder for gripping
internal surface
Bladder inside the container
 Active and Passive Grippers
• The grippers used in open loop system have no feeling
while gripping called passive grippers.
• The grippers used in closed loop system have some
sense while gripping are called active grippers.
• If the sensors are placed on wrist or on fingers, the
passive grippers become active.
• Depending on the situation, industrial tasks can be
accomplished using either active wrist with passive
fingers (or) passive wrist with active fingers and in
some cases, active wrist with active fingers.
• https://www.hilarispublisher.com/open-access/
integrated-design-of-active-and-passive-gripper-for-
robotic-pick-and-place-applications-85080.html
• ACTIVE AND PASSIVE GRIPPERS :
• Active grippers:
• Active grippers has feedback sensors
• Sensors may be on the wrist or on the fingers
• They work on closed loop systems
• Also called adaptable grippers
• Have many degrees of freedom like human hand
• Costly in comparison to passive grippers
• Complicated designs
 PASSIVE GRIPPERS
• Do not have any feeling
• Most of the industrial grippers are passive
• They work on open loop system
• Have fixed degree of freedom
• No of fingers is also fixed
• Cheaper and widely used
• simpledesigns
 Active & Passive grippers
Compact humanoid robot with 22 degrees of freedom