Industrial Robotics

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 Introduction
The Evolution of Robots:
George Moore built a walking robot in 1893 !
It had a .5 Horsepower Steam Engine using a Gas
Fired Boiler.
It was a mechanical device without any intelligence.
It could walk at 9 Miles Per Hour.

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 Robot Definition
Robot term from Websters dictionary
An automatic device that performs function ordinarily
ascribed to human being

Robot Institute of America

A robot is a programmable, multifunction manipulator
designed to move material, parts, tools, or special
devices through variable programmed motions for the
performance of a variety of tasks

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 Definition of Robotics

ISO defines Industrial Robotics as

An automatically controlled, reprogrammable,
multipurpose, manipulative machine with several
reprogrammable axes, which may be either fixed in
place or mobile for use in industrial automation
applications.

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 Robot Application Characteristics
1. Hazardous work environment for humans
2. Repetitive work cycle
3. Difficult handling task for humans
4. Multi-shift operations
5. Infrequent changeovers
6. Part position and orientation are established in the
work cell

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 Industrial Robot Applications
1. Material handling applications
Material transfer pick-and-place
Machine loading and/or unloading
2. Processing operations
Spot welding and continuous arc welding
Spray coating
Other water jet cutting, laser cutting, grinding
3. Assembly and inspection

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 General Classification Of Robots
Low technology
Medium technology
High technology

Low technology
Material handling, using simple assembly
2 to 4 axes of movement

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 Medium technology
Pick-and-place
Material handling
4 to 6 axes

High technology
Material handling
Pick-and-place
Loading and unloading
Painting and welding
6 to 9 axes 8
Robot Anatomy

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 Robot Anatomy

Robot manipulator - a series of joint-link combinations

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 Robot Anatomy
Manipulator consists of joints and links
Joints provide relative motion
Links are rigid members between joints
Each joint provides a degree-of-freedom
Most robots have five or six degrees-of-freedom

Robot manipulator consists of two sections:

Body-and-arm for positioning of objects in the
robot's work volume
Wrist assembly for orientation of objects 11
 What is a joint?
A joint of robot is
similar to a joint in the
human body
Each joint gives the
robot a degree-of-
freedom of motion
In nearly all cases, only Joint
1 degree-of-freedom is
allowed to a joint

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 What is a robot link?
Links are rigid
components that form a
chain connected
together by joints
Link
Each joint has two links,
known as an input link
and an output link

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 Types of Manipulator Joints
Translational motion
Linear joint (type L)
Orthogonal joint (type O)
Rotary motion
Rotational joint (type R)
Twisting joint (type T)
Revolving joint (type V)

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 Linear joint (type L)
The relative movement between the input link and the
output link is a linear sliding motion, with the axes of
the two links being parallel

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 Orthogonal joint (type O)
This is also linear sliding motion, but the input and
output links are perpendicular to each other during the
move

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 Rotational joint (type R)
This type provides a rotational relative motion of the
joints, with the axis of rotation perpendicular to the
axes of the input and output links

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 Twisting joint (type T)
This joint also involves a rotary motion, but the axis of
rotation is parallel to the axes of the two links

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 Revolving joint (type V)
In this type, the axis of the input link is parallel to the
axis of rotation of the joint, and the axis of the output
link is perpendicular to the axis of rotation

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Joint Drive Systems

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 Joint Drive Systems
Electric
Uses electric motors to actuate individual joints
Preferred drive system in today's robots
Hydraulic
Uses hydraulic pistons and rotary actuators
Noted for their high power and lift capacity
Pneumatic
Typically limited to smaller robots and simple
material transfer applications
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End Effectors

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 End Effectors
The special tooling for a robot that enables it to
perform a specific task.
End effectors two main categories:
Grippers to grasp and manipulate objects during
work cycle.
Tools to perform a process, e.g., spot welding,
spray painting.

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 End Effectors

Grippers
1. Mechanical Grippers
2. Suction cups or vacuum cups
3. Magnetized grippers
4. Ladles
5. Spray gun

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 Robot Mechanical Gripper

A two-finger mechanical gripper for grasping rotational

parts

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 Cam-operated hand
It can easily handle heavy weights or bulky objects.
It is designed to hold the object so that its center of
gravity (CG) is kept very closed to the wrist of hand.
The short distance between the wrist and the CG
minimizes the twisting tendency of a heavy object.

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 Simple Vacuum Cup Hand
This simple vacuum cup
hand is suitable for
handling fragile parts such
as cathode ray tube face
plates.

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Magnetic Pick up
Magnetic handling is
most suitable for parts
of ferrous contents.
Magnets can be
scientifically designed
and made in numerous
shapes and sizes to
perform various tasks.

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 Ladle
Ladling hot materials such as molten metal is a hot
and hazardous job for which industrial robots are
well suited.

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 Spray gun
Ability of the industrial robot to do
multi-pass spraying with controlled
velocity fits it for automated
application of primers, paints, and
ceramic or glass frits, as well as
application of masking agents used
before plating.

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 Wrist Configurations
Wrist assembly is attached to end-of-arm
End effector is attached to wrist assembly
Function of wrist assembly is to orient end effector
Body-and-arm determines global position of end
effector
Two or three degrees of freedom:
Roll
Pitch
Yaw
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 Wrist Configuration

Notation :RRT

Typical wrist assembly has two or three degrees-of-

freedom (shown is a three degree-of freedom wrist)
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Robot Sensors

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 Sensors in Robotics
Two basic categories of sensors used in industrial
robots:

1. Internal - used to control position and velocity of the

manipulator joints

2. External - used to coordinate the operation of the

robot with other equipment in the work cell

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 Type Of Sensors Being Used In Robotics
1. Position Monitors the location of joints
Sensors Coordinate information is feedback to controller

This communication gives the system the capability

of locating the end-effectors
2. Range Measures the distance between a point in the robot
sensors and interest point that surrounds the robots
The task is usually performed by cameras

3. Velocity Estimates the speed using a moving manipulator

sensors Due the effects caused by, mechanical force, gravity,
weight of load etc, desired speed and required force
to reach the speed should be computed
continuously
4. Proximity Sense and indication of presence of another object
sensors within specified distances
Prevents accidents and locate the existence of w.p.
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 Sensors in robotics

Required features of sensors:

1. Accuracy
2. Operation range
3. Speed of response
4. Calibration
5. Reliability
6. Cost and ease of operation

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 Robot Geometry Type
1. Cartesian or x-y-z axis
2. Cylindrical
3. Polar arm (Spherical)
4. Jointed-Arm (Articulated)
5. SCARA

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 Cartesian Coordinate
Body-and-Arm Assembly
Notation LOO:
Consists of three sliding joints,
two of which are orthogonal
Other names include rectilinear
robot and x-y-z robot

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 Cartesian Type Configuration
Cartesian manipulator are useful for table-top assembly
applications and, as robots for transfer of material and
cargo
Advantages:
1. 3 linear axes.
2. Easy to visualize.
3. Rigid structure.
4. Easy to program off-line.

Disadvantage:
1. Can only reach in front of itself
2. Requires large floor space for size of work envelop
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 Cylindrical Body-and-Arm Assembly
Notation TLO:
Consists of a vertical
column, relative to
which an arm assembly
is moved up or down.
The arm can be moved
in or out relative to the
column.

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 Cylindrical Type Configuration
Advantages:
1. 2 linear axes, 1 rotating axis
2. Can reach all around itself

Disadvantages:
1. Cannot reach above itself
2. Base rotation axis is less rigid than a linear axis
3. Horizontal motion is circular

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 Polar Coordinate
Body-and-Arm Assembly

Notation TRL:

Consists of a sliding arm (L joint) actuated relative to

the body, which can rotate about both a vertical axis
(T joint) and horizontal axis (R joint) 43
Spherical

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 Spherical Type Configuration
Advantages:
1. 1 linear axis, 2 rotating axes
2. Long horizontal reach

Disadvantages:
1. Generally has short vertical reach

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 Jointed-Arm Robot
Notation TRR:
General configuration of
a human arm

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 SCARA Robot
Notation VRO:
SCARA stands for Selectively
Compliant Assembly Robot
Arm
Similar to jointed-arm robot
except that vertical axes are
used for shoulder and
elbow joints to be compliant
in horizontal direction for
vertical insertion tasks
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 SCARA Type Configuration
There are two type of SCARA robot configuration:
either the first two joints are revolute with the third
joint as prismatic (linear), or the first joint is revolute
with the second and third Joints as prismatic.
Advantages:
1. 1 linear axis, 2 rotating axes
2. Height axis is rigid
3. Large work area floor space
4. Two ways to reach a point

Disadvantages:
1. Difficult to program off-line
2. Highly complex arm 48
Robot Performance

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 Resolution

Smallest increment of motion at the wrist end that

can be controlled by the robot. Depends on the
position control system, feedback measurement, and
mechanical accuracy

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 Accuracy

Capability to position the wrist at a target point in the

work volume.
One half of the distance between two adjacent
resolution points.
Affected by mechanical Inaccuracies.
Manufacturers dont provide the accuracy (hard to
control) .

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 Repeatability

Ability to position back to a point that was previously

taught.
Repeatability errors form a random variable.
Mechanical inaccuracies in arm, wrist components.
Larger robots have less precise repeatability values.

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 Weight Carrying Capacity

The lifting capability provided by manufacturer

doesnt include the weight of the end effector.
Usual Range 2.5lb-2000lb
Condition to be satisfied:
Load Capability > Total Wt. of workpiece +Wt. of end
effector + Safety range

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 Speed of Movement

Speed with which the robot can manipulate the end

effector.

Acceleration/deceleration times are critical for cycle

time.

Determined by:
1. Weight of the object
2. Distance moved
3. Precision with which object must be positioned
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 Motion Control

Path control - how accurately a robot traces a given

path (critical for gluing, painting, welding applications);
Velocity control - how well the velocity is controlled
(critical for gluing, painting applications)

Types of path control:

1. point to point control (used in assembly,
palletizing, machine loading);
2. continuous path control/walkthrough (paint
spraying, welding). 55
Robot Drives

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 Robot Actuators and Drive Systems
What is meant by actuator?

The commonly used actuators are:

1. Stepper motors
2. DC servomotors
3. AC servomotors
4. Hydraulic pistons
5. Pneumatic pistons

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 Electric Drive
Small and medium size robots are usually powered by
electric drives with gear trains using servomotors and
stepper motors.
Advantages
1. Better accuracy & repeatability
2. Require less floor space
3. More towards precise work such as assembly applications

Disadvantages
1. Generally not as speedy and powerful as hydraulic
robots
2. Expensive for large and powerful robots, can become fire
hazard
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 Hydraulic Drive
Larger robots make use of hydraulic drives.

Advantages:
1. more strength-to-weight ratio
2. can also actuate at a higher speed

Disadvantages:
1. Requires more floor space
2. Tendency to oil leakage

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 Pneumatic Drive
1. For smaller robots that possess fewer degrees of
freedom (two- to four joint motions).

2. They are limited to pick-and-place tasks with fast

cycles.

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 Direct Drive Robots
In 1981 a "direct- drive robot" was developed at
Carnegle-Mellon University, USA. Is used electric
motors located at the manipulator joints without the
usual mechanical transmission linkages used on most
robots.
The drive motor is located on the joint
Benefits:
1. Eliminate backlash and mechanical defficiencies
2. Eliminate the need of a power transmission
3. Joint back-drivable (allowing for joint-space force
sensing)
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 Practical Application
Automotive Component Paint Technology

Robotic Painting Justification:

1. Quality
2. Material Cost
3. Warranty cost
4. Labor Cost
5. Compliance

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 Quality

Automated robotic application of material brings

consistency to the spray out process.

Improve appearance consistency

Improve product film build
consistency
Provide consistent gun target
distance
Reduce part defects

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 Material Savings

Repeatable robot paths and gun triggering means the

material application will save material.

-Gun triggers are precise

-Consistent gun target distance
-Consistent material delivery
-Higher transfer efficiency
-Overspray reduced

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 Warranty
- Proper application per the specification
- Eliminates product defects caused by build variation
- Reduction of application related variables
- Reduced part rework
- Reduced scrap rate

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 Labor
- Reduce repetitive motion injuries
- Reduced workers compensation claims
- Reduce turnover of skilled operators
- Productivity increase
Multi shift operation savings
Greater painting speed endurance
 Compliance

1. Removes employee from a hazardous

environment
2. Eliminate cost of operator protection
3. Booth air can be recirculated
4. Lower booth air velocity

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Fanuc Robotics Off Line Programming Software
Paint Pro

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Robot Programming

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 Robot Programming
Robots execute a stored program of instructions that
define the sequence of motions and positions in the
work cycle
Much like a part program in NC

In addition to motion instructions, the program may

include commands for other functions:
Interacting with external equipment
Responding to sensors
Processing data
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Two Basic Robot Programming Methods
1. Leadthrough programming
Teaching-by-showing - manipulator is moved
through sequence of positions in the work cycle and
the controller records each position in memory for
subsequent playback

2. Computer programming languages

Robot program is prepared at least partially off-line
for subsequent downloading to robot controller

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 Robot Programming
Leadthrough programming - work cycle is taught to
robot by moving the manipulator through the required
motion cycle and simultaneously entering the program
into controller memory for later playback
Robot programming languages uses programming
language to enter commands into robot controller
Simulation and off-line programming program is
prepared at a remote computer terminal and
downloaded to robot controller for execution without
need for leadthrough methods

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Leadthrough Programming Advantages
Advantages:
Can readily be learned by shop personnel
A logical way to teach a robot
Does not required knowledge of computer
programming

Disadvantages:
Downtime - Regular production must be interrupted
to program the robot
Limited programming logic capability
Not readily compatible with modern computer-based
technologies
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Simulation and Off-Line Programming
In conventional usage, robot programming languages
still require some production time to be lost in order
to define points in the workspace that are referenced
in the program
They therefore involve on-line/off-line programming
Advantage of true off-line programming is that the
program can be prepared beforehand and
downloaded to the controller with no lost production
time
Graphical simulation is used to construct a 3-D model
of the robot cell in which locations of the equipment
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in the cell have been defined previously
Example

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 Example
A robot performs a loading and unloading operation for a
machine tool as follows:
Robot pick up part from conveyor and loads into machine
(Time=5.5 sec)
Machining cycle (automatic). (Time=33.0 sec)
Robot retrieves part from machine and deposits to
outgoing conveyor. (Time=4.8 sec)
Robot moves back to pickup position. (Time=1.7 sec)
Every 30 work parts, the cutting tools in the machine are
changed which takes 3.0 minutes. The uptime efficiency of
the robot is 97%; and the uptime efficiency of the machine
tool is 98%.
Determine the hourly production rate. 76
 Solution
Cycle time =Tc = 5.5 + 33.0 + 4.8 + 1.7 = 45 sec/cycle
Tool change time= Ttc = 180 sec/30 piece = 6 sec/piece

Robot uptime efficiency ER = 0.97, Machine tool uptime

efficiency EM = 0.98

Total time = Tc + Ttc/30 = 45 + 6 = 51 sec/piece

Theoretical Production rate = Pr.th. = 3600/51 = 70.59 piece/hr

Accounting for uptime efficiencies,

Pr = 70.59*0.97*0.98 = 67.1 piece/hr =67 piece/hr
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