ROBOTICS

It is a form of programmable automation that is made possible

by computer control.
• Exhibit some human live capabilities and cannot equal the
combined physical and mental abilities of human.
KEY WORDS
• Programmable, automatic, manipulators, human live.
DEFINITION BY INTERNATIONAL (CAM-1)
•A device that perform function ordinarily ascribed to human
beings; or operates with what appears to be almost human
intelligence.
BY RIA :-
•A programmable multi-function manipulator designed to move
materials, parts, tools, or special devices through variable
programmed motions for the performance of a variety of tasks.
• Robot is derived from czech word robota, means
compulsory service or work.
• First patent was granted to Cyril, Walter keyword of UK in
1957, second in 1961 to Devol of US.
• Elements
1. Mechanical components
a) manipulator
b) gripper
c) actuator
d) power source
2. Control system
a) sensors
b) equipment interfaces
c) mechanical, electrical & electronics controls
3. Computer ststem
a) application programe
b) processor
c)
d) system software
 INDUSTRIAL ROBOT
• NC machine is a single function robot, robot is used for multi
purposes. Function is not defined.
• NC machines restricts to canesion coordinates but robot can
be used in any coordinate system.
• In machine tool handling application we use gantry type
robot frequently than articulated arm type robot.
• Reprogrammable, multifunctional manipulator designed to
move material, parts, tools, or specialized devices through
variable programmed motion for the performance of a variety
of tasks.
• CNC machine – single purpose robot
• Robot – multi functional NC machine
 CLASSIFICATION BASED ON
• Arm configuration and reach
• Power sources and programmable speed
• Load capacity and application capabilities
• Control, techniques and intelligence.

MOUNTING TYPES
• Floor mounted
• Machine mounted and wall mounted
• Gantry
• Gripper, sensor, aries, programming
programming can be on-line, off-line, teach
 ROBOT CONTROL SYSTEM

• Robot controller have CNC type

controlling…………………………..
• Simulator for trying out robot program without actually
the operating robot.
• Interfaces to controller, peripheral equipment and other
computer.
 ROBOT PROGRAMMING LANGUAGES
• Done with high-level languages with basic motion and
position specification.
• Commands are sub routines. That are provided by the
system.
• Move, grip, release, add, sort, return, wait.
• Many robot languages.
VAL, AML, HELP, MCL, RPS.
ROBOT OPERATION:
• ……………
• Point to point
• Continuous path
• Controlled path
 SPECIFICATION OF ROBOT
1. Axes of motion:
No. of degrees of freedom of the robot
joints determine the complexity of motion.
2. Work envelops:
can be described in terms of degrees of
rotation, vertical motion and radial arm……………
3. Speed:
4. Acceleration:
hydraulic devices can be provide very high
acceleration.
5. Pay load capacity:
6. Accuracy:
how closely the end of the robot arm can be
moved to a specific position
7. Resolution : is the smallest increment of motion for which
the robot can be controlled.
8. Repeatability: is the ability of the manipulator to
repeatedly return to the exact same position.
9. Reliability:

ROBOTS PROGRAMMING
• Programming involves “teaching” it the task to be
performed storing the program, executing the program
and debugging it.
• Task of robot program is to control the motion and action
of the manipulator.
 PROGRAMMING METHODS
1. Guiding: this is also known as “walk-through” or “play
back” method. This is a simple techniques that does not
require the operator to write any programming code, but it
is limited to short and simple motion. It involves
counter………
The manipulator arm so that it can be moved manually
through the intended motion while its path is being
recorded by control system. The stored program of robot
motion can then be played back.
2. Teach pendant:- also known as lead through method. It
uses a control panel called a “teach pendant” which has
button or switches that control the motion of the robot
through a cable connected to the control system. This also
does not require code writing, but it can be used for more
complex and precise tasks. It is often used for developing
application.
3. Off-line programming:-
• High level language is used to write a control program.
 PROGRAMMING FUNCTION

1. World modeling:- define position of the objects and features

involved in the application. Position data must be obtained
from several sources line robot sensing geometric models or
external sensing system.
2. Path generating:- the position specification must be tabulated
from world coordinates to joint coordinates which the robot
control system can understand.
3. Sensing:- use of sensors permits the robot to deal with
uncertainties that cannot be preprogrammed
• The detection of failures or errors.
• The identification of objects.
• Initiation or termination of action.
4. Programming support:-
• Editing tools for idetifying program.
• Debugging tools for finding problem during program
developing.
• Diagnostic tools for finding problem during operation.
 ROBOT

1. Robot can perform simple and repetitive tasks with better

quality and consistency.
2. Can perform tasks that are different and hazardous for human
because of size, weight, reach, precision or environment.
3. Do not have limitation. Line fatigue need for rest. Diverted
attention or mentally absent.
4. Can perform superior work in speed, accuracy and
repeatability than human.
5. Robots can be used to perform tasks which human do not
want to do line low paying, poor working condition.
6. Lower operating costs, by better efficiency.
7. More economical as labor costs.
 ROBOTS V/S HARD AUTOMATION

• More flexible than hard automation, since can be

reprogrammed.

• Make easier and faster to implement in automation.

• Make easier to debug an application.

 TYPES OF ROBOTS
CLASSIFIED ON THE BASIS OF
1. Mechanical configurations: i.e. the physical geometry of
the manipulator arm and base unit. Four basic robot arm
geometries are used for industrial application.
a) Rectangular coordinate system:
• also called canesian coordinate system.
• Three linear axes
• This configuration is best suited for ….... Line and side-to-
side movements.
b) Cylindrical coordinate system:
• also called rectilinear coordinate system.
• Has three axes of motion that trace the shape of a cylinder.
This type is best suited for movement around a base.
c) Spherical coordinate system:
• Also known as polar coordinate system.
• Has three axes of motion that trace the shape of a sphere.
d) Revolute coordinate system:
• Known as anthropomorphic, articulated arm or jointed arm.
• Has three axes of motion involving a base a base that rotates
a “shoulder” that rotates and an “elbow” that also rotates.
2. Freedom of motion:
• The motion ability of a robot is termed as “degree of
freedom”.
• Six degree of freedom. X, Y and Z coordinates and rotation
about these.
• The motion ability of a robot is also described in terms of its
working envelope.
3. Driving system:
• The motion of the mechanical linkages and joints of a
…………. Drives by actuator which may…….
• The energy for these actuators is provided by some
power source. Which can be electric, hydraulic or
pneumatic.
• Actuators may be directly coupled to the linkages or
joints or may be connected through gears, chain or
screw mechanism.
a) Pneumatic:
• Driven by compressed air
• Such robots are small and have limited flexibility
• Relatively inexpensive to build and use.
• Pay load and speed of motion are limited by
compressibility and operating pressure of air
b) Hydraulic:
• Relatively compact and yet provide high levels of force,
power and speed with accurate control.
• Safe, reliable in wet and dusty environment.
c) Electric:
• Driven by rotational electric motors.
• Best suited for application involving light payloads which
require high accuracy and cleanliness.
• DC motor can provide high speed and accuracy with
simplex controls, but they are limited in their pay load
capacity.
4. Control systems:
a) Non-servo controlled:
• Simplex and least expensive limited in flexibility and
performance.
b) Servo-controlled:
• Capable of controlling the velocity, acceleration and path of
motion.
• Use electronic controllers/computers and sensors to
control the motions of robots.
• More flexible.

FUNCTION OF CONTROL SYSTEM

1. Generating the path of motion for the manipulator.
2. Monitoring sensors.
3. Coordinate translation
4. Safety controls
5. interfaces
 INTELLIGENT ROBOTICS
TYPES OF ROBOTS
1. Slave Manipulators: controlled by a human operator
2. Limited sequence robots: typical pick and place devices
uses mechanical stops.
3. Teach/replay robots: include robots that are programmed
by walk-through methods.
4. Computer-controlled robots: can be off-lined pre
programmed to perform complex tasks.
5. Intelligent robots:
• are not restricted in their action to only the preprogrammed
instructions. They can modify their actions as per sensing
technique.
• Is able to interact with its environment and adapt its
behavior to uncertain or changing condition.
• May use human live sensor such as touch, vision and
hearing.
• Intelligent robots are actually automated manufacturing
systems which integrate manipulation, sensing,
computation and control functions. The physical system
includes---
a) End effectors: which acts as the arms and hands of the
robot.
b) Sensors: which provide data about the environment by
contact or non contact techniques.
c) Computers: includes controllers, processors, and
communication channels.
d) Auxiliary equipment: which perform special tasks such as
tools, fixtures, conveyor, pallets, CMM etc.
 INTELLIGENT ROBOTS

IR includes
• Contact and non-contact sensing.
• User friendly operator interfaces
• Powerful, high level programming languages.
• AI techniques, communication links to the factory floor
control system
• Multiple arms,
• Dexterous hands.
 control

Information Position and speed

(decision making) sensors

Intelligent data recognition

base

sensors Work environment

Functional diagram of an intelligent robotic system

 END OF ARM TOOLING

1. Gripper and hands

2. Tools

3. Hand and tool holders

4. Micromanipulator
 DEXTROUS HANDS

1. Sensing
2. Articulated hand
 FEATURES

1. Multiple, articulated fingers attached to a palm.

2. Bonelike, structure for density and rigidity

3. Skin like, touch sensor.

4. Flesh like, surfaces for object-grasping compliance

5. Proximity sensors for collision avoidance

 SENSORS
• Five basic sensors of human are touching, hearing, seeing,
smelling and tasting.
• Sensors are used to detect
a) Variations in the dimensions and shapes of parts.
b) Variations in the positions and orientation of parts.
c) Unknown surfaces and obstacles.
• In manufacturing applications sensing may be used for
i) Locating parts
ii) Detecting errors
iii) Verifying quality
• Basic sensing used for ………
i) Force or torque sensing
ii) Position sensing
iii) Motion or displacement sensing
iv) Pattern recognition
 TYPES OF SENSOR
1. Contact sensor:
a) Touch sensors: contact probe at the end of robot grippers.
b) Force or torque sensors: piezoelectric devices and strain
gauges. It provides information on the forces between the
gripper fingers during grasping.
c) Position or displacement sensors: located on the joints of
manipulator to measure their movement, so that position of
the robot may be controlled.
2. non-contact sensors: includes that sensors which generate
signals using transducers.
a) Optical sensors: uses pairs of photocells mounted on the
end of the gripper.
b) Range and proximity sensors:
• Determine the relative distance between manipulator and
objects.
• Includes acoustical, ultrasonic, optical and magnetic
devices.
 ROBOT VISION
• Used to identify or verify objects.
• Used to locate objects.
• Used to inspect objects.
• Guide manipulator motion or robot navigation.
• Robot vision system is basically a large area

OPTICAL SENSING SCHEME

• It uses visible light and some type of image sensor, like
television camera, to acquire data which describe an object
or scene.
• The data is processed and interpreted by a computer which
drives robot control system.
 TYPES OF ROBOT VISION SYSTEM
1. Dimension
a) 2D system:
• Most common and least complex.
• Designed to recognize 2D features of objects such as
edges or outlines.
b) 3D system:
• More complex and expensive.
• Recognize 3D shapes…………..
2. Contrast:
a) binary: recognize 2D black or white images only.
b) Gray scale: colored objects
3. Image analysis technique:
a) Edges finding:
• Detection the edges of objects as transition from white to
black or black to white.
• Requires high contrast lightly set up.
b) ……… matching:
• Light reflected off object is used to create an outline or
……….. Of its 2D shape. The outline image is then
composed to a reference image or template which is stored
in memory.
• System attempts to align the reference image with
observed image to find matches in shapes and size.
• This is a computational process based on rules and
algorithm.
c) Feature matching:
• More complex image analysis technique.
• Slower and more expensive
 STEPS OF VISION SYSTEM

1) Image sensing
2) Pre-processing of image:-
• To enhance its quality and classify
3) Segmentation
4) Ineterpretation and recognition.
 AI IN ROBOTS

• Expert systems that use experience prior knowledge to

make decisions and solve problems
• Knowledge acquisition and representation to establish a
knowledge base for E.S.
• Heuristic search to try alternative solution to select a
path
• Deductive reasoning
• Planning or developing an approach to achieve a goal
• Image understanding to interpret and recognize memory
information about objects
• Natural language understanding for the ability to
translate human vocabulary into machine language
 INTRODUCTION TO FMS

Manufacturing can be
• Small batch
• Medium batch
• Large batch

The types of manufacturing facilities would change based

on the batch size
• GPM tools
• SPM tools
• Single purpose machine tools
• Transfer lines
Reason for employing the type of manufacturing
techniques:
• Cost
• Flexibility
• Production rate

Challenges in manufacturing are:

• Higher productivity
• Better quality
• Lower cost
• Faster turn around
Previously:
• Large product life time
• Large time for development
• Variety is small
• Cost is low

Now:-
• Variety is large
• Cost is low
• So by using mass production techniques, it is made
possible
 AUTOMATION BENEFITS
s.no. Integration Machine utilization

1 Basic CNC(manual tool & work loading) 40%

2 Basic CNC with 60%
• automatic work holding
•W/P storage
•Manual loading

3 Complete machine automation like stand 75%

alone CNC
•Automatic work and tool holding
•Tool monitoring
•W/P inspection, work and tool stotrage
4 Integration of group of machines as in 3 80%
e.g. manufacturing cell

5 FMS 90%
•Automated W/P
•Movements between machines
 A typical FMS should contain (cincinnati Mila…..)

• Load/ unload station

• Remote controlled cart with wire guided path
• CNC machining centres
• Automatic chip removal system
• Part cleaning module
• Inspection modules
• Manual inspection station
• Control center computer room
• Cart maintenance station
• Standby parking, battery charging
 Definition of FMS
• A series of automatic machine tools or items of
fabrication equipment linked together with an automatic
material handling system, a common hierarchical digital
pre programmed computer control and provision for
random fabrication of parts or ass3emblies that fall within
predetermined families.
• A FMS is a group of NC machine tools that can randomly
process a group of parts, having automated material
handling and central computer control to dynamically
balance resource utilization so that the system can adopt
automatically to change in part production, mixes and
levels of output.
• FMS is a randomly loaded automted system based on
group technology manufacturing linking integrated
computer control and a group of machine to
automatically produce and handle parts for continuous
serial processing
• An FMS is a REPROGRAMMABLE manufacturing
system capable of producing a variety of products
automatically
• FMS combines microelectronic and mechanical
engineering to bring the economies of scale to batch
work. A central online computer controls the machine
tools other work station and the transfer of components
and tooling. The computer also provides monitoring and
information control. This combination of flexibility and
overall control ,makes possible the production of a wide
range of products in small numbers.
• A process under control to produce varieties of
components and products within its stated capability and
to predetermined schedule.
• A technology which will help to achieve leaner factories
with better response time, lower unit cost, and higher
quality under an improved level of management and
capital control.
• An FMS is a collection of production equipment logically
organized under a host computer and physically
connected by a control transport system.
FMS is characterised by :-
• NC machine tools
• Automatic material handling system
• Central computer control
• Randomly loaded
• Linked together and flexible
• Distributed data handling
 Equipment in a FMS

1. Work centers
• Machining centers
• Turning centers
• Turn mill centers
• Grinding machine
• Nibbling machines (series of holes)

2. Process centers
• Washing machine
• CMM
• Robotic workstations
• Manual workstations
3. Support stations
• Pallet/ fixture
• Load/ unload station
• Tool assembly and setting station

4. Support equipment
• Robots
• Pallets/ fixtures/ magazines/ buffer stations
• Tool stores
• RM stores
• Transport system (AGV, RGV,robots)
A true FMS can handle a wide variety of dissimilar
parts producing them one at a time in any order as
needed.
 PROBLEM OF CONVENTIONAL MACHINE
TOOLS

• Schedule change
• Engineering design change
• Tooling difficulties
• Machine breakdown
• Processing problem
• Lost, misplaced and scrapped parts
• Vendor lateness
 SOLUTION

The need of the……..

• Minimum delay between order placement and delivery
• High quality and reliability
• Predictable and controllable operating costs
• Replacement parts should be available and accessible
on a quick turn around basis
FMS PROVIDES a means to manage and control the
uncontrollable disturbance while meeting customer
demands and requirement.
1. Operation control improve through
• Reduction in the no. of uncontrollable variable
• Providing tools to recognize and react quickly to
deviation in the manufacturing plan
• Reducing dependence on human communication.
2. Reduce direct labour through
• Removing operators from machining site
• Eliminating dependence on highly skilled machinist
• Providing a catalyst to introduce and support unattende
or lightly attended machine operation.
3. Improve short run responsiveness consisting of :
• Engineering changes
• Processing changes
• Machine down time or unavailability
• Cutting tool failure
• Late material delivery
4. Improve long run accommodation through quicker and easier
assilimilation.
• Changing product………..
• New product addition and introduction
• Off part mixes
5. Increase machine utilization by
• Eliminating machine set-up
• Utilizing automated features to replace manual intervention
• Providing quick transfer devices to keep the machine in the
cutting cycle.
6. Reduce inventory by
• JIT,
• Reducing lot sizes
• Improving inventory turn over.

FMS installed to get

• When extra machining capacity needed
• New company requiring new machine facilities
• To avoid move to new side
• Reduce the shortage of skilled labour
• Investment decision not known
• No desire of experiment
• Better control of work flow
• To improve quality and make it consistent.
 ADVANTAGES OF FMS

1. Integration of several machine or workplaces leads to

smaller waiting time between machine and better
utilization of each machine leading to greater
productivity.
2. Integration of job planning and material planning leads
to optimum material utilization and therefore reduction
of w/p, fixture and tools in storage leading to lower
production costs.
3. Dynamic scheduling of jobs in the light of process
monitoring leads to reduction of down time and better
utilization of machine means higher productivity and
lower costs.
4. Dynamic job scheduling also leads to greater reliability
in meeting production deadline and therefore better
market image.
5. Automatic supply of tools and w/p from common storage to
machine also leads to smaller inventory costs and human
operation costs further reducing the cost of production.
6. Production costs decrease typically 50% as compared
before FMS.
7. Very high product quality can be achieved due to integrated
process monitoring i.e. integrated tool, w/p and error
diagnosis monitoring. 100% inspection can be provided.
8. Quick production in very small lot sizes with great variation
of the same is possible. The job order can be easily
repeated any number of times.
9. The range of production is very large almost all engineering
components can be manufactured.
10. FMS offer a highly effective and economical volatile market.
The range of products covered by FMS is very wide.
1. Need heavy investment
PITFALLS OF FMS
2. Need full time planning
3. Requires continued commitment.
4. Planning would have
• detailed knowledge of machine selection
• Software and hardware
• Simulation, scheduling, communication etc.
5. Training– operators will change to planners so multi skill are needed.
6. FMS gives
• 10% reduction in material cost,
• 50% reduction in machine tools
• 50% reduction in direct labour cost,
• 30% reduction in manufacturing space.
• 50% reduction in lead time.
• 30% support labour
• ……………………………
 FLEXIBILITY
• Machine flexibility: Ease of making changes required to
produce a given set of parts.
• Process flexibility: ability to produce a set of parts using
different material in different ways.
• Product flexibility: ability to change over to new set of parts
very economically and quickly.
• Routing flexibility: ability to handle breakdown and produce a
set of given parts.
• Volume flexibility: ability to operate profitably at different
production volumes.
• Expansion flexibility: abilirty to expand the system easly and in
a modular fashion by adding new machine.
• Operation flexibility: ability to interchange ordering of several
operations for each part type.
• Production flexibility: the universe of parts that the FMS can
produce .
these are very difficult to quantify.
 LEVEL OF FLEXIBILITIES IN FMS

there are four levels of flexibilities:

1. Immediate: capacity and manufacture parts individually
(inside a given family). Limits are set-up times on
machines.
2. Short term: capability to modify the mix of parts (inside
a constant volume). Limits are variety of tooling.
3. Midterm: capability to introduce new parts limits are
size of equipment and no. of tooling.
4. Long term: capability to introduce new equipment.
Limits are mechanical interfaces data exchanges.
(graph)
HOW FMS WORKS
 CNC SYSTEM FOR FACTORY AUTOMATION

1. Stand alone CNC machining, turning and working

centres for ………… operation.
2. Flexible manufacturing modules.
3. FMC (flexible manufacturing cell)
4. FMS
5. CIMS (computer integrated manufacturing system)
S.N. FMC FMS
1. Less flexible Highly flexible
2. Small stored part program inventory and Large stored part program inventory and
accessibility accessibility
3. Low to moderate equipment and High equipment and resources cost
resource costs
4. Limited flexibility and variety of parts High flexibility and variety of parts
produced produced.
5. Limited online computing power and High-online computing power and d.m.s.
decision making software (d.m.s.)
6. Low to medium preparation and High
implementation requirement
7. Benefits narrow. But easily identified and Benefits broad but hard to identify and
quantified quantify
8. Moderate justification complaints and Difficulty and complex justification process
difficulty with mix-management approval and high level approval required
required
9. Moderate level of management High
commitment and support required
10. Low staffing and training impact High
11. Moderate effect on other internal High
operational organization
12. Low to moderate risk and minimal facility High risk and many facility changes
changes
13. Short planning to implementation cycle long
• The building blocks of a FMS system are
1. Machining system block (MSB)
2. Work piece handling block (WHB)
3. Tool handling block (THB)
4. Computer control block (CCB)
5. Auxiliary services block (ASB)

all blocks have naturally to be compatible for building a

FMS.
 MACHINING CENTRES

• Improved flexibility and reliability

• Increase rigidity, feeds and speeds
• Reduced idle operation times.
• Improved safety and diagnostics
• Increased range of operation capability.
• Machine bed:- C.I., steel welded or concrete bed, optimized by
using CAD and FEM
• Spindles:- higher speed range (6000- 7000 rpm)
more axes---- reduced settings
horizontal and vertical
• ATC:- tool storage capacity, tool change methods, tool
replenishment, random sequential tool selection.
• Accessories:- pallets, rotary tables, programming options,
probing adaptive control.
• Tool change time possible upto 3 second
• Modular component
• CNC increases flexibility and scaling is possible in CNC
• Probe path can be automated by CNC.
• We can generate profile and information can be fed
TRACE DATA OUTPUT DATA
transformation
 SOME FEATURES OF MACHINING CENTRES

• Several types of machining operation can be

automatically programmed in the desired sequence.
• Complete machining of w/p with a minimum no. of set-
ups is possible fully guarded enclosures permits closed
working space, good accessibility and reliable protection
from flying chip…………………
 SUMMARY OF FMS
1. FMS are regarded as one of the most efficient methods to employ
in reducing or eliminating problem in manufacturing industries
2. Definition of FMS vary depending upon industry type and user
view point.
3. FMS brings flexibility and responsiveness to the manufacturing
floor.
4. It enables manufacturer to machine a wide variety of w/p on few
machines with low staffing levels, productivity, reliably and
predictably.
5. FMS is made up of hardware elements (e.g. machine tools,
pallets, CMM, material handling equipment, computer hardware)
andsoftware elements (NC programming, CMM programming,
FMS software). The sophisticated FMS software is what actually
drives the system.
6. A true FMS can handle a wide variety of different parts, producing
them one at a time in random order.
7. FMS shorten the manufacturing process through improved
operational control, round-the-clock, availability of automated
equipment.
 ECONOMICS OF NC MACHINE TOOLS

Two types of costs

1. Variable cost or production cost or running cost
2. Fixed cost

Items:-
a) Material
b) Plant or machine
c) Labour overheads