Name : Raja Nur ‘Ain Bt Raja Abu Bakar

Matric.No : 06C11026

Task 1

Describe common programming methods and give an example on how the programming
is done.

Generally, robots may be programmed in a number of varies of modes, depending

on the robot and its sophistication. The following programming modes are very common:

• Physical Setup

In this mode, an operator sets up switches and hard stops that

control the motion of the robot. This mode is usually used along with other
devices such as Programmable Logic Controllers (PLC).

• Lead Through or Teach Mode

In this mode, the robots joints are moved with a teach pendant.
When the desired location and orientation is achieved, the location is
entered (taught) into the controller. During playback, the controller will
move the joints to the same location and orientation.

This mode is usually point to point , where the motions between

points is not specified or controlled . Only the points that are taught are
guaranteed to reach.

During the programming phase of the project, all of the points are
recorded in the order that the robot must move to them. When the robot
runs the program, it moves sequentially from point to point. When the
robot reaches a point, it can energize or de-energize any output signals to
energize end effectors or send output signals that are used for interfacing
to other equipment in the cell such as pneumatic cylinders that are used to
move parts into location.

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Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

The most important part about the point-to-point program is that

the robot can move one or all of its axes to move from one point to the
next. The robot does not care if the travel between one point and the next
is a straight path or if the motion has a slight arc in it.

All that is important is that the robot stops when it reaches the
next point. In most cases, the function the robot provides occurs after it
reaches a point. For instance, if the robot uses suction to pick up and place
a part, it will turn on its suction when it reaches the point where it's ready
to pick up the part, and it will turn off its suction when it reaches the point
where it will drop off the part.

The technician who programs the robot puts the robot in teach
mode, which disables the servomotors and allows the robot to be manually
pulled through the path. This action would be similar to the process if the
technician has a glue gun in hand and moved around the path placing glue
in the correct position.

Even though the servos are de-energized during this process, the
encoders of each axis are still energized and they record the exact path as
the robot is pulled through its program.

During this teaching process the robot controller is recording every

single point in this path as well as the speed at all times as the technician
pulls the robot around the contours. The robot controller also keeps track
of when the glue gun is turned on to dispense glue and when it is turned
off at any points while the robot is moving around the path.2

When the program is in the replay mode, the robot will follow the
exact path at the exact speed the technician used while the robot was being
taught.

2
http://en.wikipedia.org/wiki/Industrial_robot

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Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

This type of robot is fairly easy to program because no special

programming language is needed to get the robot to repeat the exact path it
was taught. The main drawback of this type of controller is that this type
of programming requires large amounts of memory to record the exact
path the robot was taught as well as the speed during each part of the
program

• Continuous Walk-Through Mode

In this mode, all robot joints are moved simultaneously, while the
motion is continuously sampled and recorded by the contoller.During
playback, the exact motion that was recorded is executed.

The motions are taught by an operator, either through a model, by

physically moving the end effectors, or by directing the robot arm and
moving it through its workspace. Painting robots, for example are
programmed by skilled painters through this mode.

The continuous-path control is used when the action the robot must
provide occurs at all times between points, such as spray painting,
continuous cutting, continuous welding, or continuous gluing.

Since this type of robot must follow a precise path when it is spray
painting, each location in the path the robot takes to move from point to
point is recorded during the programming phase of the project and
replayed when the robot is in the run phase.

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Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

Figure 1
Example of a continuous-path robot that is used for spray painting.

The continuous-path robot also can be used in a gluing process

where it must place a bead of glue around a complex contour like the clear
lens of a headlight assembly for an automobile. In this application the glue
is placed on the clear lens, and then the lens is placed against the
remainder of the headlight assembly (the shell) where it is allowed to dry.3

The types of headlights commonly used on automobiles today have

very complex contours to fit the design of the automobile to aid in
aerodynamics. If one looks at a variety of headlamps on cars today notice
that the path around the lens may be irregular with many curves. During
the programming phase of the project, the robot is moved around the path
with its gluing head in the correct position just above the surface.

• Software Mode

In this mode of programming the robot, a program is written off-

line or on-line and is executed by the controller to control the motions.
The programming mode is the most sophisticated and versatile mode and
can include sensory information, conditional statements and branching.

3
http://en.wikipedia.org/wiki/Industrial_robot

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Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

However, it requires the knowledge of the operating system of the

robot before any program is written .Most industrial robots can be
programmed in more than one mode.

Off-line programming uses a remote programming computer.The

programmer established the required sequence of functional and positional
steps.

The program is transferred to the robot’s controller by disk,

cassette or network link. Typically positional references are established on
the robot to calibrate or transform the coordinates used in the remote
programming for actual setup.

The robot programs can in most cases be created by the reuse of

existing CAD data so that the programming will be quick and effective.
The robot programs are verified in simulation and any errors are corrected.

Advantages Disadvantages
• Able to •Demands investing in
prepare a program without using an off-line programming
a robot. So the robot is available system.
for other uses.
•Verification of program
through simulation and
visualization.
•Layout and cycle time of the
operations can be optimized in
advanced.

•Cost independent of
production. Production can
continue while programming.

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Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

Task 2

Based on the programming method of Lead Through or Teach Mode. There are a few
facilities that have in those methods which are:

• Peripheral communications

The setup or programming of motions and sequences for an industrial robot is

typically taught by linking the robot controller by communication cable to the Ethernet,
FireWire, USB or serial port of a laptop computer. The computer is installed with
corresponding interface software. The use of a computer greatly simplifies the
programming process. Robots can also be taught by teach pendant, a handheld control
and programming unit.

Specialized robot software is run either in the robot controller or in the

computer or both depending on the system design. The teach pendant or PC is usually
disconnected after programming and the robot then runs on the program that has been
installed in its controller. In addition, machine operators often use human machine
interface devices, typically touch screen units, which serve as the operator control
panel.

Figure 2
Teach Pendant
Example:

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Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

To define three different positions

1. Press the appropriate jog key or keys to move the end of arm to an appropriate
position.
2. Suppose this is position “10”.Now , hit the following keys successively;

This sets position 10.At this time, the open/close position of the hand has also
been defined.
3. In the same manner, define positions 11 and 12 by repeating steps 1) and 2)
above.

The operator can switch from program to program, make adjustments within a
program and also operate a host of peripheral devices that may be integrated within the
same robotic system. These peripheral devices include robot end effectors which are
devices that can grasp an object, usually by vacuum, electromechanical or pneumatic
devices. Operator control panel are also accessed and controlled emergency stop
controls, machine vision systems, safety interlock systems, bar code printers and an
almost infinite array of other industrial devices4.

The controller is the name for the cabinet that contains the microprocessor (CPU)
for the robot and all of the input and output boards. The teach pendant is connected to the
controller main CPU board to provide control of the robot for jogging and programming.
From the figure notice that the teach pendant is connected to the controller with a long
cable. The long cable allows the technician to be close to the robot end effector when the
robot is being programmed. The teach pendant allows the technician to jog the robot or to
make changes in the robot program.

Controller specific languages were the original method of controlling industrial

robots, and are still the most common method today. Every robot controller has some
form of machine language, and there is usually a programming language to go with it that

4
http://en.wikipedia.org/wiki/Robot

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 Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

can be used to create programs for that robot. These programming languages are usually
very simple, with a BASIC like syntax and simple commands for controlling the robot
and program flow.

• Datum shifts

For a given robot the only parameters necessary to locate the end effector
(gripper, welding torch.) of the robot completely are the angles of each of the joints or
displacements of the linear axes (or combinations of the two for robot formats).

There are many different ways to define the points. The most common and
most convenient way of defining a point is to specify a Cartesian coordinate for it such
as the position of the end effector in mm in the X, Y and Z directions.

In addition the angles of the end effector in pitch roll and yaw and the length of
the tool must also be specified, depending on the types of joints a particular robot may
have. For a jointed arm these coordinates must be converted to joint angles by the
robot controller and such conversions are known as Cartesian Transformations which
may need to be performed iteratively or recursively for a multiple axis robot.

The mathematics of the relationship between joint angles and actual spatial
coordinates is called kinematics. Positioning by Cartesian coordinates may be done by
entering the coordinates into the system or by using a teach pendant which moves the
robot in X-Y-Z directions. It is much easier for a human operator to visualize motions
up or down, left or right or others than to move each joint one at a time.

XYZ program is similar to the point-to-point program except the positional data
are listed as XYZ positions rather than the number of pulses each motor or axis will
move. It's important to remember that the XYZ position is the place in the work envelope
where the end of the robot wrist will be for that position.

Task 3

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Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

Robot is being used widely now in the industry, several task carried out by robots. Write
a robot program that will simulate the selected tasks.

a) Pick and place program

Step Commands Operands Comments

no

10 NT Origin setting ( nesting )

20 SP 3 Set speed at 3
30 MO 1 Move to position 1
40 MS 2,1 Move straight to position 2
50 MO 3
60 MS 4,1
70 GC Close the grip of the hand
80 TI 30 Stop for 3 seconds
90 MS 5,1,C Move straight to position 5 with closed
hand
100 MO 6,C Move to position 6 with closed hand
110 MS 7,1,C
120 GO Open the grip of the hand
130 MS 8,1
140 MO 9
150 MO 10
160 MS 11,1
170 GC
180 MS 12,1,C
190 MO 13,C
200 MS 14,1,C
210 MS 15,1,C
220 ED Ending the program

b) Painting program

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Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

Step Commands Operands Comments

no

10 NT Origin setting ( nesting )

20 SP 3 Set speed at 3
30 MO 1 Move to position 1
40 MS 2,1 Move straight to position 2
50 MO 3
60 MS 4,1
70 GC Close the grip of the hand
80 MS 5,1,C Move straight to position 5 with closed hand
90 MO 6,C Move to position 6 with closed hand
100 MO 7,C
110 MS 8,1,C
120 TI 20 Stop for 2 seconds
130 MO 9,C
140 TI 20
150 MO 10,C
160 TI 20
170 MS 11,1,C
180 MO 12,C
190 MO 13,C
200 MS 14,1,C
210 TI 20
220 GO Open the grip of the hand
230 MS 15,1
240 MO 16
250 MO 17
260 ED Ending the program

Positional Sketch for Painting program

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Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

Positional List

a) Pick and Place

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Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

Position List Comment

1 Robot is in Origin position ( Nesting )

2 Move straight to the position 2
3 Move to position 3
4 Move straight to the position 4 ( pick the object )
5 Move straight to the position 5 with closed hand
6 Move to position 6 with closed hand
7 Move straight to position 7 with closed hand
8 Move straight to position 8 with opened hand
9 Move to position 9 with opened hand
10 Move to position 10 with opened hand
11 Move straight to position 11 with opened hand
12 Move straight to position 12 with closed hand
13 Move to position 13 with closed hand
14 Move straight to position 14 with closed hand
15 Move straight to position 15 with closed hand

Positional List

b) Painting

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Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

Position List Comment

1 Robot is in Origin position ( Nesting )

2 Move straight to the position 2
3 Move to position 3
4 Move straight to the position 4 ( pick the spray bottle)
5 Move straight to the position 5 with closed hand
6 Move to position 6 with closed hand
7 Move to position 7 with closed hand
8 Move straight to position 8 with closed hand
9 Move to position 9 with closed hand ( spray the
workpiece )
10 Move to position 10 with closed hand ( spray the
workpiece )
11 Move straight to position 11 with closed hand
12 Move straight to position 12 with closed hand
13 Move to position 13 with closed hand
14 Move straight to position 14 with closed hand
15 Move straight to position 15 with open hand
16 Move to the position 16 with open hand
17 Move straight to position 3 with open hand

Program flow chart

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Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

Task 4

In order to achieve Task 3, explained how the setup , procedure , and safety precautions
have to be consider so that the robot will functions safely and efficiently.

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Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

Setup

• Before turning the system power ON , set the setting switches.

• Turn ON the power switch located on the rear panel of the drive unit.
The robot of the Movemaster RV-M1 must be returned to origin after power on.
• This is done to match the robots nechanical origin with the control systems and is
required only once after the power is turned ON.
• The arm should be moved as appropriate by jog operation before return to origin so
that the robot will not interfere with any peripheral equipment during set origin.

Procedure

STEP 1 - Starting COSIPROG

• After started windows , double click onto the COSIPROG
symbol in the COSIMIR program group with the
mouse.The COSIPROG program editor is then started.

STEP 2 - Editing a new robot program

• Loading aprogram window and inputting a program

STEP 3 - Creating a position list

• Entering positions
• Teaching positions with robot
• Teaching positions off-line in COSIMIR

STEP 4 - Connecting the robot program and position list

Compiler setting command in the File menu

STEP 5 - Compiling a robot program

• Compiler command in the File menu

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Name : Raja Nur ‘Ain Bt Raja Abu Bakar
Matric.No : 06C11026

STEP 6 - Selecting a robot cell for simulation

• Setting command in the Simulation menu

STEP 7 - Calling simulation

• Start simulation command in the Simulation menu

STEP 8 - Starting simulation

• Start command in the Execute menu

Safety precaution

 Do not touch any moving parts of the robot during operation. Any work within the
operation ranges must be done after switching off the power
 Several emergency stop switches should be installed as required.
 Do not allow the robot to make contact with any person such as set up a fence
around the robot
 Signals corresponding to the robot operating states from the drive unit I/O connector
may be used as appropriate to indicate the operation status of a line.
 Ground the Movemaster to prevent noise and electric shock.
 Do not allow water, liquid or metal shavings to enter the robot and drive unit.
 Protect the plastic covers of robot from damage.

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