Robot and Automation

System Design

Dr. D. Saravanakumar,
Assistant Professor, SMBS,
VIT University - Chennai Campus.
Email: saravanakumar.d@vit.ac.in

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What is the difference between Robotics and
Automation?
Automation involves a
mechanical device that can
imitate the actions of people or
animals.
Robotics involves the design,
construction, and operation of
a robot.
A robot is a machine that
performs complicated tasks
and is guided by automatic
controls.

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 Robots

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Components of a Robotic/Automation System

1. Manipulator or Rover
2. End Effector
3. Actuators and Drives
4. Sensors
5. Processor/Controller
6. Software

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 System Design Process
Modelling / Deployment / Life
Prototyping
Simulation Cycle
Deployment of
Identifying Need HIL Simulation
Embedded Software

Conceptual Design and

Design Optimization Life Cycle Optimization
Functional Specification

Basic modular mathematical

modelling

Sensor and actuator selection

Detailed modular
mathematical modelling

Control system design

Design optimization

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 Actuators

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 Actuators and Drives
An actuator is a component of machines that is responsible for
moving or controlling a mechanism or system.
An actuator is the mechanism by which a control system acts upon an
environment. The control system can be simple (a fixed mechanical or
electronic system), software-based (e.g. a printer driver, robot control
system), a human, or any other input.

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 Electrical Actuators
Advantages
Types
easy to control
DC-motors
from mW to MW
Brushless DC-motors normally high velocities 1000 - 10000 rpm
Asynchronous Motors several types
Synchronous Motors accurate servo control
Stepper Motors ideal torque for driving
Servo Motors excellent efficiency
autonomous power system difficult

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 DC-Motors
simple, cheap
easy to control
1W - 1kW
can be overloaded
brushes wear
limited overloading on high
speeds

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 DC-motor control
Controller + H-bridge
PWM-control
Speed control by controlling
motor current or torque
Efficient small components
PID control

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 Brushless DC-Motors
no brushes no wearing parts
high speeds
coils on cover => better cooling
excellent power/weight ratio
simple
needs both speed and angle
feedback
more complicated controller
From small to medium power
(10W 50kW)

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 AC Motors
very simple, very popular in industry
0,5kW - 500kW
More difficult to control (frequency)
nowadays as accurate control as DC-
motors
In mobile machines also (5kW )

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 Stepper Motors
Stepper motors are another kind of motors that
do not require feedback
A stepper motor can be incrementally driven,
one step at a time, forward or backward
Stepper motor characteristics are:
Number of steps per revolution (e.g. 200 steps
per revolution = 1.8 per step)
Max. number of steps per second (stepping
rate = max speed)
Driving a stepper motor requires a 4 step
switching sequence for full-step mode
Stepper motors can also be driven in 8 step
switching sequence for half-step mode (higher
resolution)
Step sequence can be very fast, the resulting
motion appears to be very smooth

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 Servos

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 Hydraulic Actuators
linear movement
big forces without gears
actuators are simple
in mobile machines
Bad efficiency
motor, pump, actuator combination is lighter
than motor, generator, battery, motor & gear
combination

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 Pneumatic Actuators
like hydraulic except power from compressed air
fast on/off type tasks
big forces with elasticity
no leak problems

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 Other Actuators
Piezoelectric
Magnetic
Ultra sound
SMA
Inertial

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 Sensors

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 Why Do Robots Need Sensors?

Provides awareness of surroundings

Whats ahead, around, out there?

Allows interaction with environment

Robot lawn mower can see cut grass

Protection & Self-Preservation

Safety, Damage Prevention, Stairwell sensor

Gives the robot capability to goal-seek

Find colorful objects, seek goals

Makes robots interesting

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 Sensors - What Can Be Sensed?
Light Physical
Presence, color, intensity, orientation/attitude/position
content (mod), direction Magnitude, pitch, roll, yaw,
coordinates, etc.
Sound Magnetic & Electric Fields
Presence, frequency, intensity, Presence, magnitude,
content (mod), direction orientation, content (mod)
Heat Resistance (electrical,
Temperature, wavelength, indirectly via V/I)
magnitude, direction Presence, magnitude, etc.
Chemicals Capacitance (via
excitation/oscillation)
Presence, concentration, Presence, magnitude, etc.
identity, etc.
Inductance (via
Object Proximity excitation/oscillation)
Presence/absence, distance, Presence, magnitude, etc.
bearing, color, etc. Other Things?

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 Sensors IR
Active (emitting)
Oscillator generates IR reflections off objects
Filtered receiver looks for reflections
Pulses may be encoded for better
discrimination
Typically frequencies around 40KHz
Doesnt work well with dark, flat colored
objects

Passive (sensor only)

Pyro-electric (heat sensor)
Look for IR emissions from people & animals
Used in security systems & motion detectors

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 Laser Range Sensors

USB Interface
240 Field of View
0.36 Angular Resolution
10Hz Refresh Rate
20mm to 4m

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 Sensors Ultrasonic
Active
Emit pulses & listen for echos
Times round trip sound travel (~1ft/mS)
Reaches far fairly beyond robot (inches to
30-50)
Relatively simple, not cheap, analog
output
Directional; not everything reflects sound
well

Passive (listens only)

Sensor listens for ultrasonic sounds
Electronics may translate frequency or
modulation
Software may perform signal analysis
(FFTs, etc.)

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 Sensors Visual
Active (emitting)
Camera with field of view illumination
Looks for particular reflections
Filter removes non-significant light sources
Linear array senses single axis of motion

Passive (camera only)

Scans field of interest
Looks for objects, artifacts, features of interest
Processes digital data to simplified interpretation

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 Sensors Color
Active (emitting)
Selective field illumination (specific color(s))
Sensor filter removes extraneous light sources
Output can be analog (prop.) or digital (on/off)

Passive (sensors only)

Different sensors for different colors
Color filter removes extraneous light sources
Output can be analog (prop.) or digital (on/off)

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 Sensors Magnetic
Active (emitting)
Metal detectors
Follows metallic strips on or under the floor
Magnetometer
Magnetic Resonance Imaging (MRI)

Passive (sensors only)

Compass
Magnetic field sensor (oscillating current)

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 Sensors Orientation
Rate Gyros
Output proportional to angular rotation speed
Integrate to get position
Differentiate to get acceleration

DC Accelerometer
Output proportional to sine of vertical angle

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 Sensors Position/Location
Wheel Encoders
Relative position & motion
Integrate/Differentiate for other parameters

Global Positioning System

Absolute position/location on earth
Local differential error correction
Integrate/Differentiate for other parameters

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 Wheel Encoders

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 Sensors Position/Location

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 Sensors Compass (Orientation)

Track bearing & distance to determine position

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 Control of Robots

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 Path Generation
To find desired joint space trajectory qd(t) given the desired Cartesian
trajectory using inverse kinematics
Given workspace or Cartesian trajectory
p(t ) x(t ), y (t )
in the (x, y) plane which is a function of time t.
Arm control, angles 1, 2,
Convenient to convert the specified Cartesian trajectory (x(t), y(t))
into a joint space trajectory (1(t), 2(t))

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 Trajectory Control Types
Displacement Control
Control the displacement i.e. angles or positioning in space
Robot Manipulators
Adequate performance - rigid body
Only require desired trajectory movement
Examples:
Moving Payloads
Painting Objects
Hybrid Control Robot Manipulator
Control the force and position of the manipulator
Force Control, set-point control where end effector/ manipulator position and
desired force is constant.
Idea is to decouple the position and force control problems into subtasks via a
task space formulation.
Example:
Writing on a chalk board

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 Advanced Control Functions
Path Generation
Displacement (Position) Control
Force Control
Hybrid Control i.e. Force/Position
Feedback Linearization
Adaptive Control
Neural Network Control
2DOF Example

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