Industrial Robotics

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.

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.

Robot Application Characteristics

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

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

Robot Anatomy

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-offreedom of motion In nearly all cases, only 1 degree-of-freedom is allowed to a joint

Joint

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What is a robot link?

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

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-offreedom (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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1. Position Sensors

2. Range sensors 3. Velocity sensors

Type Of Sensors Being Used In Robotics Monitors the location of joints Coordinate information is feedback to controller This communication gives the system the capability of locating the end-effectors Measures the distance between a point in the robot and interest point that surrounds the robots The task is usually performed by cameras Estimates the speed using a moving manipulator 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 sensors

Sense and indication of presence of another object within specified distances 36 Prevents accidents and locate the existence of w.p.

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. 2. 3. 4. 5. Cartesian or x-y-z axis Cylindrical Polar arm (Spherical) Jointed-Arm (Articulated) 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. 2. 3. 4. 3 linear axes. Easy to visualize. Rigid structure. 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. 2. 3. 4. 1 linear axis, 2 rotating axes Height axis is rigid Large work area floor space Two ways to reach a point

Disadvantages:
1. Difficult to program off-line 2. Highly complex arm
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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 environment 2. Eliminate cost of operator protection 3. Booth air can be recirculated 4. Lower booth air velocity hazardous

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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 programming

computer

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 74 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.

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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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