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Q-1) How a robot is specified? Explain its terminology with suitable examples.

For selecting a robot for a specific application, it is essential to be aware about capabilities,
limitation and specification o the robot. Also it is essential to test whether the robot is matching with
the task requirement or not.
The following parameters are used to characterize robot specifications:

Payload: Payload is the weight a robot can carry and still remain within its other specifications. As
an example, a robot’s maximum load capacity may be much larger than its specified payload, but at
these levels, it may become less accurate, may not follow its intended trajectory accurately, or may
have excessive deflections.

Reach:Reach is the maximum distance a robot can reach within its work envelope. As will be seen
later, many points within the work envelope of the robot may be reached with any desired
orientation (called dexterous). Reach is a function of the robot’s joints and lengths and its
configuration. This is an important specification for industrial robots and must be considered before
a robot is selected and installed.

Precision:Precision is defined as how accurately a specified point can be reached. This is a function
of the resolution of the actuators as well as the robot’s feedback devices. The precision is a function
of how many positions and orientations were used to test the robot, with what load, and at what
speed. When the precision is an important specification, it is crucial to investigate these issues.

Repeatability Repeatability is how consistently the robot does the same thing over and over again.
It may be off-target, but if it's off-target consistently in the same place, then the repeatability is high.
It's useful to look at both repeatability and accuracy.

Grip force:The grip force is the amount of force the end effector applies on an object to hold it as
the robot moves. Grip force is not the same as payload. Think of the grip strength of a tennis player
or a rock climber. While the person can use their hand to lift a maximum weight (payload), their grip
strength also plays an important role in how successful they are at their chosen activity. So, not only
do you need to consider end effector payload or strength; you also need to consider how tightly the
end effector needs to hold objects.

Collaborative: When talking about collaborative robots, people usually mean force-limited robots
with built-in safety features that allow them to operate safely around humans. However, it is
possible to have a force-limited robot that isn’t safe for collaborative work. It’s also possible to have
a non-force limited robot with another safety feature that allows it to be used near human workers.

Robots are specified by the following terms:

1 .PITCH- with the rotating about an axis, the up and down motion of the wrist is called pitch.
Typically done by means of rotary or R type joint.

2. ROLL- the wrist of robotic arm is capable of rotating about its arm axis. It is called roll or swivel.
3. YAW- with the wrist rotating about an axis, the left and right rotation of the wrist is called yaw.

4. ACCURACY- It is defined as the ability of the robot to position its wrist end at desired target point
within its reach.

5 .RELIABILITY- Reliability identifies the percentage of time that the robot is expected to operate
without begin taken out of service for maintenance or repair.

6. RESOLUTION- The smallest increment of motion or distance that can be detected or controlled
by the robotic controlled system.

7. PRECISION OF ROBOT- It is the smallest increment of motion for which the robot can be
controlled.

8. QUALITY OF ROBOT- It is the smallest increment of motion for which the robot can be controlled.

9 .REACH- The maximum horizontal distance from the centre of robot base to the end of the wrist.

Robot Terminologies

1. Manipulator: This is the physical structure which moves around. It comprises links and joints
normally connected in series link. Links are rigid parts and joints permit relative motion between
links. Without other elements, the manipulator alone is not a robot.

2. End effector: This part is connected to the last joint (hand) of a manipulator that generally
handles objects, makes connections to other machines, or performs the required tasks. This is
equivalent to the human hand and end effector could be a mechanical hand that manipulates an
object or hold it before they moved by the robot arm.

3. Actuators: The actuators of robot actually provide motion to the manipulator links and the end
effector. This is the device that is responsible for the motion of the robotics arm. They are
following types:
a. Electrical actuator
b. Hydraulic actuator
c. Pneumatic actuator

4. Sensors:Sensors are the devices or arrangements used to gather information about the nearby
environment. Sensors are used to collect information about the internal state of the robot or to
communicate with the outside environment. For example sensory devices such as a vision
system touch and tactile sensors, speech synthesizer, and the like that enable the robot to
communicate with the outside world.

5. Controller: The controller is rather similar to your cerebellum; although it does not have the
power of the brain it still controls your motions. The controller receives its data from the
computer (the brain of the system), controls the motions of the actuators, and coordinates the
motions with the sensory feedback information. For example suppose that in order for the robot
 to pick up a part from a bin, it is necessary that its first joint be at 35 degree. If the joint is not
already at this magnitude, the controller will send a signal to the actuator—a current to an
electric motor, air to a pneumatic cylinder, or a signal to a hydraulic servo valve—causing it to
move.

6 DEGREE OF FREEDOM- The number of independent motion a device can make .(maximum number
of six). For example,Consider a robot arm built to work like a human arm. Shoulder motion can take
place as pitch (up and down) or yaw (left and right). Elbow motion can occur only as pitch. Wrist
motion can occur as pitch or yaw. Rotation (roll) may also be possible for wrist and shoulder. such a
robot arm has five to seven DOF.

7.WORK SPACE- The space within which the robot can manipulate the end of the wrist. Work space
is defined by the geometry of robot i.e Cartesian ,spherical, cylindrical, revolute. A robot work
envelop is its range of movement.

8.END-EFFECTOR- The tool,gripper,or other device mounted at the end of a manipulator, for
accomplish useful task. Example of end effector are, Grippers, force torque sensors,material removal
tools, welding torches , collision sensor.out regard to forces.

9.KINEMATICS - The study of motion with out regard to force

10. DYNAMICS- The study of motion with regard to force.

Q-2) A robot is employed in welding operation. How will it able to do its task efficiently
with minimal human intervention?

One of the most used manufacturing processes to permanently join two parts is welding. Welding
can be perform manually, i.e. done by humans, or automated, i.e. carried out by robots. These
robots are called “Welding Robots”. In large manufacturing plants, they are becoming more and
more popular, because they provide a lot of advantages to the production line. They are fast,
consistent and do quality welds.
Welding is a process where two materials are fused together through heating, intermixing, and then
cooling the materials and/or a filler to form a strong join. From arc welding to spot welding, new and
used welding robots are typically used in welding processes where the weld required is repetitive
and quality and speed are crucial. Robotic welding is an automated process that increases
efficiency, consistency, and your ROI.
Welding, where the robot, along with proper set-ups and a welding end effector, is used to weld
parts together. This is one of the most common applications of robots in the auto industry. Due to
their consistent movements, robotic welds are very uniform and accurate. Welding robots are
usually large and powerful.
There are several advantages to automating a factory with welding robots, including faster,
consistent cycle times, no break in production, and better weld quality. Basically, by
using welding robotic automation, the process takes less time, and manufacturers can cut the cost of
direct labor and safety and conserve materials.
Robotic weld cells provide an even safer work environment, dramatically reducing arc glare,
overspray, and direct contact with the robot and part. A robot welder is more consistent and can
move from one weld to the next quickly, speeding up the entire process.
1. Increase in Productivity
2. Consistent and Repeatability
3. Flexibility
4. Safety
5. Quality
6. Reduce Consumables
7. Reduced Production Costs
8. Reduction in Weld Distortion
9. Increased Competitive Advantage

Q3). What are end effector? Give it’s classification with suitable real world examples.

Ans- An end effector is usually attached to the robot's wrist, and it allows the robot to
accomplish a specific task. This means that end effectors are generally custom-engineered
and fabricated for each different operation. There are two general categories of end
effectors viz. grippers and tools.

Classification of Grippers:-

1. Mechanical Gripper: It is used as an end effector in a robot for grasping the objects
with its mechanically operated fingers. In industries, two fingers are enough for
holding purposes.
2. Vacuum Gripper: They are used in the robots for grasping the non –ferrous objects.
It uses vacuum cups as the gripping device, which is also commonly known as suction
cups. This type of grippers will provide good handling if the objects are smooth, flat,
and clean.
3. Magnetized Devices: Based on the principal of magnetism. They are for holding
ferrous workparts.
4. Adhesive Devices: By deploying adhesive substances, these are used to hold flexible
materials, such as fabric.
5. Simple Mechanical devices: Hooks and scoops.
6. Dual grippers: It is a mechanical gripper with two gripping devices in one end
effector. It is used for machine loading and unloading. It reduces cycle time per part
by gripping two workparts at the same time.
7. Interchangeable fingers: Mechanical gripper with an arrangement to have modular
fingers to accommodate different sizes workpart.
8. Sensory feedback fingers: Mechanical gripper with sensory feedback capabilities in
the fingers to aid locating the workpart; and to determine correct grip force to
apply(for fragile workparts)
9. Multiple fingered grippers: Mechanical gripper as per the general anatomy of
human hand.
 10. Standard grippers: Mechanical grippers that are commercially available, thus
reducing the need to custom-design a gripper for separate robot applications.

The robot end effecter may also use tools. Tools are used to perform processing operations
on the workpart. Typically the robot uses the tool relative to a stationary or slowly-moving
object. For example, spot welding, arc welding, and spray painting robots use a tool for
processing the respective operation. Tools also can be mounted at robotic manipulator
spindle to carry out machining work such as drilling, routing, grinding, etc.

Q-4) A robot is equipped with a variety of sensors. Comment on this.

Sensor is a device that senses the working conditions of robots and gives the information about the
working environment to the robot.
Sensors are sophisticated devices that are frequently used to detect and respond to electrical or
optical signals. A Sensor converts the physical parameter (for example: temperature, blood
pressure, humidity, speed, etc.) into a signal which can be measured electrically.
Robots use a variety of different electromechanical sensors to explore and understand their
environment and themselves. Emulating a living creature’s senses is currently very difficult, so
researchers and developers have resorted to alternatives to biological senses.
Using a camera, a robot may be able to pick up an image made up of millions of pixels but without
significant programming, it would not know what any of those pixels meant. Distance sensors would
indicate the distance to an object, but would not stop a robot from bumping into it. Researchers and
companies are experimenting with a variety of different approaches to permit a robot to not only
“see” but “understand” what it is looking at. It may be a long time before a robot is able to
differentiate between objects placed before it on a table, especially if they do not appear to be
exactly the same as what is in its database of objects
Types of sensors

1) Internal sensors: Variety of encoders in robot joints used to measure the current position and
velocity of the particular joint or link.

a) Velocity sensors:- Velocity sensors measure by taking consecutive position measurements at

known time intervals and computing time rate change of position
 All position sensors :- no of pulses given by incremental position encoder
 Tachometer:- used for rotation

b) Acceleration sensors:-
c) Force sensors

2) External sensors contact type:-Added to robot to find external environment.limit switch etc
they are NO NC type. These are mechanical type and subjected to mechanical failure:The mean type
between failure is low .Speed of operation is relatively low.

 Contact :-Ability of the robot to determine shape size weight or even surface texture by
touching it. They are situated at gripper of the robot to give the information to robot in the
wrist or the object to be handled. Important in grinding operation in assembly line
  Non-contact:-Information on process or environment of the object without touching it.
These operate in the form of sound waves as in ultrasonic's, light and laser beam technique.

Que-5) Give the classification of robots.

The following is the classification of robots according to the Japanese Industrial Robot
Association ( JIRA):

Class 1: Manual Handling Device:a device with multiple degrees of freedom, actuated by an
operator

Class 2: Fixed Sequence Robot: a device that performs the successive stages of a task according
to a predetermined, unchanging method, which is hard to modify.

Class 3: Variable Sequence Robot: same as in class 2, but easy to modify.

Class 4: Playback Robot: a human operator performs the task manually by leading the robot,
which records the motions for later playback; the robot repeats the same motions according to the
recorded information.

Class 5: Numerical Control Robot: the operator supplies the robot with a movement program
rather than teaching it the task manually.

Class 6: Intelligent Robot: a robot with the means to understand its environment and the ability to
successfully complete a task despite changes in the surrounding conditions under which it is to be
performed.