This document discusses mechatronics and various types of robots. It begins by defining mechatronics and key elements of mechatronic systems. It then discusses 7 broad areas where robots are often used: dangerous environments, industrial, entertainment/leisure, space, research, underwater, and medical. For each area, examples of specific robot applications are provided. The document also discusses different types of industrial robots, entertainment robots, space robots, research robots, underwater robots, and medical robots. It covers similarities and differences between remote control devices, telerobots, and autonomous robots. Finally, it discusses automation and different types of automated manufacturing systems.

1. Module -4
Introduction to Mechatronics

6. Key Elements in Mechatronic System

14. What are the 7 broad areas often Using Robots?
1. Dangerous environment
2. Industrial
3. Entertainment and Leisure
4. Space
5. Research
6. Underwater
7. Medical

15. Dangerous Environments
• Carrying out bomb disposal
• Collecting data from volcanoes
• Exploring
• Military
• Rescue

16. Dangerous Environments
▪Predator flown via remote control by airmen
on the ground flies up to 25,000 feet.
▪Used to conduct reconnaissance and attack
operations; takes real-time photos of troop
movements on ground.
Soldier Rescue
Air Force Predator
(Aerial Vehicle)
Designed for Firefighter Rescue
▪ Uses its arms to identify and pick up people who
might have passed out from smoke and fumes.

17. Industrial Robots
• A typical industrial robot is a robot arm
with several independent joints and you
will see them welding, painting and
handling heavy materials..
▪ ‘Pick and place’ robots can move
products from a conveyor belt to
package them at very quick speeds.

18. Industrial Robots
• An AGV is a mobile robot that
follows markers or wires in the
floor, or uses vision or lasers.
An example of a mobile robot that is in common use today
is the automated guided vehicle (AGV)

19. Industrial Robots
Robots are very useful in
food processing since it
needs to be done in a
germ-free environment.
Robotic Paint
Sprayer
Used for stacking
products on pallets
for shipping and
storage.

20. Entertainment & Leisure Robots

21. Space Robots
• NASA is constantly developing
and producing robots which can
perform maintenance in space –
especially on its International
Space Station.
▪ 2003 Rover landing
on Mars

22. Space Robots
• R2 is able to use the same
tools station crew members
use.
• In the future, the greatest
benefits of humanoid robots in
space may be as assistants or
stand-in for astronauts during
spacewalks or for tasks too
difficult or dangerous for
humans.
Humanoid robot joined crew of International Space Station

23. Research Robots
• One important area of robotics research is to
enable the robot to cope with its environment
• Honda is the company that is spending a great
deal of money developing research robots,
such as the Asimo show on left.
• ASIMO moves like we do and could be useful to
help the elderly or people in wheelchairs. It
can answer the door, pick up the phone or get
a cup of tea.

24. Underwater Robots
• Underwater robots are often
remote controlled vehicles with
thrusters for maneuvering and
robot arms for grabbing.
• They are particularly useful in
the oil industry for welding and
valve maintenance on oilrigs.
• Robotuna used for exploration

25. Medical Robots
• In laboratories, used
too transport
biological or chemical
samples between
instruments.
▪ Used in minimal invasive surgical
procedures that reduce trauma in
surgery
▪ Prosthetics.

26. Future Medical Robots
Scientists believe that tiny robots (called “nanorobots”) will
be developed which will be used in patients’ bloodstreams
to cure illness.

27. Similarities and Differences
Remote-Control
Devices
Telerobots Autonomous robots
Physical link between
controller and object
being controlled
No physical connection to
the remotely operated
system (i.e. WiFI). Requires
remote sensory feedback
Makes decisions based on
programming and sensory
feedback. Controlled by an
internal computer.
Human operator is
controlling the device
without physically
touching it
Human operator is
controlling the device
without physically touching
it
Work for an extended period
without human intervention
Short Distance Any Distance Any Distance
Requires remote camera or
interactive component to
sense what is happening
on the remote end of the
system
Gains information and about the
surrounding environment and
adapt to changes.

28. Methods To Move
Other than by tracks & wheels
Flying Robots
• Swimming Robots
Walking Robots Climbing Robots
Adhesive
bond
Electrostatic bond

29. Assembly & Dispensing
Assembling small parts into larger units is a crucial part of the manufacturing
process. Previously, g human dexterity, vision, and intelligence was the only way such
assembly could be done. Recent advancements in technology have now made it possible
for robots to do many of these tasks. Since many assembly processes require adhesives,
robots that can dispense bonding agents are a related technology.

30. Handling & Picking
Robots that transport goods within a warehouse, or that pick
items out of a tote and place them into a shipping container,
are examples of handling and picking robots. With the rise of e-
commerce, there is a large and growing demand for robots that
can pick and fulfill orders.
❑ Material Handling Robots
❑ Liquid Handling Robots
❑ Pick and Place Robots
❑ Order Picking Robots

31. Machining and Cutting
In a manufacturing or machine tool shop environment, there
are many operations that are repetitive and can be automated
using robots.
❑ Machine Tending and Loading Robots
❑ Milling Robots
❑ Drilling Robots
❑ Laser Cutting Robots
❑ Plasma Cutting Robots
❑ Waterjet Cutting Robots

32. Welding & Soldering
Arc Welding Robots
Arc welding joins metal pieces
together by using electricity to heat the metals
to their melting point. When the melted metals
cool, they are permanently joined, and the joint
is airtight. Arc welding is flexible, allowing for
flat sheets, tubes, and rods to be joined
together, and the weld can be located anywhere
along the surface of the workpiece. Many arc
welding tasks can be automated using robotics,
and robotic arc welding has been growing
rapidly.

33. Welding & Soldering
Spot Welding Robots
Spot welding joins relatively thin steel objects together using electrodes that clamp the metals together and pass
electricity through the workpieces. Robotic spot welding is commonly used in the automotive industry and results in greatly
increased production speed and higher repeatability and quality than manual welding.
MIG Welding Robots
MIG (Metal Inert Gas) welding involves three elements: heat produced by electricity, an electrode that fills the
joining area, and inert gas to temporarily shield the weld from the air. The process of MIG welding can be automated using
robotics. Robotic MIG welding results in higher productivity and lower costs, as well as improved worker safety.
Laser Welding Robots
Laser welding uses a laser beam to join workpieces together. Unlike arc welding, which uses a filler to join two
pieces of metal together, a laser weld creates a direct metal-to-metal bond. Laser welding results in a bond that is much
cleaner than conventional arc welding.
Soldering Robots
Soldering is a process in which items are joined together by putting a melted filler material (solder) into the
joint. The filler material has a lower melting temperature than the workpieces. Unlike welding, soldering does not involve
melting the pieces to be joined. Some additional kinds of robots that fall into the category of Welding & Soldering include
Brazing robots, electrical resistance welding robots, and solid-state welding robots, as well as robots that join items by using
diffusion, friction, magnetic pulse, electron beam, and infrared welding techniques.

34. Casting & Mouldings
❑ Die Casting Robots
❑ Injection Molding Robots
❑ Finishing and Sanding
❑ Deburring Robots
❑ Grinding Robots
❑ Polishing Robots
Casting is the process of forming metallic objects
by injecting liquid metal into a die or cavity shaped
in the form of the object to be made. Molding is
similar to casting, except the material used is
generally plastic, although other types of materials
can be used. Molding is typically faster than
casting.

35. Painting & Coating
Industrial painting and coating are the processes of applying
paint or other coatings to a workpiece. In manufacturing, the
part to be painted or coated is well-defined in shape and size,
so the painting and coating operations are highly repetitive.
As a result, painting and coating operations are well-suited for
robotic automation. The results are consistent, high-quality,
and the machines can work continuously with no breaks and
downtime except for periodic maintenance. By using robotics,
workers are not exposed to harmful fumes or overspray, and
safety is improved.
❑ Painting Robots
❑ Spray Painting Robots
❑ Coating Robots

36. Cleaning & Hygiene
Maintaining clean industrial facilities is important for product
quality and for the safety and hygiene of the people who work
there. The process of cleaning is often repetitive and not very
interesting. Consequently, robots are being increasingly used
for cleaning applications.
❑ Cleaning Robots
❑ Disinfection Robots
❑ Industrial Robot Vacuums

37. Logistics & Storage
Warehouse Robots
Robots that operate in a warehouse or
distribution center can be used to automate a wide variety of
tasks, including order picking, packing, sorting, labeling, and
transporting. Automated Guided Vehicles (AGVs) and
Autonomous Mobile Robots (AMRs) are among the fastest-
growing categories of robots for the transportation of goods
within the warehouse or distribution center.
Delivery Robots
Delivery robots are commercially available in
various shapes and sizes and for different functions. Some delivery
robots are designed to deliver food in a city environment and look like
carts with wheels. Other delivery robots look like humans because they
walk on two legs and have arms, and the head is replaced with a dome
full of sensors. Unmanned aerial vehicle (UAV) delivery robots can fly
packages to the customer and drop them off. And there are four-
legged delivery robots that look a little bit like dogs. Self-driving
vehicles are in limited use in certain areas deployed as delivery
robots. In all cases, the advantages of delivery robots are many,
including speed of delivery, lower labor costs, and reliability.

38. Packing & Palletizing
Packing and palletizing are two operations common to manufacturing, warehouses, and distribution centers. As the trend
toward smaller packages continues, the repetitive nature of the packaging and palletizing operations increases. This can
negatively impact the health and safety of workers. Implementing robotics for these tasks increases productivity and helps to
protect operatives from work-related injuries.
Packaging Robots
Packing food orders is an area of rapid growth, and robots are
increasingly capable of gently handling even produce and
perishable items. Packaging robots can create multiple sizes of
boxes automatically according to need.
Palletizing Robots
Palletizing robots can stack boxes and containers onto a pallet
optimally. If there are various items in the boxes, artificial
intelligence can be used so that the heavier containers are placed on
the bottom. The boxes can be oriented in such a way as to maximize
the number of boxes that will fit onto the pallet.
Shrinkwrapping the entire pallet with plastic to stabilize it for
transportation can also be automated with palletizing robots.

39. Inspection & Quality Control
Some quality control issues are life-and-death, because a failed or incorrectly installed part can cause a
life-threatening situation. Human inspection is often only 80% accurate. Robotic inspection can be 100% accurate.
Vision Robots
Combined with a six-axis robotic arm in a factory
environment, a camera can be positioned to see parts from
any desired angle. The existence of cracks, the
measurement of dimensions, and the uniformity of coating
are only a few properties that can be inspected using vision
robots.
There are inspection robots that can travel down a pipeline
for the oil and gas industry and underwater robots for
inspecting oil rigs and salvage operations. There are aerial
drones for inspecting rooftops and other high places.
Some inspection robots do not use vision. These robots
might use a special End of Arm Tooling (EoAT) to measure
dimensions or electrical resistance, to name but a few of
the many possibilities.

40. Harvesting Robots
Timely harvesting of fruits and vegetables is critical to ensure a high-quality product reaches the customer and to reduce
spoilage and waste. Harvesting of grains and other crops is also time-sensitive and labor-intensive.
Harvesting robots are equipped with special soft grippers that enable them to handle fragile crops without damage. Special
vision systems are used to determine if a particular piece is ripe or not. Harvesting robots can relieve people from back-
breaking, often hot, and uncomfortable labor. The robots increase the efficiency of the process and reduce labor costs. Read
more about agricultural robots.

41. Similarities and Differences
Remote-Control
Devices
Telerobots Autonomous robots
Physical link between
controller and object
being controlled
No physical connection to
the remotely operated
system (i.e. WiFI). Requires
remote sensory feedback
Makes decisions based on
programming and sensory
feedback. Controlled by an
internal computer.
Human operator is
controlling the device
without physically
touching it
Human operator is
controlling the device
without physically touching
it
Work for an extended period
without human intervention
Short Distance Any Distance Any Distance
Requires remote camera or
interactive component to
sense what is happening
on the remote end of the
system
Gains information and about the
surrounding environment and
adapt to changes.

42. Robot - Flexible Automation
Advanced manufacturing and assembly of discrete products require flexible automation technologies to
enable higher production efficiencies and improved final product quality. This is especially true in
manufacturing of products characterized by high product mix and variable production volumes. While
industrial robots enable tremendous flexibility in manufacturing and assembly, they lack the accuracy
required for precision manufacturing and assembly tasks.
Flexible automation for advanced manufacturing research is focused on the following aspects:
•Accurate industrial robotics for automation of precision manufacturing processes with a focus on external
sensing and feedback control methods for robot trajectory error compensation
•Use of data-driven methods for modeling various aspects of industrial robot behavior
•Robotic manufacturing capability that integrates additive, subtractive, and other processes into a hybrid
flexible manufacturing system
•Robotics for biomanufacturing applications

43.  To automate a process, power is required, both to drive
the process itself and to operate the program and
control system.
 Automated processes can be controlled by human
operators, by computers, or by a combination of the
two.
43
Industrial Automation

44. 44

45. 45
Automated Assembly lines

46. • Automation is a technique that can be used to reduce
costs and/or to improve quality. Automation can increase
manufacturing speed, while reducing cost. Automation
can lead to products having consistent quality, perhaps
even consistently good quality.
OR
• Automation is a technology concerned with application
of mechanical, electronic and computer-based system to
operate and control system. This technology includes;
46
Automation defined.

47. • Automatic assembly machines
• Automation machine tools to process parts
• Industrial robots
• Automatic materials handling and storage
system
• Automatic inspection system and quality
control
• Feedback control and computer process
control
• Computer system for planning, data
collection and decision making to support
manufacturing activities
47

48. • If a human operator is available to monitor
and control a manufacturing process, open
loop control may be acceptable.
• If a manufacturing process is automated, then
it requires closed loop control, also known
as feedback control.
• example of open loop control and closed loop
control.
48

49. • Hard Automation
• Controllers were built for specific purposes and
could not be altered easily.
• Early analog process controllers had to be rewired
to be reprogrammed.
49
TYPE OF AUTOMATION
◦ This controllers do what they are designed and built to do,
quickly and precisely perhaps, but with little adaptability for
change (beyond minor adjustments).
◦ Modification of hard automation is time-consuming and
expensive, since modifications can only be performed while
the equipment sits idle.

50. • Soft Automation
• Modern digital computers are reprogrammable.
• It is even possible to reprogram them and test the
changes while they work.
• Even if hardware changes are required to a soft
automation system, the lost time during changeover
is less than for hard automation
50

51. • Automated Mfg. System can be classified into three basic
types:
Fixed Automation
• A system which the sequence of processing (or
assembly) operations is fixed by the equipment
configurations.
• Each operations in the sequence is usually simple.
51
AUTOMATED MFG. SYSTEM

52. • The features of fixed automation;
• High initial investment for custom-engineered
equipment
• High production rates
• Relatively inflexible in accommodating product
variety.
• Examples, machining transfer lines and automated
assembly machines.
52
Fixed Automation

53. • Programmable Automation
• The production equipment is designed with the
capability to change the sequence of operations to
accommodate different product configurations.
• The operation sequence is controlled by a program,
which is a set of instruction coded so that they can be
read and interpreted by the system.
53
Programmable Automation

54. • New programs can be prepared and entered into
the equipment to produce new products.
• The physical setup of the machine must be
changed for each new products.
• This changeover procedures takes time.
• Eg: numerical control (NC) machine tools,
industrial robots and PLC.
54

55. • The features of programmable automation;
• High investment in general purpose equipment.
• Lower production rates than fixed automation.
• Flexibility to deal with variations and changes in
product configuration.
• Most suitable for batch production.
55
Programmable Automation Features

56. • Flexible Automation
• An extension of programmable automation.
• Capable of producing a variety of parts/products with
virtually no time lost for changeovers from one part
style to the next.
56
Flexible Automation

57. • The features of flexible automation;
• High investment for custom-engineered system.
• Continuous production of variable mixtures of
products.
• Medium production rates.
• Flexibility to deal with product design variations.
57
Flexible Automation Features

58. Examples, flexible manufacturing systems for performing
machining operations.
The relative positions of the three types of automation for
different production volume and product varieties are shown
below.
58
Relationship between
product variety & quantity
100 10000 1,000,000
Product
Variety
Production Quantity
LOW
MEDIUM
HIGH

59. 59
Relationship of fixed, programmable and flexible
automation