Robotics and Automation Introduction

Mr. Anand H. D.
1
Department of Electronics & Communication Engineering
Dr. Ambedkar Institute of Technology
Bengaluru-56

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Topics to be covered:
Introduction
Basic Configuration of Robots
Robot Drive Systems
Robot Control Systems
End Effectors
Robotic Sensors
Robot Programming
Robot Applications
Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems
End Effectors Robotic Sensors Robot Programming Robot Applications

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Introduction
Basic Configuration of Robots Robot Drive Systems Robot Control Systems
Automation and Robotics are 2 closely related technologies.
In industrial context, we can define Automation as:
a technology that is concerned with the use of mechanical, electronic and computer-based
systems in the operation and control of production
“
”
Examples of this technology includes transfer lines, mechanized assembly machines,
feedback control systems(applied to industrial processes), numerically controlled machine tools
and robots.
Accordingly, Robotics is a form of industrial automation.
There are 3 broad classes of industrial automation:
Fixed Automation
Programmable Automation
Flexible Automation

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Introduction
Fixed Automation
Programmable Automation
Flexible Automation
is used when volume of production is very high, it is therefore appropriate to design specialized equipment to
process the product very efficiently and at high production rates
a good example is found in automobile industry, where highly integrated transfer lines consisting of several
dozen workstations are used to perform machining operations on engine and transmission components
Unit cost is low relative to other alternative methods of production
if the volume of production turns out to be lower than anticipated then unit cost will be greater than
anticipated
the equipments are specifically designed to produce one product and after that product’s life cycle is finished ,
the equipment is likely to become obsolete.
is used when volume of production is relatively low, and there is variety of products to be made
the production equipment is designed to be adaptable to variations in product configurations
this adaptability is achieved under the control of a ‘Program’ of instructions developed for a particular
product
Unique products can be made economically in small batches
is a relationship of first two types, as function of product variety and production volume
is most suitable for mid-volume production range.
a central computer is used to control the various activities that occur in the system, routing the various parts
to the appropriate stations and controlling the programmed operations at different stations.

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Introduction
The “official“ definition of an industrial robot is provided by the Robotics
Industries Association (RIA), formerly Robotics Institute of America (RIA):
An industrial robot is a reprogrammable, multifunctional manipulator
designed to move materials, parts, tools or special devices through variable
programmed motions for the performance of a variety of tasks
from the above definition we can classify Industrial robots as a form of
Programmable automation
but sometimes they are used in flexible automation and even fixed automation
systems
A production line that performs spot welds on automobile bodies is a typical
example.
The welding line might consists of 2 dozen Robots or more, and is capable of
accomplishing 100s of separate spot welds on two or three different body styles.
The Robot programs are contained in the computer or programmable controller
and are downloaded to each robot for the particular automobile body that is to be
welded at each station.
“
”

Robot Drive Systems Robot Control Systems
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Introduction Basic Configuration of Robots
Cartesian/Gantry Robot
There are 6 types of robot :
Cylindrical Robot
Spherical/Polar Robot
SCARA Robot
Articulated Robot
Parallel Robot
Basic Configurations

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It used for pick and place work, application
of sealant, assembly operation, handling
machine tools and arc welding
Cartesian Robot
Other names include XYZ Robot, Rectilinear
Robot, Gantry Robot
It uses 3 perpendicular Slides to construct X, Y
& Z axes and uses 3 prismatic joints
X =horizontal, left and right motions
 Y = vertical, up and down motions
 Z = horizontal, forward and
backward motions
by moving 3 slides relative one other, robot
is capable of operating with in Rectangular
workspace
XYZ

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It used for pick and place work, application
of sealant, assembly operation, handling
machine tools and arc welding
Cartesian Robot
Other names include XYZ Robot, Rectilinear
Robot, Gantry Robot
It uses 3 perpendicular Slides to construct X, Y
& Z axes and uses 3 prismatic joints
X =horizontal, left and right motions
 Z = horizontal, forward and
backward motions
by moving 3 slides relative one other, robot
is capable of operating with in Rectangular
workspace
Example: IBM RS-1 Robot

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It used for assembly operations, handling at
machine tools, spot welding and handling at
die-casting machines
Cylindrical Robot
It uses a vertical column and a slide that can be
moved up and down along the column, the
robot arm is attached to slide so that it can
move radially w.r.t. column
X = horizontal rotation of 360°, left and right
motions
 Z = horizontal, forward and backward
motions
by rotating the column, robot is capable of
achieving approximately Cylindrical work
space
Y Z

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It used for assembly operations, handling at
machine tools, spot welding and handling at
die-casting machines
Cylindrical Robot
It uses a vertical column and a slide that can be
moved up and down along the column, the
robot arm is attached to slide so that it can
move radially w.r.t. column
motions
motions
by rotating the column, robot is capable of
achieving approximately Cylindrical work
space
Example: SciClops Benchtop Robot

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It is used for handling at machine tools, spot
welding, diecasting, fettling machines, gas
welding and arc welding.
Spherical/Polar Robot
It uses a telescopic arm that can be raised or
lowered about the horizontal pivot
Pivot is mounted on a rotating base
Robot axes form a polar coordinate system.
motions
 Y = vertical rotation of 270°, up and down
motions
motions
various joints provide the robot capability to
move its arm with in a Spherical work space

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It is used for handling at machine tools, spot
welding, diecasting, fettling machines, gas
welding and arc welding.
Spherical/Polar Robot
It uses a telescopic arm that can be raised or
lowered about the horizontal pivot
Pivot is mounted on a rotating base
Robot axes form a polar coordinate system.
motions
 Y = vertical rotation of 270°, up and down
motions
motions
various joints provide the robot capability to
move its arm with in almost Spherical work
space
Example: Unimate 2000 series
https://youtu.be/hxsWeVtb-JQ

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It is used for Automated part handling and part
picking processes, loading, Inspection, In-Mold
Labeling (IML) and In-Mold Decorating (IMD),
packaging and palletizing, stacking and sorting
Articulated/Jointed Arm Robot
are designed to have a few joint structures/axes
ranging from two to as many as ten structures.
various joints provide the robot capability to move
its arm with in a Spherical work space
Usually, these robots have four to six axes, and are
well-known for having the most DOF, compared to
any other robot type in the industrial field.
also called as anthropomorphic as its anatomy
resembles human arm
All the links will be connected through a rotatory
joints and a wrist will be attached at the end.

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It is used for Automated part handling and part
picking processes, loading, Inspection, In-Mold
Labeling (IML) and In-Mold Decorating (IMD),
packaging and palletizing, stacking and sorting
Articulated/Jointed Arm Robot
are designed to have a few joint structures/axes
ranging from two to as many as ten structures.
various joints provide the robot capability to move
its arm with in a Spherical work space
Usually, these robots have four to six axes, and are
well-known for having the most DOF, compared to
any other robot type in the industrial field.
also called as anthropomorphic as its anatomy
resembles human arm
All the links will be connected through a rotatory
joints and a wrist will be attached at the end.
Example: KUKA indudtrial Robot
https://youtu.be/DiuFkMkReSs

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It is used for pick and place work, application of
sealant, assembly operations and handling machine
tools
SCARA Robots
Selective Compliance Assembly Robot ARM
Usually, this robot has 2 parallel rotary joints to
provide compliance in a plane
Example: THE 400 SCARA Robot
https://youtu.be/97KX-j8Onu0

Example: Fanuc F-200iB
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It is used for mobile platform handling cockpit
flight simulators, automobile simulators, assembly
of PCBs
Parallel Robot
is a mechanical system that utilized multiple
computer-controlled limbs to support one common
platform or end effector. Comparing to a serial robot,
a PR generally has higher precision and dynamic
performance and, therefore, can be applied to many
applications.
also called as Delta Robots and parallel kinematic
machine, when used as machine tool
It's a robot whose arms have concurrent prismatic or
rotary joints.
https://youtu.be/3fbmguBgVPA

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Introduction Basic Configuration of Robots Robot Drive Systems
The drive is the engine that moves the articulations into their designated positions.
They are also called as Actuators
There are basically three types of power sources for robot:
Hydraulic Drive/Actuator
Electric Drive/Actuator
Pneumatic Drive/Actuator
Actuators play vital role while implementing control. Controller provides control
signal to actuator for actuation.
Actuators are the muscles of Robots. There are many types of actuators available
depending upon the load involved .
Load is associated with many factors like force, torque, speed of operation,
accuracy , precision and power consumption.

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Mainly rotating but linear ones are also available
Electric Drive/Actuator:
Types: Servo-motors, DC-motors, brushless DC motors, asynchronous motors,
synchronous motors, reluctance motors, stepper motors.
Can generate high torque/force which allows high acceleration, high zero speed
torque, high Bandwidth of operation, robustness
Most of the robotic applications involves servo-motors
provides a robot with less speed and strength.
Slower movement compare to the hydraulic robots
Good for small and medium size robots
Better positioning accuracy and repeatability
Cleaner environment

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Generally associated with larger robots, provides robot greater speed
and strength
Hydraulic Drive/Actuator:
actuators Noted for their high power and lift capacity
Provide fast movements
Preferred for moving heavy part
Preferred to be used in expressive environments
Occupy large space area
There is a danger of oil leak
It can actuate both rotatory and linear joints. Uses hydraulic pistons for
linear motion and rotary vane for rotatory motion

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Similar to hydraulic actuators except powered from compressed air.
Pneumatic Drive/Actuator:
Can be readily adapted to actuation of piston device to provide translational
movement.
Suitable for Fast ON/OFF tasks
Preferred for smaller robots
Less expensive than electric or hydraulic robots
Suitable for relatively less degrees of freedom design
Suitable for simple pick and place application
Can be used to operate rotatory actuation for rotational joints.

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1. Limited sequence control
2. Playback with point-to-point control
3. Playback with continuous path control
4. Intelligent control
Controls the operation of robot by means of controlling its drive system.
Commercially available industrial robots can be classified into four categories:
Limited sequence control
 doesn’t use servo-control to indicate relative position of robot joints, instead
use limit switches and/or mechanical stops to set end position of each joint.
Used for pick-and-place operations.
These robots do not require any sort of programming, and just uses the
manipulator to perform the operation.
 every joint can only travel to the intense limits
Lowest level
Most sophisticated

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Playback Robots with Point to Point Control:
They can be programmed (taught) to move from a point within the
work envelope to another point within the work envelope.
Capable of performing motion cycles that consists of a series of
desired point locations related actions.
The robot is thought each point and these points are recorded into
robot’s control unit.
Point to point robots do not control the path taken by the robot to get
from one point to other.
Application: machine loading and unloading applications as well as
more-complex applications, such as spot welding and assembly

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Playback Robots with Continuous Path Control
This type of robots can control the path, and can end on any specified position.
These robots commonly move in the straight line. The initial and final
point is first described by the programmer.
it can also move in a curved path by moving its arm at the desired points.
Applications are arc welding, spray painting, and gluing operations.
The individual points are defined by control unit rather than the programmer.
Typically uses digital computer as controller.
To achieve continuous-path control to more than a limited extent requires that
the controller unit be capable of storing a large number of individual point
locations that define the compound curve path..

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Intelligent control
The intelligent control robot is capable of performing some of the functions and
tasks carried out by human beings.
It can interact with its environment by means of sensory perception.
Controller unit consists of a digital computer or similar device.
They are capable of altering their programmed cycle in response to conditions
that occur in workplace.
They are usually programmed using high level languages to accomplish the
complex and sophisticated activities.
Typical applications are assembly task, space application, under sea, nuclear
applications, defense applications etc.
It is equipped with a variety of sensors providing visual (computer vision) and
tactile (touching) capabilities to respond instantly to variable situations

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End Effectors
Robotic Sensors Robot Programming Robot Applications
Basic capabilities of robot can be augmented using End Effectors
Connected to the robot wrist.
End effectors can be either grippers or tools
End effectors are custom engineered for the particular task which is to
be performed.
Can be engineered by the company installing the robot or commercially
available from a third party firm
Some robots can change end-effectors and be programmed for a
different task.
 If robot has more than one arm, there can be more than one end-
effector on the same robot

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End Effectors
Grippers are used to grasp an object, usually the workpart and hold it during the robot work
cycle
Based on holding method. Grippers can be classified as:
Mechanical Grippers
Vacuum Cups
Magnetic Grippers
Adhesive Grippers
Hooks, scoops and others

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End Effectors
Tools are used when robot needs to perform some operation on the workpart
during the robot work cycle
Tools used as end effectors in robot application includes:
Spot-welding tools, Arc-welding tools, spray painting nozzle, rotating spindle (for
drilling, routing, wire brushing, grinding), heating torches, water jet cutting tool
etc…
With the recent needs for holding micro and nano size parts several new devices
have been developed using smart actuators, PZT and ionic polymers etc.
Tools can be directly attached to robot wrist or it can be grasped by the gripper
Use of gripper to grasp tool facilitates multi tool handling function.

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Vision sensors can be used to locate workpart for manipulation, measure their
dimensions, direct intrusions into workcell etc.
Sensors allow the robot to receive feedback about its environment.
The sensor collects information and sends it to the robot controlled.
Sensors used in robotics can be classified into external sensors and internal
sensors
External sensors are used for interacting with the environment
Internal sensors are required to close the loop for feedback control.
External sensors : vision, force, torque, touch, proximity etc.
Internal sensors : position, velocity, acceleration
Sensors are required not only for working of robot and interaction with the
environment but also for safety and workcell control and monitoring.
Among all the external sensors, vision is more versatile and can be used for
several applications.

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Type of Robot Programming
Joint level programming
 basic actions are positions (and possibly movements)
joint angles in the case of rotational joints .
linear positions in the case of linear or prismatic joints.
Robot-level programming
the basic actions are positions and orientations (and perhaps
trajectories) and the frame of reference attached to it
High-level programming
Object-level programming
Task-level programming

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On line
teach pendant
Manual leadthrough programming
Typically performed using one of the following
Off line
robot programming languages
task level programming

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Online teach pendant programming
hand held device with switches used to control the robot motions
End points are recorded in controller memory
sequentially played back to execute robot actions
trajectory determined by robot controller
suited for point to point control applications
Lead Through Programming
Programmer lead the robot physically through the required sequence of motions
If the robot is large, a special programming apparatus is often substituted for the actual robot. It
has same geometry as the robot, but easier to manipulate during programming
Motion cycle is divided into 100s or even 1000s of individual closely spaced points along the path
and these points are recorded in the controller memory.
https://youtu.be/EA6pWwNI_wg

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Advantage:
Easy to program
No special programming skills or training
Can specify other conditions on robot movements (type of trajectory to use – line, arc)
Disadvantages:
Potential dangerous (motors are on)
The robot cannot be used in production while it is being programmed
Not readily compatible with modern Computer Based Technologies as CAD/CAM, data
communication networking & integrated manufacturing information system.
The control systems for both leadthrough procedures operate in either of two modes:
Teach mode or Run mode
Teach mode is used to program the Robot and Run mode is used to execute the program.

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Off-line Programming
Programs can be developed without any need to use the robot
The sequence of operations and robot movements can be optimized or easily
improved
Previously developed and tested procedures and subroutines can be used
Existing CAD data can be incorporated-the dimensions of parts and the geometric
relationships between them
Programs can be tested and evaluated using simulation techniques, though this can
never remove the need to do final testing of the program using the real robot
Programs can more easily be maintained and modified
Programs can more be easily properly documented and commented.

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Robot Programming Languages:
Textual robot programming languages possess a variety of structures and capabilities. These are still
evolving
First Generation Languages
Combination of command statements and teach pendent procedure.
Second Generation Languages
Called as structured programming languages because they possess structured control structures
used in computer programming languages.
AML, RAIL, MCL and VAL II are commercially available second generation programming languages.
Developed largely to implement motion control with textual programming-motion level language.
The VAL language is example
Inability to specify complex arithmetic computations, inability to use complex sensors and
sensors data , limited capacity to communicate with other computers.
Also, these languages cannot be readily extended for future enhancements.
Provides advanced sensor capabilities, supports limited intelligence, can interact greatly with
other computer based systems, provides extensibility.

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1.Agriculture
2.Automobile
3.Construction
4.Entertainment
5.Health care: hospitals, patient-care, surgery , research, etc.
6.Law enforcement: surveillance, patrol, etc.
7.Manufacturing
8.Military: demining, surveillance, attack, etc.
9.Mining, excavation, and exploration
10.Transportation: air, ground, rail, space, etc.
11.Material handling
12.Material transfer
13.Machine loading/ unloading
14.Spot welding
15.Continuous arc welding
16.Spray painting
17.Assembly
18.Inspection
19.Laboratories: science, engineering , etc.
Robots in Industries: https://youtu.be/lR7c2rEFOH0

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Reference
•Introduction to Robotics : J. Craig , Pearson
•Industrial Robotics : M. P. Groover, Mitchel Weises, Roger N
Negal, Nicholas G Ordey, Ashish Dutta , McGraw Hill
•Internet Sources

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Multi finger Gripper: https://youtu.be/T6FPwX8gvFI
6-axis industrial robot: https://youtu.be/7coUcEHxnYA
Programming using teach pendent: https://youtu.be/303LHXET0W4
Medical Robots: https://youtu.be/zCt4PGLsb9M
Robots in Space applications: https://youtu.be/r7CW92i0z_o
Robots in medical field: https://youtu.be/G2N62DVRlSU
Robots in military: https://youtu.be/yliThCy3RxY
Robots in agriculture: https://www.youtube.com/watch?v=Xr4aBFUzLmw

Prof. Anand H. D.
M. Tech. (PhD.)
Assistant Professor,
Department of Electronics & Communication Engineering
Dr. Ambedkar Institute of Technology, Bengaluru-56
Email: anandhdece@dr-ait.org
Phone: 9844518832

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