Robotics and Automation Introduction

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

2 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

3 Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 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

4 Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 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.

5 Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 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 End Effectors Robotic Sensors Robot Programming Robot Applications 6 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

Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 7 Introduction Basic Configuration of Robots 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

Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 8 Introduction Basic Configuration of Robots 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 Example: IBM RS-1 Robot

Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 9 Introduction Basic Configuration of Robots 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  Y = vertical, up and down motions  Z = horizontal, forward and backward motions by rotating the column, robot is capable of achieving approximately Cylindrical work space Y Z

Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 10 Introduction Basic Configuration of Robots 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  Y = vertical, up and down motions  Z = horizontal, forward and backward motions by rotating the column, robot is capable of achieving approximately Cylindrical work space Example: SciClops Benchtop Robot

Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 11 Introduction Basic Configuration of Robots 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. X = horizontal rotation of 360°, left and right motions  Y = vertical rotation of 270°, up and down motions  Z = horizontal, forward and backward motions various joints provide the robot capability to move its arm with in a Spherical work space

Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 12 Introduction Basic Configuration of Robots 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. X = horizontal rotation of 360°, left and right motions  Y = vertical rotation of 270°, up and down motions  Z = horizontal, forward and backward 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

Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 13 Introduction Basic Configuration of Robots 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.

Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 14 Introduction Basic Configuration of Robots 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

Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 15 Introduction Basic Configuration of Robots 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 Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 16 Introduction Basic Configuration of Robots 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

17 Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 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.

18 Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 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

19 Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 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

20 Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 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.

21 Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 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

22 Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 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

23 End Effectors Robotic Sensors Robot Programming Robot Applications Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems 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..

24 End Effectors Robotic Sensors Robot Programming Robot Applications Intelligent control Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems 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

25 End Effectors Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems 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

26 End Effectors Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems Robotic Sensors Robot Programming Robot Applications 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

27 End Effectors Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems Robotic Sensors Robot Programming Robot Applications 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.

28 End Effectors Robotic Sensors Robot Programming Robot Applications Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems 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.

29 End Effectors Robotic Sensors Robot Programming Robot Applications Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems 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

30 End Effectors Robotic Sensors Robot Programming Robot Applications Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems On line teach pendant Manual leadthrough programming Typically performed using one of the following Off line robot programming languages task level programming

31 End Effectors Robotic Sensors Robot Programming Robot Applications Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems 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

32 End Effectors Robotic Sensors Robot Programming Robot Applications Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems 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.

33 End Effectors Robotic Sensors Robot Programming Robot Applications Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems 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.

34 End Effectors Robotic Sensors Robot Programming Robot Applications Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems 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.

35 End Effectors Robotic Sensors Robot Programming Robot Applications Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems 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

36 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 Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications

37 Introduction Basic Configuration of Robots Robot Drive Systems Robot Control Systems End Effectors Robotic Sensors Robot Programming Robot Applications 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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