VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana sangam, Belagavi-59018, Karnataka, India

ASSIGNMENT OF
“ROBOTICS AND AUTOMATION”
submitted in partial fulfilment of the requirements for the award of the degree
BACHELOR OFINENGINEERING
MECHANICAL ENGINEERING
Submitted by
AKASH Y V 1AY23ME005
Under the guidance of
Prof. Akshay Simha

DEPARTMENT OF MECHANICAL ENGINEERING

ACHARYA INSTITUE OF TECHNOLOGY, BENGALURU– 560107
2024-2045
 MODULE 1
1.) Define Automation?
Automation in the context of robotics and automation refers to the use of technology
to perform tasks with minimal human intervention. Specifically:
Automation (in Robotics and Automation):
Automation is the process of designing and using control systems, such as
computers, robots, or software, to operate machinery, handle processes, or perform
tasks that were traditionally carried out by humans. It aims to improve efficiency,
accuracy, consistency, and productivity.
Key Features:
Minimizes human input
Uses sensors, actuators, and control systems
Can be programmed for repetitive or complex tasks
Enhances safety and quality in industrial environments
In Robotics:
In robotics, automation is integrated with robotic systems to perform specific
functions—such as welding, assembling, or material handling—autonomously or semi
-autonomously.
Example:
An industrial robot arm assembling car parts on a production line without human help
is an example of automation in robotics.
Let me know if you'd like a diagram or breakdown of different types of automation
(like fixed vs. flexible automation).
2.) Explain different types of automation?
There are three main types of automation used in robotics and industrial systems,
each suited to different kinds of tasks and production environments:
1. Fixed Automation (Hard Automation)
Definition:
A highly specialized system designed to perform a specific task or set of
operations repeatedly, with little to no flexibility.
Characteristics:
High initial cost
High production rate
Low flexibility
Ideal for mass production
Examples:
Car assembly lines
Bottle filling systems
Conveyor-belt packaging systems
2. Programmable Automation
Definition:
A type of automation where equipment can be reprogrammed to handle different
tasks or product types. It's used for batch production.
Characteristics:
Moderate flexibility
Medium production volume
High changeover time between batches
Suitable for customizable products
Examples:
CNC machines
Industrial robots used for multiple products
Automated textile machinery
3. Flexible Automation (Soft Automation)
Definition:
A system that is capable of easily switching between tasks or product types with
minimal reprogramming or setup.
Characteristics:
High flexibility
Quick changeover
Moderate to high production volume
Suitable for varied or customized production
Examples:
Multi-purpose robotic arms
Automated Guided Vehicles (AGVs)
Flexible manufacturing systems (FMS)
Summary Table:
Type Flexibility Volume Changeover
Time Example Use Case
Fixed Automation Low High Long Car assembly line
Programmable Medium Medium Moderate CNC machining of custom parts
Flexible High Medium- Short Robotic systems in electronics
Automation High industry

3.) Define an Industrial Robot.

Definition of an Industrial Robot:
An industrial robot is a programmable, mechanical device used in manufacturing
and production environments to perform repetitive, dangerous, or precise tasks
with high speed, accuracy, and efficiency.
Key Characteristics:
Programmable: Can be configured to carry out a variety of tasks.
Multifunctional: Capable of handling different operations (e.g., welding, painting,
assembly).
Automatic: Operates without continuous human intervention.
Reprogrammable: Easily adjusted for new tasks or production changes.
Manipulative: Often includes a robotic arm with joints and end-effectors (tools) to
interact with the environment.
Typical Applications:
Welding
Material handling
Assembly
Painting
Quality inspection
Packaging and palletizing
Example:
A robotic arm on an automotive assembly line that welds car body panels together
is a typical example of an industrial robot.
4.) Explain the different types of industrial robot configurations (+sketch).
 A Cartesian robot is a type of industrial robot whose arm moves in straight lines
along the three principal axes: X, Y, and Z. It uses linear actuators for each
movement and is often used in applications requiring high precision and
repeatability.
🔧 Structure and Motion:
Axes: Linear motion along X, Y, and Z axes
Shape of Work Area: Rectangular or cubic
Joints Used: Prismatic (sliding) joints only
Orientation: Fixed, unless combined with an external rotary axis

🛠Applications:
Pick-and-place operations
3D printing
CNC machining
Automated drawing, cutting, or inspection
Palletizing and packaging
Cylindrical robot:

A Cylindrical Robot is an industrial robot with a cylindrical-shaped workspace. It moves

using a combination of rotary and linear motions — rotating around a vertical axis,
moving vertically (up and down), and extending/retracting horizontally. It is commonly
used in assembly, material handling, and spot welding.
🔧 Structure and Motion:
Rotational motion around the base (θ-axis)
Linear motion vertically (Z-axis)
Linear motion radially outward/inward (R-axis)
🛠Applications:
Assembly lines
Spot welding
Handling machine tools
Packaging and pick-and-place tasks
Plastic injection molding part removal
SCARA ROBOT:
 A SCARA robot is a type of industrial robot designed primarily for high-speed,
precise assembly and pick-and-place tasks. It features two parallel rotary joints
to provide movement in a horizontal plane, along with a vertical motion (Z-axis)
for insertion tasks like fitting or pressing.

Structure and Motion:

Two rotational joints (for X-Y plane motion)
One vertical linear joint (for Z-axis motion)
The robot has "selective compliance"—it is flexible in the X-Y plane but rigid along
the Z-axis, making it ideal for tasks like inserting components.
🛠Applications:
Electronics assembly
Pick-and-place operations
Screw driving and small part insertion
Packaging and sorting
3D printing (in some designs)
ARTICULATED ROBOT
An articulated robot is a type of industrial robot that features rotary joints (also known as
revolute joints) to allow movement in multiple directions, similar to a human arm. These
robots typically have 4 to 6 axes, providing high flexibility and a wide range of motion.

🔧 Structure and Motion:

Composed of a base, shoulder, elbow, wrist, and end-effector
Each joint offers rotational movement
6-axis robots can position a tool in 3D space with full orientation control (pitch,
yaw, roll)
⚙ Main Components:

1. Base – stationary foundation

2. Shoulder joint – first rotational axis
3. Elbow joint – allows middle arm rotation
4. Wrist joint – controls end-effector orientation
5. End-effector – tool (e.g., gripper, welder, etc.)
6. Motors and sensors – drive and control each axis
🛠Applications:
Welding (arc welding, spot welding)
Material handling
Assembly
Painting and coating
Machine loading/unloading
 Inspection and testing

DELTA ROBOT

Also known as Parallel Robot or Spider Robot)

A Delta robot is a type of high-speed industrial robot with three arms connected
to a common base, arranged in a triangular or spider-like configuration. The end-
effector is suspended below the arms and moves rapidly in 3D space, making
delta robots ideal for fast, precise, lightweight pick-and-place tasks.
🔧 Structure and Motion:
Consists of three arms (usually with parallelogram linkages)
The arms move in coordination to position the end-effector in X, Y, and Z
directions
Some models have a rotational (4th) axis for orientation control
The motors are fixed at the base, making the moving parts very light

⚙ Main Components:
1. Fixed triangular base
2. Three robotic arms (often carbon fiber for speed)
3. Parallel linkages for synchronized movement
4. End-effector (suction cup, gripper, etc.)
5. Control system for coordinated motion
🛠Applications:
High-speed pick-and-place (up to hundreds per minute)
Sorting and packaging in food, pharmaceuticals, and electronics
3D printing (delta-style printers)
Lightweight assembly operations

5.) List and explain ten Major Challenges (Disadvantages) of robotics in industries.
1. High Initial Cost
Explanation: The purchase price of industrial robots, including installation, setup,
and training, can be quite expensive. The initial investment often makes it difficult
for small and medium-sized businesses to adopt robotics, even though the long-
term benefits might justify the cost.
Example: High upfront costs for robotic arms, sensors, and control systems,
which can run into hundreds of thousands of dollars for large-scale production
setups.
2. Maintenance and Downtime
Explanation: Robots require regular maintenance to ensure they perform
optimally. This includes hardware repairs, software updates, and calibration. Any
breakdown or malfunction can lead to costly downtime that affects the entire
production line.
Example: If a robot arm fails during an assembly line process, the entire line could
stop, causing delays and financial losses.
3. Lack of Flexibility for Complex Tasks
Explanation: While robots excel at repetitive tasks, they often struggle with tasks
that require a high level of adaptability, creativity, or decision-making. Robots are
less capable of performing tasks that require problem-solving or dealing with
unexpected situations.
Example: In industries that require continuous changes in product design or
production processes (such as fashion or personalized products), robots may
struggle to adapt without reprogramming or retooling.
4. Job Displacement and Workforce Impact
Explanation: The widespread use of robots in industries can replace human jobs,
leading to unemployment or the need for workers to retrain for new roles. This
can cause economic and social consequences in areas reliant on human labor for
manufacturing.
Example: A factory that replaces human assembly line workers with robotic arms
might face protests or backlash from communities that depend on these jobs.

5. Limited Ability to Work in Unstructured Environments

Explanation: Industrial robots are typically designed for controlled, structured
environments, where they can repeat the same task over and over. However,
they can struggle to perform effectively in unpredictable or chaotic environments,
such as handling products with varying shapes, sizes, or orientations.
Example: A robot might face challenges in a warehouse environment where
objects are stacked in disarray, as it would need advanced vision and decision-
making capabilities.
6. Complex Programming and Setup
Explanation: Programming and setting up industrial robots can be time-
consuming and complex, especially for tasks that require fine-tuning. While
advances in AI and machine learning are helping, specialized knowledge is often
required to make robots functional in specific industrial environments.
Example: Reprogramming a robotic arm for a different type of task may require
hours of programming and testing, leading to delays in production.
7. Safety Concerns
Explanation: Robots operate with high precision and power, which can present
safety risks if they malfunction or interact with humans. Proper safety protocols
are essential, but accidents still happen, potentially causing injury or damage.
Example: An articulated robot arm performing welding might pose a risk of injury
to workers if proper safety shields and barriers are not in place, especially during
maintenance or testing.
8. Limited Sensory Capabilities
Explanation: While robots can be equipped with sensors like cameras, lasers, or
force sensors, they still lack the sophisticated sensory and decision-making
abilities of humans. Robots struggle with sensing complex or subtle information,
 such as identifying small defects or making judgments about a product’s quality.
Example: A robot might not detect a minor scratch or surface imperfection on a
product that a human worker could easily identify.
9. Integration with Existing Systems
Explanation: Integrating robots into an existing legacy production system can be
challenging. Older machines may not be compatible with modern robotic systems,
requiring significant modifications to the entire production line or workflow.
Example: A factory with older conveyor systems and machines may need to
upgrade the entire setup to work seamlessly with new robotic arms, which can be
expensive and disruptive.
10. Energy Consumption
Explanation: Robots, especially large industrial robots, can be energy-intensive.
Over time, their energy consumption may outweigh the benefits of automation,
especially if the robots are operating continuously in high-demand environments.
Example: A large factory using several robotic arms to automate production may
experience a rise in energy costs, reducing the overall profitability if the energy
consumption is not properly managed.

MODULE 2
1.) Explain the Robot Anatomy (+sketch).
Robot Anatomy
The anatomy of a robot refers to the structure and components that work together
to enable the robot to perform its intended tasks. These parts can be broken down
into the following categories:
1. Base (or Frame)
Description: The base is the foundation of the robot. It provides stability and is
typically stationary. The base supports the rest of the robot's components and
ensures that the robot remains firmly anchored during operations.
Function: It holds the robot's actuators, sensors, and control systems, ensuring
they are properly aligned and balanced.
Example: The base could be a metal frame or a fixed platform.
2. Joints (Rotary or Prismatic)
Description: Joints connect the segments (links) of the robot, enabling
movement. These can be of two main types:
o Rotary joints: Provide rotational motion (like human arm joints).
o Prismatic joints: Provide linear (sliding) motion.
Function: They allow the robot to move in specific directions and reach different
positions within its workspace.
Example: The shoulder, elbow, and wrist in a humanoid robot, or the rotating and
 sliding arms of industrial robots.
3. Links
Description: The links are the segments or rigid parts that connect the joints. They
form the “limbs” of the robot.
Function: Links transmit the motion from the joints to the end-effector,
determining the robot's range of motion and workspace.
Example: The upper arm and forearm of a robotic arm.
4. Actuators
Description: Actuators are the devices responsible for moving the joints. They
convert electrical, hydraulic, or pneumatic energy into mechanical motion.
Function: Actuators power the movement of the robot’s joints, driving the arm or
other parts into motion.
Types:
o Electric actuators: Use electric motors (most common).
o Pneumatic actuators: Use air pressure to move parts.
o Hydraulic actuators: Use pressurized liquids.
Example: DC motors, stepper motors, pneumatic cylinders.
5. End-Effector
Description: The end-effector is the tool or device at the tip of the robot’s arm. It
interacts directly with the environment and carries out the robot's task.
Function: The end-effector performs the specific operation the robot is designed
for, such as picking objects, welding, or painting.
Example: Grippers, vacuum cups, welding torches, spray nozzles, and tools for
cutting or assembly.
6. Sensors
Description: Sensors provide the robot with feedback about its environment and
its internal state. They help the robot “sense” where it is and interact with its
surroundings.
Function: Sensors help the robot navigate, avoid obstacles, detect objects, and
ensure accuracy in its operations.
Types:
o Position sensors: To know the position of joints.
 o Proximity sensors: To detect nearby objects.
o Force sensors: To measure the amount of force applied by the robot.
o Vision sensors: Cameras or LIDAR for detecting objects and navigation.
Example: Proximity sensors, infrared sensors, force-torque sensors.
7. Controller (Brain)
Description: The controller is the central processing unit (CPU) or brain of the
robot. It is responsible for receiving inputs from the sensors, processing the data,
and sending signals to the actuators to control the robot’s movements.
Function: It executes the robot’s programmed instructions and manages its tasks
based on real-time data from sensors and user inputs.
Example: A PLC (Programmable Logic Controller) or a robotic controller with a
microprocessor.
8. Power Supply
Description: The power supply provides energy to the robot’s actuators, sensors,
and controller.
Function: It ensures the robot has enough energy to operate efficiently, whether
from electric, hydraulic, or pneumatic sources.
Example: Electric battery packs, power adapters, or compressed air systems.

2.) Explain the Robot Control System (+sketch).

The Robot Control System is the “brain” and nervous system of a robot. It manages all
robot functions by receiving input from sensors, processing that data, and then sending
commands to the actuators (motors) to move the robot accordingly.
🔁 Basic Working Principle:
1. Input: Sensors detect environmental or internal conditions.
2. Processing: The controller interprets this input and makes decisions based on a
pre-programmed algorithm.
3. Output: The controller sends control signals to actuators to generate the desired
motion or action.
🧠Main Components of a Robot Control System:
Component Function
Controller (CPU) Central processor that runs the robot program
and manages all operations.
Memory Stores programs, instructions, and operational
data.
Input Devices Receive signals from sensors or external systems
(e.g., keyboards, sensors).
Output Devices Send commands to actuators or other external
devices.
Power Supply Provides energy to all components of the control
system.
Interface/Communication Connects robot to human operators, computers,
System or other robots.
📌 Types of Control in Robotics:
1. Open-Loop Control System
No feedback from sensors.
Executes predefined instructions blindly.
Simple but less accurate.
Example: A conveyor belt motor running for a set time regardless of load.
2. Closed-Loop Control System (Feedback Control)
Uses sensor feedback to adjust actions in real-time.
More precise and adaptable.
Example: A robotic arm adjusting its position based on camera feedback.

🛠Control Modes in Industrial Robots:

Mode Description
Mode Description
Manual Control Operator controls the robot using a teach pendant or joystick.
Automatic Robot follows pre-programmed instructions with little or no
Control human involvement.
Supervisory Operator monitors and intervenes occasionally; mostly
Control autonomous operation.
📈 Sketch (Text-Based) of Robot Control System:
+---------------------+
| Input Devices | ← (Sensors, switches)
+---------------------+
↓
+---------------------+
| Controller | ← (CPU, memory, logic)
+---------------------+
↓
+---------------------+
| Output Devices | → (Motors, actuators)
+---------------------+
↓
+---------------------+
| End Effector | → (Gripper, tool, etc.)
+---------------------+
Optional feedback loop from end effector/sensors back to controller in closed-loop
systems.
✅ Advantages of a Good Control System:
Accurate and smooth motion
Error detection and correction
Safe and reliable operation
Adaptability to dynamic conditions
❌ Challenges:
 Complexity increases with task difficulty
Requires precise programming
High cost for advanced control systems (e.g., AI-driven)
🧠Real-World Example:
In a car manufacturing plant, a robot arm welds parts together using a closed-loop
control system. It uses a vision sensor to detect exact weld positions, and the
controller continuously adjusts the arm's movements to ensure perfect welds.

MODULE 3
1.) Discuss in detail the factors involved in the selection and design of grippers in robotic
systems
Grippers are the end-effectors of robotic arms used to grasp, hold, and manipulate
objects. Choosing and designing the right gripper is critical to the success of any robotic
application, as it directly affects the accuracy, efficiency, and reliability of the robot’s
task.
🔍 Key Factors in Gripper Selection and Design:
1. Type of Object to Be Handled
Shape: Regular (cylindrical, rectangular) vs. irregular (organic shapes).
Size: Affects jaw opening range and gripper size.
Weight: Heavier objects require stronger gripping force and a sturdier gripper.
Surface texture: Smooth, rough, or slippery surfaces affect gripping method.
Material: Fragile (glass), flexible (plastic), or rigid (metal) influence contact
method.
📌 Example: A vacuum gripper for smooth surfaces like glass; a two-finger
mechanical gripper for boxes.
2. Type of Gripping Force Required
Mechanical gripping: Uses fingers or claws to grip via friction or form fit.
 Vacuum gripping: Uses suction cups for flat, smooth surfaces.
Magnetic gripping: For ferromagnetic materials (steel, iron).
Adhesive gripping: For lightweight and delicate items (e.g., electronics).
📌 Design impact: Selection of actuators (electric, pneumatic) and gripping interface.
3. Gripping Force and Pressure
Too much force can damage delicate parts.
Too little force can cause the object to slip or fall.
Must account for acceleration, orientation, and object weight during motion.
📌 Example: For handling eggs, a soft, compliant gripper with gentle pressure is
required.
4. Number of Fingers / Contact Points
2-finger grippers: Simple, efficient for cylindrical or boxy items.
3-finger grippers: Better for round or irregular items (centred gripping).
Multi-fingered / anthropomorphic grippers: Mimic human hand, used for complex
or dexterous tasks.
📌 Design factor: More fingers increase control but also add mechanical and control
complexity.
5. Actuation Method
Pneumatic: Fast, simple, and cost-effective; suitable for on/off gripping.
Electric: More precise, programmable force and position control.
Hydraulic: For high-force applications, though bulkier and messier.
📌 Selection depends on: Environment, power source availability, and required
control accuracy.
6. Compliance and Flexibility
Some tasks need compliant (flexible) grippers to adapt to shape or surface
variations.
Passive compliance: Built-in flexibility (e.g., soft materials).
Active compliance: Sensors adjust grip dynamically during operation.
2.) Classify robot sensors and illustrate with suitable examples.
Sensors are essential in robotics as they allow a robot to perceive its environment,
monitor its internal state, and respond intelligently. They can be classified based on
function, type of data, and application.
🔹 1. Based on Function
A. Internal Sensors (Proprioceptive)
Measure the robot’s internal state such as position, speed, or joint angles.
📌 Examples:
o Encoders – Measure joint or motor rotation.
o Gyroscope – Measures angular velocity.
o Accelerometer – Measures acceleration or orientation.
B. External Sensors (Exteroceptive)
Provide information about the robot’s surroundings.
📌 Examples:
o Cameras / Vision Systems – Detect objects, read barcodes, inspect parts.
o Proximity Sensors – Detect nearby objects.
o LIDAR / Ultrasonic Sensors – For mapping and obstacle detection.

🔹 2. Based on Measured Quantity

Sensor Type Measured Quantity Examples
Position Sensors Angular or linear position Potentiometer, rotary/linear encoders
Velocity Sensors Speed of Tachometers, differential encoders
rotation/movement
Force/Torque Applied force or torque Strain gauge, 6-axis force/torque
Sensors sensor
Proximity Sensors Presence of nearby Infrared (IR), inductive, capacitive,
objects ultrasonic
Touch/Tactile Surface contact or texture Pressure-sensitive pads, resistive touch
Sensors sensors
Vision Sensors Light or image capture CCD/CMOS cameras, stereo vision
Temperature Heat measurement Thermistors, RTDs, thermocouples
Sensors
Sound Sensors Audio or vibrations Microphones, piezoelectric sensors
🔹 3. Based on Signal Type
A. Analog Sensors
Produce continuous output signals.
📌 Examples: Thermocouples, analog accelerometers, strain gauges.
B. Digital Sensors
Provide discrete output, often ON/OFF or binary values.
📌 Examples: Limit switches, digital encoders, IR beam sensors.
🔹 4. Based on Application in Robotics
Application Sensor Type Example
Obstacle detection Ultrasonic, LIDAR, Infrared Self-driving robots, AGVs
Object recognition Vision sensors (camera, 3D Robotic pick-and-place systems
vision)
Gripping control Tactile, force/torque sensors Robotic grippers handling fragile
items
Navigation and LIDAR, GPS, IMU Mobile robots, drones
mapping
Joint position Encoders, potentiometers Industrial robotic arms
monitoring
Balance and Gyroscope, accelerometer Humanoid and legged robots
orientation
🧠Illustration (Text-Based Sketch):
✅ Summary of Robot Sensor Classification:
Criteria Sensor Type Example
Function Internal / External Encoders / Cameras
Measured QuantityPosition, Force, Temperature, etc.Strain gauge, IR sensor
Signal Type Analog / Digital Thermistor / Limit switch
Application Navigation, gripping, safety, etc. LIDAR, tactile sensors, cameras
MODULE 4
1.) Describe the essential requirements of an effective robot programming language.
Essential Requirements of an Effective Robot Programming Language
An effective robot programming language is critical for commanding and controlling
robot operations efficiently, safely, and accurately. It should offer the tools needed to
develop, simulate, test, and execute robotic tasks across various environments and
applications.
Here are the key requirements that define an effective robot programming language:
🔹 1. Ease of Use and Readability
Description: The language should be simple to learn and easy to read with clear
syntax.
Why Important? Simplifies learning, reduces programming errors, and enables
faster development.
Example: Python-based robotic frameworks (e.g., ROS with Python) are user-
friendly and readable.
🔹 2. Support for Motion and Kinematics
Description: Should allow control over robotic motion, including:
o Joint-level control
o Cartesian movements
o Inverse/forward kinematics
Why Important? Enables the robot to move precisely and efficiently in space.
Example: Commands like MoveJ, MoveL in ABB RAPID or trajectory planning in
ROS.
🔹 3. Real-Time Execution Capability
Description: The language should support real-time control of robotic systems.
Why Important? Ensures timely and predictable responses, especially for tasks
requiring safety and accuracy (e.g., collision avoidance, path tracking).
Example: Real-time variants of C or proprietary languages like KUKA’s KRL.
🔹 4. Device and Sensor Integration
Description: Must allow easy integration of various sensors and actuators (e.g.,
cameras, force sensors, encoders).
Why Important? Robots rely on sensor feedback for intelligent behaviour and
adaptability.
 Example: ROS (Robot Operating System) offers packages for sensor fusion and
integration.
🔹 5. Modularity and Reusability
Description: The language should support modular programming using functions,
procedures, or classes.
Why Important? Helps in organizing code, simplifying debugging, and reusing
code across projects.
Example: Object-oriented programming in C++ or modular task blocks in Fanuc’s
KAREL.
🔹 6. Error Handling and Debugging Support
Description: Should include built-in error detection, exception handling, and
debugging tools.
Why Important? Improves reliability and safety by managing faults and
unexpected behavior.
Example: try-catch blocks in high-level languages, or robot-specific error
messages in URScript.
🔹 7. Support for Simulation and Offline Programming
Description: Should allow simulation of robot programs before deployment on
hardware.
Why Important? Reduces risk, saves time, and helps in validating programs
virtually.
Example: RoboDK, ABB RobotStudio, and ROS Gazebo simulate robot behavior
with the same codebase.
🔹 8. Compatibility with Multiple Robot Models and Platforms
Description: The language should work across different robots or platforms, or at
least be portable.
Why Important? Ensures code longevity and flexibility to adapt to hardware
upgrades.
Example: Python/ROS or languages based on universal standards like IEC 61131-3.
2.) Enumerate the limitations of both online and offline robot programming methods.
Limitations of Online and Offline Robot Programming Methods
Robot programming can be done using two primary methods:
Online Programming: Programming the robot directly on the robot controller (real
hardware).
Offline Programming (OLP): Creating and testing robot programs virtually in a
computer simulation before deploying them to the robot.
Both methods have their own advantages and drawbacks. Below are the key limitations
of each:
🔹 A. Limitations of Online Robot Programming
Limitation Explanation
1. Production Downtime Programming
production lines.
is done while the robot is stopped, halting
2. Time-Consuming Manual teaching and testing on the robot take significant
time.
3. Risk to Equipment Errors during direct programming can cause collisions or
damage.
4. Requires Skilled Needs trained personnel to operate teach pendants and
Operator controllers.
5. Difficult Debugging Real-time error diagnosis is harder without simulation or
visualization tools.
6. Limited Complexity Challenging to handle complex trajectories or logic directly
Handling on the robot.
7. No Simulation Can't simulate or visualize tasks before execution.
Capabilities
8. Operator Fatigue Repetitive and manual teaching may lead to errors or
inefficiency.
🔹 B. Limitations of Offline Robot Programming
Limitation Explanation
1. Model Accuracy Accuracy depends on how well the virtual model matches
Dependency the real robot/workcell.
2. Calibration Required Requires precise calibration to ensure virtual paths match
real-world paths.
3. Software Complexity Requires knowledge of simulation tools and CAD
integration.
4. High Initial Cost Offline software and hardware licenses can be expensive.
5. Steep Learning Curve Users may need advanced training in 3D modeling and
Limitation Explanation
kinematics.
6. Hardware Limitations Not Some real-world issues (e.g., cable drag, tool wear) may
Simulated not appear in simulation.
7. Limited Real-Time Testing May not expose unexpected robot behavior under
dynamic loads or noise.
8. Version Compatibility OLP tools might not support all robot brands or firmware
Issues versions equally.
 MODULE 5
1.) Define a material handling system.
A Material Handling System refers to the mechanized, automated, or manual
methods used to move, store, protect, and control materials throughout the
manufacturing, warehousing, distribution, consumption, and disposal stages of
production.
🔧 Key Elements:
Movement: Transferring materials from one location to another.
Storage: Holding materials until needed.
Control: Tracking and managing inventory or flow of materials.
Protection: Preventing damage or loss during handling or storage.
📌 Formal Definition:
“A material handling system is a system designed for the efficient, safe, and cost-
effective movement, storage, and control of materials, products, or components
within a facility or across supply chain nodes.”
🏭 Typical Applications Include:
Manufacturing plants
Warehouses and distribution centres
Airports (baggage handling)
Construction sites
Ports and logistics hubs
🚚 Examples of Material Handling Equipment:
Conveyors
Automated Guided Vehicles (AGVs)
Robotic arms
Forklifts
Cranes and hoists
Storage systems (racks, bins, AS/RS)
✅ Purpose and Benefits:
Increase productivity
Improve safety
Reduce handling time and labour
Minimize product damage
Optimize space utilization
2.) Explain the types of material handling.

Types of Material Handling

Material handling refers to the movement, storage, protection, and control of materials
throughout manufacturing, warehousing, distribution, and disposal. It is classified based
on how the materials are moved, the level of automation, and the type of equipment
used.

🔹 1. Manual Material Handling (MMH)

🛠Description:
Involves the physical handling of materials by humans without the use of powered
equipment.
📌 Examples:
Lifting boxes by hand
Carrying tools or raw materials
Using hand trolleys or carts
✅ Advantages:
Low cost of equipment
Flexibility in handling irregular or fragile items
❌ Limitations:
Risk of injury (e.g., back strain)
Low efficiency and throughput
Not suitable for heavy or repetitive tasks

🔹 2. Mechanized Material Handling

🛠Description:
Involves the use of powered mechanical equipment to handle materials.
📌 Examples:
Forklifts
Conveyors
Cranes and hoists
Pallet jacks
✅ Advantages:
Reduces physical strain
Handles heavier loads than manual methods
Increases speed and efficiency
❌ Limitations:
Requires trained operators
Higher maintenance and operational costs

🔹 3. Automated Material Handling (AMH)

🛠Description:
Uses automated systems and robotics to move and control materials with minimal
human intervention.
📌 Examples:
Automated Guided Vehicles (AGVs)
Robotic arms for pick-and-place
Automated Storage and Retrieval Systems (AS/RS)
Sortation systems in warehouses
✅ Advantages:
High efficiency and precision
Suitable for high-volume operations
Reduces labor cost and human error
❌ Limitations:
High initial investment
Requires technical expertise
Complex to implement and maintain

🔹 4. Semi-Automated Material Handling

🛠Description:
Combines human involvement with automation for improved performance.
📌 Examples:
Operators using conveyor-fed workstations
 Human-operated forklifts guided by sensors
Cabot’s (collaborative robots) working alongside humans
✅ Advantages:
Balances flexibility and efficiency
Easier to adapt to varying workloads
Less costly than full automation
❌ Limitations:
Still involves some manual effort
Potential for coordination issues between man and machine

3.) What is ASRS in material handling systems?

ASRS stands for Automated Storage and Retrieval System. It is a computer-controlled

system used in warehouses, manufacturing plants, and distribution centre’s for
automated placement and retrieval of goods from storage locations.
🧠Definition:
“ASRS is a material handling system that automatically places and retrieves loads from
defined storage locations using automated machines, often integrated with warehouse
management software (WMS).”
Component Function
Storage Rack System Structured storage area to hold inventory or materials
Storage/Retrieval Machine Automated crane or shuttle that moves items in/out of
(SRM) storage positions
Conveyors/Shuttles Move items between ASRS and other parts of the facility
Controller/Software Directs machine movements, tracks inventory, and
integrates with ERP/WMS
How It Works:
1. Item enters the system via conveyor or operator input.
2. The controller determines an optimal storage location.
3. The robot or crane moves the item into storage.
4. When needed, the system automatically retrieves the item and delivers it to a pick
-up location.
Type Description Example Use
Unit Load ASRS Handles
crates)
large and heavy loads (pallets, Distribution centers

Mini Load ASRS Handles small bins, totes, or cartons E-commerce

warehouses
Vertical Lift Items stored vertically; internal extractor Spare parts, tools
Modules (VLM) delivers items to an operator storage
Carousel-Based Uses rotating shelves (horizontal or Retail stockrooms,
ASRS vertical) pharma storage
Robotic Shuttle Robots shuttle goods between storage High-speed order
Systems racks and picking stations fulfilment
Benefits of ASRS:
Saves space through high-density vertical storage
Improves accuracy and inventory control
Increases throughput and operational efficiency
Reduces labour costs and manual handling errors
Enhances safety by limiting human access to storage zones

❌ Limitations:
High initial capital cost
Requires technical setup and maintenance
Best suited for operations with stable, high-volume throughput

🧠Real-World Example:
An e-commerce fulfilment centre uses a mini-load ASRS to store thousands of small
SKU bins. When an order is placed, the system automatically retrieves the right bin and
delivers it to a human operator for packing — all in seconds.
4.) Explain different types of ASRS.

Types of ASRS (Automated Storage and Retrieval Systems)

ASRS (Automated Storage and Retrieval System) refers to automated systems that
handle the storage and retrieval of goods with high efficiency, accuracy, and space
optimization. There are several types of ASRS systems, each designed for specific load
sizes, throughput requirements, and space constraints.

🔹 1. Unit Load ASRS

🛠Description:
Designed to handle large, heavy loads like pallets or heavy containers (typically >500
lbs).
📌 Features:
Uses stacker cranes to move pallets in/out of storage racks.
Ideal for bulk storage and large item inventory.
✅ Applications:
Manufacturing plants
Distribution centre’s
Cold storage warehouses

🔹 2. Mini Load ASRS

🛠Description:
Handles smaller items, usually stored in totes, bins, or cartons.
📌 Features:
Smaller and faster retrieval machines than unit-load systems.
Often integrated with goods-to-person picking stations.
✅ Applications:
E-commerce fulfilments
Spare parts storage
Electronics assembly
🔹 3. Vertical Lift Modules (VLMs)
🛠Description:
An enclosed system with two columns of trays and a central robotic extractor that
moves trays in/out vertically.
📌 Features:
Trays are automatically brought to an ergonomic access window.
Highly space-efficient (uses ceiling height).
✅ Applications:
Tool and parts storage
Healthcare and lab environments
Aerospace industry

🔹 4. Vertical Carousel Modules (VCMs)

🛠Description:
A series of rotating shelves or carriers that move vertically (like a Ferris wheel).
📌 Features:
Brings stored items directly to the operator.
Useful in low ceiling areas.
✅ Applications:
Retail stockrooms
Pharmacy and medical supply storage
Office supply management

🔹 5. Horizontal Carousel Systems

🛠Description:
Rotating bins or shelves move horizontally around a track.
📌 Features:
Ideal for fast, high-volume order picking.
Often used in zones with pick-to-light systems.
✅ Applications:
 Order fulfilments centre’s
Automotive parts warehouses
High-speed picking lines

🔹 6. Robotic Shuttle Systems / Cube-Based ASRS

🛠Description:
Autonomous mobile shuttles move bins or totes along multi-level tracks or within a cube-
based grid.
📌 Features:
Extremely fast and scalable.
Allows simultaneous access to multiple SKUs.
✅ Applications:
E-commerce distribution
Grocery fulfilments centre’s
High-density storage in compact spaces