CHAPTER 2: INDUSTRIAL

ROBOTICS

1.0 INTRODUCTION TO INDUSTRIAL

ROBOTICS
 Learning objectives

Upon completion of this chapter, students should be able to:-

1. Explain the definition of industrial robotics.
2. Explain the robot component system.
3. Sketch robot design configuration and its workspace.
4. Expose the robot programming operation methods.
5. Expose robot applications in manufacturing processes.
 What is an Industrial Robot?

• Industrial robots are programmable multifunctional manipulator designed to move

material, parts, tools, or specialized devices through variable programmed motions to
perform a variety of tasks.

• An industrial robot consists of a number of rigid links connected by joints of different

types, controlled and monitored by a computer.

• Industrial robots are robots used in an industrial manufacturing environment such as

for welding, material handling, painting and others. If we judge purely by application
this type could also include some automated guided vehicles and other robots.

• An industrial robot system includes not only industrial robots but also any devices
and/or sensors required for the robot to perform its tasks as well as sequencing or
monitoring communication interfaces.
1. Laws of Robotic defined by Isaac Asimov

The First Law:

A robot may not injure a human being or, through inaction, allow a human being to come
to harm.

The Second Law:

A robot must obey orders given to it by human beings, except where such orders would
conflict with the First Law.

The Third Law:

A robot must protect its own existence as long as such protection does not conflict with
the First or Second Laws.
Robot Terminology
• Link and Joint – Links are the solid structural members of a robot and joint are moveable
couplings between them.
• Degree of Freedom (DoF) – is the number of independent movements the robot can
realize with respect to its base.
• Accuracy – how close the arm will be when its moves to the desired point.
• Precision (validity) – how accurately a specified point can be reach.
• Repeatability (variability) – how accurately the same position can be reached if the
motion is repeated many times.
• Work envelope/ workspace – is the work area robot can move. Its can determined by how
far robot arm can reach and how flexible the robot is.

Work envelope

• Stability – refers to the robot motion with the least amount of oscillation.
• Speed – maximum velocity that is achievable.
• Payload – is the weight a robot can carry and still remain within its specifications.
• Reach – is the maximum distance a robot can reach within its work envelope.
• Settling time – is the time required for a robot to be within a given distance from the final
position.
Functions of Robot

• Industrial robots often have movable robotic arms. The amount of movement in robots is
called the degrees of freedom. Many robotic arms have end effectors attached on the last
joint. There are all sorts of end effectors that are suited to particular applications.

• One common end effector is called a gripper. Grippers are capable of grasping, holding
and controlling objects. Some robots have hands with built-in pressure sensors that
indicate how hard a robot is gripping an object. End effectors are also tools capable of
performing physical actions such as cutting, painting or drilling.

• The operation of a robot is dependent on sensors, actuators, computer control and

software programs.
Motivating Factor Using Robotics System

Technical Factors:
i. High flexibility of product type and variation
ii. Lower preparation than hard automation
iii. Better quality of products
iv. Fewer rejects and less waste than labour intensive production

Economics Factor:
v. The needs to increase production rates to remain competitive
vi. Pressure form market place to improve quality
vii. Increasing costs
viii. Shortage of skilled labour

Social factors:
ix. Reduction of workload on worker
x. Prevent dangerous physically harm
Comparison Between a Robot and an Automated Machine
Robot Automated Machine
Robots are made to perform several jobs at Automated machine can only follow one set
once, and the sequence of operations can of operations, and it cannot be changed
be switched around to make the processes once programmed
more efficient. The timing of the operations
also can be changed if needed.

Robots are made to react if something The automated machine will not react; even
blocks or stops the robot, it will change if there is an object blocking the
operations to best fit the situation. automation, it will continue doing the same
operation.

Robots can be made with intelligence and Unable to collect knowledge and can't be
they are able to learn from mistakes; this programmed with any form of intelligence.
allows the robot to fix problems, if it is
exposed to them long enough.

Can work faster and is able to Work slow and are typically programmed
accommodate complex movements. with very simple movements.
 Robotic Devices Not Considered an Industrial robot
Domestic or household robots -Robots used at home. This type of robots includes many quite different devices such
as robotic vacuum cleaners, robotic pool cleaners, sweepers, gutter cleaners and other robots that can do different
chores. Also, some surveillance and telepresence robots could be regarded as household robots if used in that
environment. 

Medical robots - Robots used in medicine and medical institutions. First and foremost - surgery robots. Also, some
automated guided vehicles and maybe lifting aides. 

Sceintific robots - Robots that do not fall into other types by usage. These could be different data gathering robots,
robots made to show off technologies, robots used for research or data gathering.
Military robots - Robots used in military. This type of robots includes bomb disposal robots, different transportation
robots, reconnaissance drones. Often robots initially created for military purposes can be used in law enforcement,
search and rescue and other related fields. 

Entertainment robots - These are robots used for entertainment. This is a very broad category. It starts with toy robots
such as robo sapien or the running alarm clock and ends with real heavyweights such as articulated robot arms used as
motion simulators. 

Space robots - Id like to single out robots used in space as a separate type. This type would include robots used on
the International Space Station, Canadarm that was used in Shuttles, as well as Mars rovers and other robots used in
space. 

Hobby and competition robots - Robots that you create. Line followers, sumo-bots, robots made just for fun and
robots made for competition
 Medical Robot
Vacuum Robot
Data Gathering Robot

Robot Soccer Robo Sapien

Military Robot
Capabilities of Industrial Robot

• The use of robots improves efficiency and accuracy on a variety of applications.  

• Robots are controlled by a computer.  They save time and money as they replace human
labour for hazardous or repetitive tasks.  Since they never grow tired, they can work long
hours in harsh environments.

• Applications such as assembly, welding, painting, product inspection, picking and placing,

die casting, drilling, glass making, and grinding are all accomplished by robots.

• Many industries rely heavily on robots, including:  aerospace, automotive, consumer

goods, electronics, metals, food and beverage, foundry, medical, military, pharmaceutical,
plastics, and wood.
 Advantages of Industrial Robot
Quality
Robot have the capacity to dramatically improve product quality. Applications are performed with
precision and high repeatability every time. This level of consistency can be hard to archive any other
way

Production
With robots, throughput speeds increase, which directly impact production. Because robots have the
ability to work at a constant speed without pausing for breaks, sleep, vacations, they have the
potential to produce more than human worker

Safety
Robots increase workplace safety. Workers are moved to supervisory roles, so they no longer have to
perform dangerous applications in hazardous settings.

Saving
Greater worker safety leads to financial savings. There are fewer healthcare and insurance concerns
for employers. Robots also offer untiring performance which saves valuable time. Their movement are
always exact, so less material is wasted.
 Disadvantages of Industrial Robot

Expense
The initial investment of robots is significant, especially when business owners are limiting their
purchases to new robotic equipment. The cost of automation should be calculated in light of business
greater financial budget. Regular maintenance needs can have a financial toll as well

Return of Investment (ROI)

Incorporating industrial robot does not guarantee results. Without planning, companies can have
difficulty achieving their goals.

Expertise
Employees will require training in programming and interacting with the new robotic equipment. This
normally takes times and financial output.

Safety
Robot may protect workers from hazard, but in the meantime, their very presence can create other
safety problems. These new dangers must be taken into consideration.
INDUSTRIAL ROBOTICS

Robot Classification and

Component Systems
INDUSTRIAL ROBOTS COMPONENTS

1. ROBOT MANIPULATOR
2. ROBOT CONTROLLER
3. ROBOT END EFFECTOR
4. ROBOT ACTUATOR
5. ROBOT SENSOR
 MANIPULATOR (ARM)
• The manipulator are mechanical parts of the robot system that can
be moved into different direction, the result of a combination of
movement axes.
• It consist component such as the human arm of the upper arm and
forearm are connected to the ‘base’, ‘shoulder’, ‘elbow’ and ‘wrist’.
• It can carry sensor tip (end effector) to the required destinations.
 CONTROLLER
• The controller is the ‘brain’ of the industrial
robotic arm and allows the parts of the robot
to operate together.

• It works as a computer and allows the robot to

also be connected to other systems.

• The robotic arm controller runs a set of

instructions written in code called a program.
The program is inputted with a ‘teach
pendant’.

• Many of today's industrial robot arms use an

interface that resembles or is built on the
Windows operating system
 Teach
Industrial Controller Pendant
Robot Arm
Man-Machine Interface
 END EFFECTOR
• The end effector is a equipment installed on the
end of the arm plate processor. Which operates
under the duties to be performed.

• Two types:
i. Grippers – to grasp and manipulate objects
(e.g., parts) during work cycle
ii. Tools– to perform a process, e.g., spot
welding, spray painting

• Some variations of an end effector are a gripper, a

vacuum pump, magnets, and welding torches.

• Some robots are capable of changing end effectors

and can be programmed for different sets of tasks.
Grippers and Tools
 ACTUATOR (DRIVE)
• The actuators are used in the robots for providing the power to the
robot joints. It can be powered by anyone of the following sources:

i. Hydraulic – pressurized fluid

ii. Pneumatic – compressed air
iii. Electric – electricity

• Hydraulic drive systems give a robot great speed and strength.

• Pneumatic drive systems are used for smaller robots that have
fewer axes of movement.
• An electric system provides a robot with less speed and strength.
 SENSOR
• Sensors allow the industrial robotic arm to
receive feedback about its environment.

• The sensor collects information and sends it

electronically to the robot controller. One use of
these sensors is to keep two robots that work
closely together from bumping into each other.

• Sensors can also assist end effectors by

adjusting for part variances. Vision sensors
allow a pick and place robot to differentiate
between items to choose and items to ignore.
 ROBOT JOINTS & MOTIONS
• A robot joint is a mechanism that permits relative movement
between parts of a robot arm.

• The joint of a robot are designated to enable the robot to move its
end-effector along a path from one position to another as desired.

• The basic movements required for a motion of industrial robot are:

a) Rotational movement : This enable the robot to place its arm in
any direction on a horizontal plane.
b) Radial movement : This enables the robot to move its end effector
radially to reach distant point.
c) Vertical movement: This enables the robot to take its end-effector
to different heights.
The industrial robot joints are classified as:

1. Prismatic joints - also known as sliding as a well as linear joints.

They are called prismatic because the cross section of the joint is
considered as a generalized prism. They permit links to make a
linear displacement along a fixed axis.

2. Revolute joints – where a pair of links rotates about a fixed axis.

Variation of revolute joints:
i. Rotational Joint (R) – rotation about an axis perpendicular to the
adjoining links.

ii. Twisting Joint (T) – rotation takes place about an axis that is parallel to
both adjoining links.

iii. Revolving Joint (V) - rotation takes place about an axis that is parallel to
one of the adjoining links. The links are aligned perpendicular to one
another at this kind this joint.
 DEGREE OF FREEDOM (DoF)
• Degree of Freedom (DoF) refers to the freedom of movement of a rigid body in
the three- dimensional space.

• The degree of freedom or grip of a robotic system can be compared to the way in
which the human body moves.

• Specifically, the body is free to move forward/backward, up/down, left/right

(translation in three perpendicular axes) combined with rotation about three
perpendicular axes, often termed pitch, yaw and roll.

• A total six degrees of freedom is needed to locate a robot’s hand at any point in
its work space. Six degrees of freedom are needed for maximum flexibility.

• The more the degree of freedom, the greater is the complexity of motions
encountered.
Six degree of freedom:

1. Rotational traverse is movement on a vertical axis. This is the

side-to-side swivel of the robot’s arm on its base.
2. Radial traverse is the extension and retraction of the arm, creating
in-and-out motion relative to the base.
3. Vertical traverse provides up-and-down motion.
4. Pitch or bend, is the up-and-down movement of the wrist.
5. Yaw is the side-to-side movement of the wrist.
6. Roll or swivel, is a rotation of the wrist.
ROBOT CLASSIFICATION AND CONFIGURATION

• Different types of geometric configurations can be adopted to an

industrial robot. Among the most common ones:

1. Cartesian configuration (rectangular)

2. Cylindrical configuration
3. Spherical configuration (polar)
4. Articulated arm configuration
(Anthropomorphic)
5. SCARA configuration
CARTESIAN ROBOT (RECTANGULAR)
 CARTESIAN ROBOT (RECTANGULAR)
ADVANTAGES:

1. THEY CAN OBTAIN LARGE WORK ENVELOPE BECAUSE RAVELLING ALONG THE X-AXIS, THE VOLUME REGION CAN
BE INCREASED EASILY.

2. THEIR LINEAR MOVEMENT ALLOWS FOR SIMPLER CONTROLS.

3. THEY HAVE HIGH DEGREE OF MECHANICAL RIGIDITY, ACCURACY, AND REPEATABILITY DUE O THEIR
STRUCTURE.

4. THEY CAN CARRY HEAVY LOADS BECAUSE THE WEIGHT-LIFTING CAPACITY DOES NOT VARY AT DIFFERENT
LOCATIONS WITHING THE WORK ENVELOPE.

DISADVANTAGES:

5. THEY MAKES MAINTENANCE MORE DIFFICULT FOR SOME MODELS WITH OVERHEAD DRIVE MECHANISMS AND
CONTROL EQUIPMENT.

6. ACCESS TO THE VOLUME REGION BY OVERHEAD CRANE OR OTHER MATERIAL-HANDLING EQUIPMENT MAY BE
IMPAIRED BY THE ROBOT-SUPPORTING STRUCTURE.

7. THEIR MOVEMENT IS LIMITED TO ONE DIRECTION AT A TIME.

CARTESIAN ROBOT (RECTANGULAR)
APPLICATIONS:

1. PICK-AND-PLACE OPERATIONS.

2. ADHESIVE APPLICATIONS(MOSTLY LONG AND STRAIGHT).

3. ADVANCED MUNITION HANDLING.

4. ASSEMBLY AND SUBASSEMBLY(MOSTLY STRAIGHT).

5. AUTOMATED LOADING CNC LATHE AND MILLING OPERATIONS.

6. NUCLEAR MATERIAL HANDLING.

7. WELDING.
 CYLINDRICAL ROBOT
• HAS TWO LINEAR MOTIONS AND ONE ROTARY MOTION.

• ROBOTS CAN ACHIEVE VARIABLE MOTION.

• THE FIRST COORDINATE DESCRIBE THE ANGLE THETA OF BASE ROTATION--- ABOUT
THE UP-DOWN AXIS.

• THE SECOND COORDINATE CORRESPOND TO A RADICAL OR Y--- IN OUT MOTION AT

WHATEVER ANGLE THE ROBOT IS POSITIONED.

• THE FINAL COORDINATE AGAIN CORRESPONDS TO THE UP-DOWN Z POSITION.

• ROTATIONAL ABILITY GIVES THE ADVANTAGE OF MOVING RAPIDLY TO THE POINT IN Z

PLANE OF ROTATION.

• RESULTS IN A LARGER WORK ENVELOPE THAN A RECTANGULAR ROBOT MANIPULATOR.

• SUITED FOR PICK-AND-PLACE OPERATIONS.

CYLINDRICAL ROBOT
CYLINDRICAL ROBOT
 CYLINDRICAL ROBOT
ADVANTAGES:

1. THEIR VERTICAL STRUCTURE CONSERVES FLOOR SPACE.

2. THEIR DEEP HORIZONTAL REACH IS USEFUL FOR FAR-REACHING OPERATIONS.

3. THEIR CAPACITY IS CAPABLE OF CARRYING LARGE PAYLOADS.

DISADVANTAGES:

4. THEIR OVERALL MECHANICAL RIGIDITY IS LOWER THAN THAT OF THE RECTILINEAR

ROBOTS BECAUSE THEIR ROTARY AXIS MUST OVERCOME INERTIA.

5. THEIR REPEATABILITY AND ACCURACY ARE ALSO LOWER IN THE DIRECTION OF

ROTARY MOTION.

6. THEIR CONFIGURATION REQUIRES A MORE SOPHISTICATED CONTROL SYSTEM THAN

THE RECTANGULAR ROBOTS.
 CYLINDRICAL ROBOT
APPLICATIONS:

1. ASSEMBLY
2. COATING APPLICATIONS.
3. CONVEYOR PALLET TRANSFER.
4. DIE CASTING.
5. FOUNDARY AND FORGING APPLICATIONS.
6. INSPECTION MOULDING.
7. INVESTMENT CASTING.
8. MACHINE LOADING AND UNLOADING.
 SPHERICAL ROBOT
• HAS ONE LINEAR MOTION AND TWO ROTARY MOTIONS.

• THE WORK VOLUME IS LIKE A SECTION OF SPHERE.

• THE FIRST MOTION CORRESPONDS TO A BASE ROTATION ABOUT A VERTICAL AXIS.

• THE SECOND MOTION CORRESPONDS TO AN ELBOW ROTATION.

• THE THIRD MOTION CORRESPONDS TO A RADIAL, OR IN-OUT, TRANSLATION.

• A SPHERICAL-COORDINATED ROBOTS PROVIDES A LARGER WORK ENVELOPE

THAN THE RECTILINEAR OR CYLINDIRICAL ROBOT.

• DESIGN GIVES WEIGHT LIFTING CAPABILITIES.

• ADVANTAGES AND DISADVANTAGES SAME AS CYLINDIRICAL-COORDINATED

DESIGN.
SPHERICAL ROBOT
SPHERICAL ROBOT
 SPHERICAL ROBOT
APPLICATIONS:

1. DIE CASTING
2. DIP COATING
3. FORGING
4. GLASS HANDLING
5. HEAT TREATING
6. INJECTION MOLDING
7. MACHINE TOOL HANDLING
8. MATERIAL TRANSFER
9. PARTS CLEANING
10. PRESS LOADING
11. STACKING AND UNSTICKING
 ARTICULATED ROBOT
• The revolute configuration, or jointed-arm, is the most common.
• These robots are often referred to as anthropomorphic because their
movements closely resemble those of the human body.
• A revolute coordinate robot performs in an irregularly shaped work
envelope.
• There are two basic revolute configurations: vertically articulated
and horizontally articulated
ARTICULATED ROBOT
ARTICULATED ARM ROBOT
 ARTICULATED ARM ROBOT
Advantages:

• High mechanical flexibility

• Can move with high speed at three degrees of freedom
• All joints can be sealed from the environment

Disadvantages:

• Extremely difficult to visualize, control and program.

• Restrict volume coverage
• Low accuracy
 SCARA ROBOT
• SCARA (Selective Compliance Assembly Robot Arm) is a
combination of the articulated arm and cylindrical robot.
• Use widely in electronic assembly.
• This configuration minimizes deflection when its carries an object
while moving at a programmed speed.
 SCARA ROBOT
Advantages:

• High speed
• Excellent repeatability
• Good payload capacity
• Large work area for floor space
• Moderately easy to program

Disadvantages:

• Limited application
• 2 ways to reach point
• Difficult to program-offline
• High complex arm
 SCARA ROBOT
Applications:

• Pick and place work

• Assembly operation
• Application of sealant
• Handling machine tool
ROBOT PROGRAMMING
OPERATIONS AND
INTERFACING
 Types of Robot Programming
 Walk-through programming (Teaching pendant)
A programming method in which a robot is placed in "teach mode“ while the trainer uses a remote teach pendant to
manipulate the robot through the different steps of the job. Also known as teach pendant programming.

 Lead-through programming (Teaching by demonstration)

A programming method in which the trainer physically moves the robot through different steps of the job process. Also
known as teaching by demonstration.

 Off-line programming (Simulation)

A programming method in which the trainer writes a program and uploads it to the robot.

 On-line programming
A programming method in which trainer write a program directly to robot data base. Teaching pendant & demonstration
are on-line programming.

https://www.youtube.com/watch?v=EA6pWwNI_wg
https://www.youtube.com/watch?v=Ic-iKGSc7dk
 Walk-through Programming
 Common for point-to-point robots
 Uses teach pendant
 Data from the teach pendant will be saved in
the control cabinet
 Any editing will be through the teach
pendant before the robot can operate.
 One of the most common programming
methods
 Advantages of Walk_through Programming
 Most traditional industrial robots come with a teach pendant, which makes them
familiar to technicians.
 They allow precise positioning, as the robot can be programmed using numerical
coordinates, in either world coordinates, robot coordinates or another coordinate
system.
 Teach pendants are great for simple movements, such as painting in a straight line or
over a large flat surface.

 Disadvantages Walk_through Programming

 Disruptive to the whole system due to robot downtime.
 The robot must be put into "teach mode" and all operations using the robot halted
until it has been programmed.
 Lead-through Programming

 Convenient for continuous path control robots.

 Human programmer physically moves the manipulator.
 Lead-through Programming
 Use for continuous process such as welding and painting.
 Programming being done through holding or lead the end effector or using
special device that being attached to the end effector to perform the action
needed for the task.
 All of the movement will be recorded into the control cabinet.
 Special programming will be built by the programmer for the robot to execute
the action given.
 Advantages of Lead-through Programming
 Quicker than traditional teach pendants (walk-through)
 It removes the need for multiple button pressing, allowing the operator to simply move the robot to the desired
position.
 More intuitive than both traditional teach pendants and simulation programs, as the task is programmed in almost the
same way a human operator would perform it.
 This makes it simple for operators to learn. Generally, this method requires no knowledge of programming concepts
or being familiar with 3D CAD environments (as simulation does).
 Very good for detailed tasks which would require many lines of code to achieve the same effect, such as welding or
painting.

 Disadvantages Lead-through Programming

 As with traditional a teach pendant, this method uses the physical robot for programming. This means that it does not
reduce downtime, as much as offline programming.
 Moving the robot to precise coordinates is not as straightforward as with the other methods. This is especially true
with some joystick based systems, where there is no way of entering a numerical value. 
 Not so good for tasks which are "algorithmic" in nature. For example, if a robot had to paint a flat surface by moving
horizontally along the surface, then move down an inch, move horizontally in the opposite direction, etc. Moving the
robot by hand would be arduous and inaccurate for such a task.
Off-line Programming
 C/C++ The easiest way to get started with robotics is to learn C and C++. ...
 Python. Python is a powerful programming language that may be used to create and
test robots. ...
 Java. ...
 4. . ...
 MATLAB. ...
 Lisp. ...
 Pascal.
Coordinate Systems

World coordinate system Tool coordinate system

Motion Commands
MOVE P1
HERE P1 - used during lead through of manipulator
MOVES P1
DMOVE(4, 125)
APPROACH P1, 40 MM
DEPART 40 MM
DEFINE PATH123 = PATH(P1, P2, P3)
MOVE PATH123
SPEED 75
Interlock and Sensor Commands

Interlock Commands
WAIT 20, ON
SIGNAL 10, ON
SIGNAL 10, 6.0
REACT 25, SAFESTOP
Gripper Commands
OPEN
CLOSE
CLOSE 25 MM
CLOSE 2.0 N
Simulation and Off-Line Programming
 Advantages of Offline Programming
 Reduces downtime required for robot programming. Programs are developed offline, so the robot
only has to be halted while the new program is being downloaded and tested.
 Can be quite intuitive, especially if the robot can be moved around in a 3D CAD environment
with drag and drop techniques.
 Easy to test many different approaches to the same problem, which would be inefficient for online
programming methods.

 Disadvantages of Offline Programming

 Virtual models will (probably) never be able to represent the real world with 100% accuracy.
Programs may still need to be altered after they are applied to the real robot.
 Might take longer overall. Although offline programming reduces the downtime of the robot, it
means that someone has to spend extra time developing the simulation, as well as testing it on the
robot.
 Can sometimes end up wasting time sorting out simulator issues instead of solving production
challenges. This could be related to the quality of the simulator.
 On-line Programming
 This involves stopping the robot from its productive work and switching it to “programming
mode.” Then, you create or update the program while the robot is online.

 Online programming methods involve stopping the six axis robot, taking it out of production, and
putting it into programming or teaching mode. Programs are then created or modified using the 
articulated robot.

 The main programming methods in the online category are teach pendant and lead through
programming.
Advantages of On-line Programming
 No extra hardware or software is required
 Most technicians are familiar with teach pendants
 Best for simpler applications

Disadvantages of On-line Programming

 Most of the time requires robot to be taken out of production, increasing downtime
 Pendants require knowledge of brand specific programming language
 ROBOT
APPLICATIONS
 Industrial Robot Applications
1. Material handling applications
 Material transfer – pick-and-place, palletizing
 Machine loading and/or unloading
2. Processing operations
 Welding
 Spray coating
 Cutting and grinding
3. Assembly and inspection

https://www.youtube.com/watch?v=1BgYl-f4VZY
https://www.youtube.com/watch?v=HwjCGxsLO4c
https://www.youtube.com/watch?v=HUU3HdxOqZs
https://www.youtube.com/watch?v=yfzYUCZM3fE
https://www.youtube.com/watch?v=fqmokmsHTRM
https://www.youtube.com/watch?v=KaaeetUCF14
https://www.youtube.com/watch?v=lTsL6gf__IE
General characteristics of industrial work situations that promote the use of industrial
robots

1. Hazardous work environment for humans

2. Repetitive work cycle
3. Difficult handling task for humans
4. Multi shift operations
5. Infrequent changeovers
6. Part position and orientation are established in the work cell
Welding Process

 Robot welding is the use of mechanized programmable tools (robots), which completely automate
a welding process by both performing the weld and handling the part.
 Processes such as gas metal arc welding, while often automated, are not necessarily equivalent to
robot welding, since a human operator sometimes prepares the materials to be welded.
 Robot welding is commonly used for resistance spot welding and arc welding in high
production applications, such as the automotive industry.
 Welding applications are classified in three categories:
– resistance, arc, and gas.
• In each application area, only servo type robots are used because path control is
critical.
• Resistance or spot welding was developed by the automotive
industry in the mid1970s and continues to be a major application in that industry.

• The robot became a standard item on the assembly line due to its ability to move the 150 pound welding
gun effortlessly into position on a moving car body and produce accurate resistance welds at a rate of one
every 3 seconds.
Robots performing spot welding on car bodies.
• Robotic arc welding is frequently used in the heavy equipment manufacturing industries to produce off-road
hauling and earthmoving equipment.
• Lighter applications occur in the automotive, electronics, and aerospace industries.
• Metal inert gas (MIG) and tungsten inert gas (TIG) welding with real time interactive control permit the robot
to track the seam between two metal plates.
• The seam to be welded is located and tracked by a photo sensor, such as the vision camera , or by welding
parameters. The location of the seam or welding path is passed to the robot controller, which moves the arm
holding the welding tooling.
• The location and control are dynamic, so that corrections in the direction of the welding gun are made as the
weld is in progress.
• Robotic arc welding is cost effective when compared with manual and semiautomatic systems.
Robotic Arc-Welding Cell
 Robot performs flux-cored arc
welding (FCAW) operation at
one workstation while fitter
changes parts at the other
workstation
Spraying Process
Paint Spraying

• In general, paint spraying applications require limited automation technology.

• The number of sensors required is relatively low, the support equipment is primarily material
handling, and robot precision is not critical.
• Servo paint spraying robots have traditionally cost more than the standard servo robot, but the cost
of the work cell is about the same because the support hardware is less.
• Several applications are supported by robotics: part is lowered into the coating material reservoir
and removed to allow excess material to flow off the part. In some cases parts are spun to remove
excess coating material.
• Paint spraying—airless:
The coating material is pushed through a small nozzle opening by a pump in the spray head to atomize the
material. The residual momentum from the atomizing process causes the material to coat the part. Servo arms
are required when robots are used, and continuous path control of the spray gun is necessary.
• Paint spraying—compressed air:
The atomizing action in this system is caused by compressed air passing over a venturi. The residual
momentum of the paint and air mixture carries the material to the target. Again, servo type controllers
with continuous path control are necessary.
• Paint spraying—electrostatic:
Paint is given an electrostatic charge as it passes through the spray head, and the part is connected to a
voltage source with the opposite polarity. The paint is pulled to the part by the difference in the
electrical charge between the paint droplets and the part. Continuous path servo machines are used for
robot applications in this area.
Advantages using Robot Paint Spraying
1) Improve Quality
With an automated robotic spray painting arm can create a more reliable, high-quality end product. The consistency and thoroughness offered by a
robotic spray-painting arm is unparalleled. The robotic spray gun always remains at the proper distance away from the target object. Painting
robots provide excellent accessibility, coating hard-to-reach areas with ease.

2) Conserve Paint
A spray painting automated robotic system can cut material costs considerably. Reliable and precise, it doesn't overspray. The amount of paint
used for any given part is consistent.

3) Play it Safe
Painting is often tedious, repetitive work. Workers risk exposure to harmful toxins including VOCs, insocyanates, and carcinogens. With an
automated robot to spray paint, workers no longer have to endure the strain and hazards associated with this job. In the end, companies
with painting robots spend less on safety concerns (i.e. protective gear, health insurance).

4) Make Room
Automated robots are well-suited for high-density paint booth layouts. Whether shelf, wall, or rail-mounted, paint robots offer compact work
cell solutions. Robots are designed to work in close proximity to each other and other equipment. Companies not only save floor space, but they
can also achieve faster cycle times and better accessibility with creative robot placement.

5) Save Energy
Spray painting booths require a carefully maintained atmosphere. The air inside the booth must be regulated and replaced constantly. Incinerators
Assemble Process
Assembly Operations

 The applications involve both material handling and the manipulation of a tool.
 They typically include components to build the product and to perform material handling operations.
 Are traditionally labour intensive activities in industry and are highly repetitive and boring. Hence are logical
candidates for robotic applications.

 These are classified as:

1. Batch assembly: As many as one million products might be assembled. The assembly operation has long
production runs.
2. Low volume: In this a sample run of ten thousand or less products might be made.

 The assembly robot cell should be a modular cell.

 One of the well suited area for robotics assembly is the insertion of odd electronic components.
Inspection Process
– Some inspection operation require parts to be manipulated, and other applications require that an
inspection tool be manipulated.
– Inspection work requires high precision and patience, and human judgment is often needed to
determine whether a product is within quality specifications or not.
– Inspection tasks that are performed by industrial robots can usually be divided into the following
three techniques:
• By using a feeler gauge or a linear displacement transducer known as a linear variable differential
transformer(LVDT), the part being measured will come in physical contact with the instrument or by
means of air pressure, which will cause it to ride above the surface being measured.
• By utilizing robotic vision, matrix video cameras are used to obtain an image of the area of interest,
which is digitized and compared to a similar image with specified tolerance.
• By involving the use of optics and light, usually a laser or infrared source is used to illustrate the
area of interest.
– The robot may be in active or passive role.
• In active role robot is responsible for determining whether the part is good or bad.
• In the passive role the robot feeds a gauging station with the part. While the gauging station is
determining whether the part meets the specification, the robot waits for the process to finish.

KUKA ROBO INSPECT -

INSPECTION OF DRILLED
HOLE DIAMETERS
• Robot loading and unloading with automated test equipment:
– The operation of this inspection method is almost similar to the machine tool
loading and unloading functions. Robot loads several inspection devices like
electrical, pneumatic, and mechanical gauges, and as well as functional testing
devices.
– At first, the robot unloads the finished work part from the machine and loads it
into the inspection device for checking the accuracy. If the work part satisfies the
specified conditions, then it will be sent to next process, the testing process.
Otherwise, it will be rejected.
Testing Process
• Another quality control operation that is related with inspection function is the Testing.
• Checking whether the work part is operating correctly in the work cell.
• Involves environment testing, fatigue testing, and other similar methods.

Durability testing of car seat heaters

Loading and Unloading Process
• Machine loading and/or unloading:
– Robot transfers parts into and/or from a production machine.
– There are three possible cases:
• Machine loading in which the robot loads parts into a production machine, but the
parts are unloaded by some other means. Example: a press working operation, where the
robot feeds sheet blanks into the press, but the finished parts drop out of the press by
gravity.
• Machine loading in which the raw materials are fed into the machine without robot
assistance. The robot unloads the part from the machine assisted by vision or no vision.
Example: bin picking, die casting, and plastic moulding.
• Machine loading and unloading that involves both loading and unloading of the work
parts by the robot. The robot loads a raw work part into the process ad unloads a
finished part. Example: Machine operation
Material Handling Applications

 Palletizing process
 Pick & Place process

Palletizing

Pick & Place

• Palletizing and/or Depalletizing
A process where robots take a material or a product and stack them together on a pallet. Robot will
arrange the material neatly and efficiency to avoid any unwanted situation while moving the pallet.
– Example: process of taking parts from the assembly line and stacking them on a pallet or vice
versa.
 Pick & Place Process
A process where robots are used to load and unload any material or product from one
station to another station. This is because each station has their own task. Therefore the
products need to be move by robot carefully and highly efficient.

Part Placement:
– The basic operation in this category is the relatively simple pick and place operation.
– This application needs a low technology robot of the cylindrical coordinate type.
– Only two, three, or four joints are required for most of the applications.
– Pneumatically powered robots are often utilized.
Advantages of Robots Application
i. Increase in productivity
Robot can perform task a lot faster than a human being. Human needs to take a break several times in a day, but robot only
need several times in a week. Therefore productivity will increase after replacing human with robots.

ii. Improvement in quality

Robot can perform task in a very high accuracy manner, about 0.001 cm for some specific task. Human can sometime be lazy
to achieve perfection, but robot will always do and at every time. Therefore quality will increase when robots take over.

iii. Improvement in effectiveness

Robot always do task according to the program written. There are no disobeying to the programmer instruction. Compared to
human, sometime they tend to disobey and skipping procedure. This will cause decrement in effectiveness. Therefore,
introducing robot to production system will overcome effectiveness issue.

iv. Human safety

There are a number of tasks that are too dangerous, too exposed to toxins, or just plain too dirty for humans to conveniently
do them. These are ideal robotics tasks. This includes tasks as simple as spray painting, because there is no need to worry
about the robot inhaling the paint fumes. It also includes such daunting tasks as defusing bombs and such dirty tasks as
cleaning sewers.
End of chapter 2