ST.

MOTHER THERESA ENGINEERING COLLEGE

Department of Mechanical Engineering

2 Marks and 16 Marks solved

UNIT I Fundamentals of Robots

Part-A Questions

1. Define a Robot. (AU-Nov/Dec-2010)

RIA defines a robot as a ―programmable, multifunction manipulator designed to Move materials,
parts, tools or special devices through variable programmed motions for the performance of the
variety of tasks‖.

2. Explain the types of rotary joint notations (AU-Nov/Dec-2008)

 Rotational joint (type R)
 Twisting joint (type T)
 Revolving joint (type V)

3. What is meant by Work space? (AU-Nov/Dec-2010)

The space in which the end point of the robot arm is capable of operating is called as workspace
in other words reach ability of robot arm is known as workspace.

4. What is meant by accuracy of robot?

The robot‘s ability to reach a reference point within the robot‘s full work volume is known as
accuracy of robot.

5. What are the benefits of industrial robots?

 Increased Productivity
 Significant Savings
 Improved Quality
 Better Safety
 Competitive Edge

6. What is repeatability of robot?

Repeatability refers to robot‘s ability to return to the programmed point when it is commanded to
do so.

7. What is meant by pitch, yaw and roll? (AU-Nov/Dec-2008)

Pitch is rotation around the X axis, yaw is around the Y axis, and roll is around the Z axis. Yaw is
side to side swinging around an axis. Pitch is up and down movement about an axis and roll is
rotatory motion about an axis.

8. What is work volume? (AU-Nov/Dec-2008)

The volume of the space swept by the robot arm is called work volume.
9. What is meant by Quality of robot?
A Robot is said to be high quality when the precision and accuracy is more.

10. What is meant by robot anatomy? (AU-Nov/Dec-2009)

Study of structure of robot is called robot anatomy. Manipulator is constructed of a series of joints
and links. A joint provides relative motion between the input link and the output link.

11. What are the three degrees of freedom associated with the arm and body motion?
· Right (or) left movement (X-axis motion) (AU-Nov/Dec-2009)
 In and out movement (Y-axis motion)
 Vertical movement (Z-axis motion)

12. Define an Industrial Robot. (AU-Nov/Dec-2010)

An industrial robot is an automatically controlled, reprogrammable, multipurpose manipulator
programmable in three or more axes. A programmable mechanical device that is used in place of a
person to perform dangerous or repetitive tasks with a high degree of accuracy.

13. Define payload capacity of Robot? (AU-Nov/Dec-2010)

The maximum load which can be carried by the manipulator at low or normal speed.

14. Define base and tool Coordinate system. (AU-Nov/Dec-2012)

A tool coordinates definition system capable of easily obtaining a transformation matrix for
defining a tool coordinates system of a robot. The tool coordinates system at the 0° position of the
robot is rotated around each axis so that the tool coordinates system becomes parallel to a base
coordinates system.

15. Name the important specifications of an industrial robot. (AU-Nov/Dec-2012)

 Accuracy
 Repeatability
 Degree of Freedom
 Resolution
 Envelope

16. What are the four basic robot configurations available commercially? (AU-Apr/May-2010)
 Cartesian coordinate system
 Cylindrical coordinate system
 Polar or spherical coordinate system
 Revolute coordinate system

17. Define the term work envelop? (AU-Apr/May-2010)

The work envelop is described by the surface of the work space.
 Part-B Questions

1. Briefly explain the different types of robots. (AU-Nov/Dec-2008)

Industrial robots
Industrial robots are robots used in an industrial manufacturing environment. Usually these are
articulated arms specifically developed for such applications as welding, material handling, painting
and others. If we judge purely by application this type could also include some automated guided
vehicles and other robots.
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.
Service robots
Robots that dont fall into other types by usage. These could be different data gathering robots,
robots made to show off technologies, robots used for research, etc.
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 robosapien or the running alarm clock and ends with real heavyweights such as articulated
robot arms used as motion simulators.
Space robots
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
Most of the hobbyist robots are mobile and made to operate by rolling around on wheels
propelled by electric motors controlled by an on board microprocessor.
Explorer robots
The majority of these robots are completely self-reliant due to their sensory systems, however
they may also be controlled by humans giving orders through computer commands. The other types
of explorer robots are underground mine exploring robots, seeing and walking undersea robots, and
even bomb defusing robots used by police.
 Laboratory robots
Laboratory robotics is the act of using robots in biology or chemistry labs. For example,
pharmaceutical companies employ robots to move biological or chemical samples around to synthesize
novel chemical entities or to test pharmaceutical value of existing chemical matter.
Sequence robots
A manipulator which progresses successively through the various stages of an operation according to
the predetermined sequence.
Playback robots
The playback robots are capable of performing a task by teaching the position. These positions are
stored in the memory, and done frequently by the robot. Generally, these playback robots are employed
with a complicated control system. It can be divided into two important types, namely:
Point to Point control robots
Continuous Path control robots

2. Sketch and explain the four basic robot configurations classified according to the coordinate
(AU-Nov/Dec-2009; 2010)

system.
Classification Based on Physical Configuration (or) Co-ordinate Systems:
• Cartesian configuration
• Cylindrical configuration
• Polar configuration
• Joint-arm configuration

Cartesian Configuration:
Robots with Cartesian configurations consist of links connected by linear joints (L). Gantry robots
are Cartesian robots (LLL).

Cylindrical Configuration:
Robots with cylindrical configuration have one rotary (R) joint at the base and linear (L)
joints succeeded to connect the links.
 The designation of the arm for this configuration can be TRL or TRR. Robots with the designation
TRL are also called spherical robots. Those with the designation TRR are also called articulated
robots. An articulated robot more closely resembles the human arm.

Joint-arm Configuration:
The jointed-arm is a combination of cylindrical and articulated configurations. The arm of the
robot is connected to the base with a twisting joint. The links in the arm are connected by rotary joints.
Many commercially available robots have this configuration.

Simple Comparison

3. Write short notes on Joint Notation Scheme. (AU-Nov/Dec-2009)

A robot joint is a mechanism that permits relative movement between parts of a robot arm. The
joints of a robot are designed 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 desired motion of most industrial robots are:
 1. Rotational movement: This enables the robot to place its arm in any direction on a
horizontal
plane.
2. Radial movement: This enables the robot to move its end-effector radially to reach
distant
points.
3. Vertical movement: This enables the robot to take its end-effector to different heights.

These degrees of freedom, independently or in combination with others, define the complete
motion of the end-effector. These motions are accomplished by movements of individual joints of the
robot arm. The joint movements are basically the same as relative motion of adjoining links.
Depending on the nature of this relative motion, the joints are classified as prismatic or revolute.
Prismatic joints are also known as sliding as 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 move
in a linear relationship.
Revolute joints permit only angular motion between links. Their variations include:
• Rotational joint (R)
• Twisting joint (T)
• Revolving joint (V)
In a prismatic joint, also known as a sliding or linear joint (L), the links are generally parallel to
one another. In some cases, adjoining links are perpendicular but one link slides at the end of the
other link. The joint motion is defined by sliding or translational movements of the links. The
orientation of the links remains the same after the joint movement, but the lengths of the links are
altered.
A rotational joint (R) is identified by its motion, rotation about an axis perpendicular to the
adjoining links. Here, the lengths of adjoining links do not change but the relative position of the links
with respect to one another changes as the rotation takes place.
A twisting joint (T) is also a rotational joint, where the rotation takes place about an axis that is
parallel to both adjoining links.
A revolving joint (V) is another rotational joint, where the rotation takes place about an axis that is
parallel to one of the adjoining links. Usually, the links are aligned perpendicular to one another at this
kind of joint. The rotation involves revolution of one link about another.
4. Write short notes on technical specification in Robotics. (AU-Nov/Dec-2008; 2009)
Accuracy:
How close does the robot get to the desired point? When the robot's program instruct the robot to
move to a specified point, it does not actually perform as per specified. The accuracy measure such
variance. That is, the distance between the specified position that a robot is trying to achieve
(programming point), and the actual X, Y and Z resultant position of the robot end effector.
Repeatability:
The ability of a robot to return repeatedly to a given position. It is the ability of a robotic system or
mechanism to repeat the same motion or achieve the same position. Repeatability is is a measure of
the error or variability when repeatedly reaching for a single position. Repeatability is often smaller
than accuracy.
Degree of Freedom (DOF):
Each joint or axis on the robot introduces a degree of freedom. Each DOF can be a slider, rotary,
or other type of actuator. The number of DOF that a manipulator possesses thus is the number of
independent ways in which a robot arm can move. Industrial robots typically have 5 or 6 degrees of
freedom. 3 of the degrees of freedom allow positioning in 3D space (X, Y, Z), while the other 2 or 3
are used for orientation of the end effector (yaw, pitch and roll). 6 degrees of freedom are enough to
allow the robot to reach all positions and orientations in 3D space. 5 DOF requires a restriction to 2D
space, or else it limits orientations. 5 DOF robots are commonly used for handling tools such as arc
welders.
Resolution:
The smallest increment of motion or distance that can be detected or controlled by the robotic
control system. It is a function of encoder pulses per revolution and drive (e.g. reduction gear) ratio.
And it is dependent on the distance between the tool center point and the joint axis.
Envelope:
A three-dimensional shape that defines the boundaries that the robot manipulator can reach; also
Known as reach envelope.
Reach:
The maximum horizontal distance from the center of the robot base to the end of its wrist.
Maximum Speed:
A robot moving at full extension with all joints moving simultaneously in complimentary directions
at full speed. The maximum speed is the theoretical values which does not consider under loading
condition.
Payload:
The maximum payload is the amount of weight carried by the robot manipulator at reduced speed
while maintaining rated precision. Nominal payload is measured at maximum speed while maintaining
rated precision. These ratings are highly dependent on the size and shape of the payload due to
variation in inertia.
5. Explain the various parts of a robot with neat sketch. (AU-Nov/Dec-2008)

Controller:
Every robot is connected to a computer, which keeps the pieces of the arm working together. This
computer is known as the controller. The controller functions as the "brain" of the robot. The controller
also allows the robot to be networked to other systems, so that it may work together with other
machines, processes, or robots.
Robots today have controllers that are run by programs - sets of instructions written in code.
Almost all robots of today are entirely pre-programmed by people; they can do only what they are
programmed to do at the time, and nothing else. In the future, controllers with artificial intelligence, or
AI could allow robots to think on their own, even program themselves. This could make robots more
self-reliant and independent.
Arm:
Robot arms come in all shapes and sizes. The arm is the part of the robot that positions the end-
affector and sensors to do their pre-programmed business.
Many (but not all) resemble human arms, and have shoulders, elbows, wrists, even fingers. This
gives the robot a lot of ways to position itself in its environment. Each joint is said to give the robot 1
degree of freedom. So, a simple robot arm with 3 degrees of freedom could move in 3 ways: up and
down, left and right, forward and backward.
Drive:
The drive is the "engine" that drives the links (the sections between the joints into their desired
position. Without a drive, a robot would just sit there, which is not often helpful. Most drives are
powered by air, water pressure, or electricity.
End-Effector:
The end-effector is the "hand" connected to the robot's arm. It is often different from a human
hand - it could be a tool such as a gripper, a vacuum pump, tweezers, scalpel, blowtorch - just about
anything that helps it do its job. Some robots can change end-effectors, and be reprogrammed for a
different set of tasks.
 Sensor:
Most robots of today are nearly deaf and blind. Sensors can provide some limited feedback to the
robot so it can do its job. Compared to the senses and abilities of even the simplest living things,
robots have a very long way to go.
The sensor sends information, in the form of electronic signals back to the controller. Sensors
also give the robot controller information about its surroundings and lets it know the exact position of
the arm, or the state of the world around it.

6. Explain the main Robot anatomy with neat sketch.

Robot anatomy is concerned with the physical construction and characteristics of the body, arm,
and wrist, which are the component of the robot manipulator.
- Base.-fixed are mobile
- The manipulator- arm which several degrees of freedom (DOF).
- The end-effector or gripper- holding a part or tool
- Drives or actuators – Causing the manipulator arm or end effector to move in a space.
- Controller – with hardware & software support for giving commands to the drives

- Sensors - To feed back the information for subsequent action of the arm or grippers as well as
to interact with the environment in which the robot is working.
- Interface – Connecting the robot subsystem to the external world.

Which consist of a number of component that allowed be oriented in a verity of position

movements between the various components of the body, arm, and wrist are provided by a series of
joints. These joint movements usually involve either rotation or sliding motions.
7. Describe the types of joints used in robots.
The Robot Joints is the important element in a robot which helps the links to travel in different
kind of movements. There are five major types of joints such as:

 Rotational joint

 Linear joint

 Twisting joint

 Orthogonal joint

 Revolving joint

Rotational Joint:
Rotational joint can also be represented as R – Joint. This type will allow the joints to move in a
rotary motion along the axis, which is vertical to the arm axes.

Linear Joint:
Linear joint can be indicated by the letter L – Joint. This type of joints can perform both
translational and sliding movements. These motions will be attained by several ways such as
telescoping mechanism and piston. The two links should be in parallel axes for achieving the linear
movement.

Twisting Joint:

Twisting joint will be referred as V – Joint. This joint makes twisting motion among the output and
input link. During this process, the output link axis will be vertical to the rotational axis. The output link
rotates in relation to the input link.

Orthogonal Joint:
The O – joint is a symbol that is denoted for the orthogonal joint. This joint is somewhat similar to
the linear joint. The only difference is that the output and input links will be moving at the right angles.

Revolving Joint:
Revolving joint is generally known as V – Joint. Here, the output link axis is perpendicular to the
rotational axis, and the input link is parallel to the rotational axes. As like twisting joint, the output link
spins about the input link.

8. Discuss the four types of robot controls. (AU-Apr/May-2010)

1. Point-to-point (PTP) control robot

2. Continuous-path (CP) control robot
3. Controlled-path robot
4. Stop-to-Stop
Point to Point Control Robot (PTP):
The PTP robot is capable of moving from one point to another point. The locations are recorded
in the control memory. PTP robots do not control the path to get from one point to the next point.
Common applications include:
• Component insertion
• Spot welding
• hole drilling
• Machine loading and unloading
• Assembly operations

Continuous-Path Control Robot (CP):

The CP robot is capable of performing movements along the controlled path. With CP from one
control, the robot can stop at any specified point along the controlled path. All the points along the
path must be stored explicitly in the robot's control memory. Applications Straight-line motion is the
simplest example for this type of robot. Some continuous-path controlled robots also have the
capability to follow a smooth curve path that has been defined by the programmer. In such cases the
programmer manually moves the robot arm through the desired path and the controller unit stores a
large number of individual point locations along the path in memory (teach-in).
Typical applications include:
• spray painting
• finishing
• gluing
• Arc welding operations

Controlled-Path Robot:
In controlled-path robots, the control equipment can generate paths of different geometry such as
straight lines, circles, and interpolated curves with a high degree of accuracy. Good accuracy can be
obtained at any point along the specified path.
Only the start and finish points and the path definition function must be stored in the robot's
control memory. It is important to mention that all controlled-path robots have a servo capability to
correct their path.

Stop-to-Stop:
 It is open loop system

 Position and velocity unknown to controller

 On/off commands stored as valve states

 End travel set by mechanical stops

 UNIT II Robots Drive Systems and End Effectors
Part-A Questions

1. Define End effector.

End effector is a device that is attached to the end of the wrist arm to perform specific task.

2. Give some examples of Robot End Effector.

 Gripper

 Tools

 Welding equipments

 End of arm Tooling (EOAT)

3. What is meant by Gripper?

Gripper is the End effector which can hold or grasp the object.

4. What is the difference between internal grippers and external grippers? (AU-Nov/Dec-2008)

In internal grippers, the finger pads are mounted on the inside of the fingers. This mounting
allows the pads to fit into the inside diameter of the part it must lift. The pads are pressed against the
inside wall of the part.
An external gripper is designed so that the finger pads press against the outside of the
component. Grips the exterior surface of the objects with closed fingers.

5. What are the types of Mechanical Grippers? (AU-Apr/May-2010)

 Linkage actuation gripper

 Gear and rack actuation gripper

 Cam actuated gripper

 Screw actuated gripper

6. List any two limitations of magnetic grippers

 Residual magnetism

 Side slippage

 More than one sheet will be lifted by the magnet from a stack

7. List any four important factors to be considered in the selection and design of grippers.
· The gripper must have the ability to reach the surface of a work part. (AU-Apr/May-2011)
 The change in work part size must be accounted for providing accurate positioning.
 During machining operations, there will be a change in the work part size. As a result,
the gripper must be designed to hold a work part even when the size is varied.
 The gripper must not create any sort of distort and scratch in the fragile work parts.
8. Give some examples of tool as robot End effector.
 Spot Welding Tools

 Arc welding Torch

 Spray painting nozzle

 Water jet cutting tool

9. Name some feedback devices used in robotics.

 Potentiometer

 Resolver

 Encoder

10. What are the types of encoders?

(a) Linear encoder
(b). Rotary encoder
(i) Absolute encoder (ii) Incremental encoder

11. List out the types of Drive systems used in Robots.

 Electric motors like: Servomotors, Stepper motors

 Hydraulic actuators

 Pneumatic actuators

12. Write the characteristics of actuating systems.

 Weight

 Power-to-weight ratio

 Operating Pressure

 Stiffness Vs. Compliance

13. List any two unique features of a stepper motor.

 Moves in known angle of rotation.

 Position feedback is not necessary.

 Rotation of the shaft by rotation of the magnetic field.

14. What is a RCC device? for what purpose is it used in a robo

In robotics, a Remote Center Compliance, Remote Center of Compliance or RCC is a mechanical
device that facilitates automated assembly by preventing peg-like objects from jamming when they are
inserted into a hole with tight clearance. In a naive design without an RCC, a robot might pick up a peg with
its gripper, center the peg over the hole and then push the peg along the axis of the hole.
 Part-B Questions

1. Explain Mechanical drives system.

When the various driving methods like hydraulic, pneumatic, electrical servo motors and stepping
motors are used in robots, it is necessary to get the motion in linear or rotary fashion. When motors
are used, rotary motion is converted to linear motion through rack and pinion gearing, lead screws,
worm gearing or bail screws.

Rack and Pinion Movement:

The pinion is in mesh with rack (gear of infinite radius). If the rack is fixed, the pinion will rotate.
The rotary motion of the pinion will be converted to linear motion of the carriage.

Ball Screws:
Sometimes lead screws rotate to drive the nut along a track. But simple lead screws cause
friction and wear, causing positional inaccuracy. Therefore ball bearing screws are used in robots as
they have low friction. The balls roll between the nut and the screw. A cage is provided for
recirculation of the balls. The rolling friction of the ball enhances transmission efficiency to about 90%.

Gear Trains:
Gear trains use spur, helical and worm gearing. A reduction of speed, change of torque and
angular velocity are possible. Positional errors are caused due to backlash in the gears.

Harmonic Drive:

For speed reduction, standard gear transmission gives sliding friction and backlash. Moreover, it
takes more space. Harmonic drive due to its natural preloading eliminates backlash and greatly
reduces tooth wear. Harmonic drives are suitable for robot drives due to their smooth and efficient
action. The harmonic drive as shown in figure is made up of three major elements: the circular spline,
the wave generator and the flex spline. The circular spline is a rigid ring with gear teeth machined on
the inside diameter. The flex spline is a flexible ring with the teeth cut on its outside diameter. The flex
spline has fewer teeth (say 2 teeth less) than the circular spline. The wave generator is elliptical and
is given input motion. The wave generator is assembled into the flex spline the entire assembly of.
Wave generator and flex spline is placed into the circular spline such that the outer tooth of flex spline
is in mesh with the internal teeth of circular spline
 If the circular spline has 100 teeth and the flex spline has 98 teeth, and if the wave generator
makes one complete revolution, the flex spline will engage 98 teeth of the circular spline. Since
circular spline has 100 teeth and only 98 teeth have been in engagement for one complete rotation,
the circular saline's position has been shifted by 2 teeth. Thus after 50 revolutions of the wave
generator, the circular spline will have made one full rotation. The ratio of harmonic drive is 2: 100 or
1: 50. The gear ratio is influenced by the number of teeth cut into the circular spline and the flex
spline. The harmonic drive has high torque capacity.

2. Explain Pneumatic actuators system with neat sketch.

Pneumatic systems use pressurized air to make things move. Basic pneumatic system consists
of an air generating unit and an air-consuming unit. Air compressed in compressor is not ready for
use as such, air has to be filtered, moisture present in air has to be dried, and for different
applications in plant pressure of air has to be varied. Several other treatments are given to the air
before it reaches finally to the Actuators. The figure gives an overview of a pneumatic system.
Practically some accessories are added for economical and efficient operation of system.
Compressor:
A device, which converts mechanical force and motion into pneumatic fluid power, is called
compressor. Every compressed-air system begins with a compressor, as it is the source of airflow for
all the downstream equipment and processes Electric Motor Electric motor is used to drive the
compressor.
Air Receiver:
It is a container in which air is stored under pressure. Pressure Switch. Pressure Switch is used
to maintain the required pressure in the receiver; it adjusts the High Pressure Limit and Low Pressure
Limit in the receiver. The compressor is automatically turned off when the pressure is about to exceed
the high limit and it is also automatically turned on when the pressure is about to fall below the low
limit.
Safety Valve:
The function of the safety valve is to release extra pressure if the pressure inside the receiver
tends to exceed the safe pressure limit of the receiver.
 Check Valve:
The valve enables flow in one direction and blocks flow in a counter direction is called Check
Valve. Once compressed air enters the receiver via check valve, it is not allowed to go back even
when the compressor is stopped.
Direction Control Valve:
Directional-control valve are devices used to change the flow direction of fluid within a
Pneumatic/Hydraulic circuit. They control compressed-air flow to cylinders, rotary actuators, grippers,
and other mechanisms in packaging, handling, assembly, and countless other applications. These
valves can be actuated either manually or electrically.
Pneumatic Actuator:
A device in which power is transferred from one pressurized medium to another without
intensification. Pneumatic actuators are normally used to control processes requiring quick and
accurate response, as they do not require a large amount of motive force. They may be reciprocating
cylinders, rotating motors or may be a robot end effectors.

3. Explain various types of Gripper mechanisms. (AU-Nov/Dec-2010)

Pivoting or Swinging Gripper Mechanisms:

This is the most popular mechanical gripper for industrial robots. It can be designed for limited
shapes of an object, especially cylindrical work piece. If actuators that produce linear movement are
used, like pneumatic piston- cylinders, the device contains a pair of slider-crank mechanisms.
When the piston 1 is pushed by pneumatic pressure to the right, the elements in the cranks 2 and
3, rotate counter clockwise with the fulcrum F and clockwise with the fulcrum F respectively, when B <
1800. These rotations make the grasping action at the extended end of the crank elements 2 and 3.
The releasing action can be obtained by moving the piston to the left. An angle B ranging from 160° to
is commonly used.
 This is the swing block mechanism. The sliding rod 1, actuated by the pneumatic piston transmits
motion by way of the two symmetrically arranged swing-block linkages 1--2--3--4 and 1—2—3‘—4‘ to
grasp or release the object by means of the subsequent swinging motions of links 4 and 4‘ at their
Pivots F.

A gripper using a rotary actuator in which the actuator is placed at the cross point of the two
fingers. Each finger is connected to the rotor and the housing of the actuator, respectively. The
actuator movement directly produces grasping and releasing actions.

The cam actuated gripper includes a variety of possible designs, one of which is shown.
A cam and follower arrangement, often using a spring-loaded follower, can provide the opening
and closing action of the gripper. The advantage of this arrangement is that the spring action would
accommodate different sized objects.

The screw is turned by a motor, usually accompanied by a speed reduction mechanism. Due to
the rotation of the screw, the threaded block moves, causing the opening and dosing of the fingers
depending on the direction of rotation of the screw.
4. Write note on Gripper selection and design (AU-Apr/May-2011)
5. Write a note on Magnetic Grippers.

Magnetic grippers are used extensively on ferrous materials. In general, magnetic grippers offer
the following advantages in robotic handling operations
 Variations in part size can be tolerated

 Pickup times are very fast

 They have ability to handle metal parts with holes

 Only one surface is required for gripping

The residual magnetism remaining in the work piece may cause problems. Mother potential
disadvantage is the problem of picking up one sheet at a time from a stack. The magnetic attraction
tends to penetrate beyond the top sheet in the stack, resulting in the possibility that more than a
single sheet will be lifted by the magnet.

Magnetic grippers can use either electromagnets or permanent magnets. Electromagnetic

grippers are easier to control, but require a source of dc power and an appropriate controller. When
the part is to be released, the control unit reverses the polarity at a reduced power level before
switching off the electromagnet. This procedure acts to cancel the residual magnetism in the work
plece ensuring a positive release of the part. The attractive force, P of an electromagnet is found from
Maxwell‘s equation given by
 Permanent magnets do not require an external power and hence they can be used in hazardous
and explosive environments, because there is no danger of sparks which might cause ignition in such
environments. When the part is to be released at the end of the handling cycle, in case of permanent
magnet grippers, some means of separating the part from the magnet must be provided. One such
stripping device is shown in figure.

6. Explain the various drive system used with an industrial robot and compare their features,
merits and demerits. (AU-Nov/Dec-2010)
7. Explain the working of a stepper motor. (AU-Nov/Dec-2010)

A stepper motor is an electromechanical device which converts electrical pulses into discrete
mechanical movements. The shaft or spindle of a stepper motor rotates in discrete step increments
when electrical command pulses are applied to it in the proper sequence. The motors rotation has
several direct relationships to these applied input pulses. The sequence of the applied pulses is
directly related to the direction of motor shafts rotation. The speed of the motor shafts rotation is
directly related to the frequency of the input pulses and the length of rotation is directly related to the
number of input pulses applied.

This mean that a digital signal is used to drive the motor and every time it receives a digital pulse
it rotates a specific number of degrees in rotation.

 Each step of rotation is the response of the motor to an input pulse (or digital command).

 Step-wise rotation of the rotor can be synchronized with pulses in a command-pulse train,
assuming that no steps are missed, thereby making the motor respond faithfully to the pulse
signal in an open-loop manner.

 Stepper motors have emerged as cost-effective alternatives for DC servomotors in high-

speed, motion-control applications (except the high torque-speed range) with the improvements
in permanent magnets and the incorporation of solid-state circuitry and logic devices in their drive
systems.

 Today stepper motors can be found in computer peripherals, machine tools, medical
equipment, automotive devices, and small business machines, to name a few applications.

Advantages Of Stepper Motors:

 Position error is noncumulative. A high accuracy of motion is possible, even under open-
loop control.

 Large savings in sensor (measurement system) and controller costs are possible when
the open-loop mode is used.
 Because of the incremental nature of command and motion, stepper motors are easily
adaptable to digital control applications.
 No serious stability problems exist, even under open-loop control.

 Torque capacity and power requirements can be optimized and the response can be
controlled by electronic switching.
 Brushless construction has obvious advantages.
 UNIT III Sensors and Machine vision
Part-A Questions

1. What is the common imaging device used for robot vision systems?
Black and white videocon camera, charge coupled devices, solid-state camera, charge injection
devices.

2. What is segmentation? (AU-Nov/Dec-2009)

Segmentation is the method to group areas of an image having similar characteristics or features
into distinct entities representing part of the image.

3. What is thresholding?
Thresholding is a binary conversion technique in which each pixel is converted into a binary value
either black or white.

4. What are the functions of machine vision system?

 Sensing and digitizing image data
 Image Processing and analysis
 Application

5. Define sensors and transducer.

Sensor is a transducer that is used to make a measurement of a physical variable of interest.

Transducer is a device that converts the one form of information into another form without
changing the information content.

6. What are the basic classifications of sensors?

 Tactile Sensors,
 Proximity Sensors,
 Range sensors,
 Voice sensors etc.,

7. What is a tactile sensor? (AU-Apr/May-2011)

Tactile sensor is device that indicates the contact between themselves and some other solid
objects.

8. What is meant by Region growing?

Region growing is a collection of segmentation techniques in which pixels are grouped in regions
called grid elements based on attribute similarities.

9. What is meant by Feature Extraction?

In vision applications distinguishing one object from another is accomplished by means of
features that uniquely characterize the object. A feature (area, diameter, perimeter) is a single
parameter that permits ease of comparison and identification.
 10. What are the various techniques in image processing and analysis?
 Image data reduction
 Segmentation
 Feature extraction
 Object recognition

11. Give an application example of a proximity sensor.

 Ground proximity warning system for aviation safety
 Vibration measurements of rotating shafts in machinery
 Sheet break sensing in paper machine.
 Roller coasters
 Conveyor systems

12. Brief on the working of inductive type proximity sensor. (AU-Nov/Dec-2009)

Inductive proximity sensors operate under the electrical principle of inductance.
Inductance is the phenomenon where fluctuating current, which by definition has a magnetic
component induces an electromotive force (emf) is a target object.
To amplify a devices inductance effect, a sensor manufacturer twists wire into a tight coil and runs
a current through it.

13. Name some feedback devices used in robotics.

 Position Sensors
 Velocity Sensors

14. What are the types of encoders?

 Incremental encoders
 Absolute encoders

15. What is frame grabber?

It is a hardware device used to capture and store the digital image.

16. Classify the position sensors. (AU-Nov/Dec-2009)

 Incremental encoders
 Absolute encoders
 Resistive position sensors
 Linear variable differential transformer.
 Encoders
 Potentiometer
 Resolver.

17. What is a tactile array sensor?

 Tactile array sensor is a special type of force senor composed of a matrix of force sensing
elements.
 Part-B Questions

1. Briefly explain the characteristics of Sensors.

Resolution:
It is the minimum step size within the range of measurement of a sensor.in a wire-wound
potentiometer, it will be equal to resistance of one turn of wire. In digital devices with ‗n‘ bits,
resolution is ‗Full range/2n‘.
Sensitivity:
 It is defined as the change in output response divided by the change in input response.
 Highly sensitive sensors show larger fluctuations in output as a result of fluctuations in
input.
Linearity:
 It represents the relationship between input variations and output variations.
 In a sensor with linear ouput, any change in input at any level within the range will
produce
the same change in output.
Range:
It is the difference between the smallest and the largest outputs that a sensor can provide, or the
difference between the smallest and largest inputs with which it can operate properly.
Response time:
 It is the time that a sensor‘s ouput requires to reach a certain percentage of total change.

 It is also defined as the time required to observe the changein output as a result of
change in input for example, ordinary mercury thermometer responsetime and digital
thermometer
response time.
Frequency response:

 The frequency response is the range in which the system‘s ability to resonate to the input
remains relatively high.
 The larger the range of frequency response, the better the ability of the system to
respond to
varying input.
Reliability:

 It is the ratio between the number of times a system operates properly and the number of
times it is tried.
 For continuous satisfactory operation, it is necessary to choose reliable sensors that last
long while considering the cost as well as other requirements.
Accuracy:
 It shows how close the output of the sensor is to the expected value.
 For a given input, certain expected output value is related to how close the sensor‘s
output
 value is to this value.
Repeatability:

 For the same input if the output response is different each time, then repeatability is poor.
Also, a specific range is desirable for operational performance as the performanve of robots
depends on sensors.
  Repeatability is a random phenomenon and hence there is no compensation.

Interfacing:

 Direct interfacing of the sensor to the microcontroller/microprocessor is desirable while

some add-on circuit may be necessary in certain special sensors.
 The type of the sensor output is equally important. An ADC is required for analogue
output
sensors for example, potentiometer ouput to microcontroller.
Size,weight and volume:
 Size is a critical consideration for joint displacement sensors.
 When robots are used as dynamic machines, weight of the sensor is important.
 Volume or spaces also critical to micro robots and mobile robots used for surveillance.
 Cost is important expecially when quantity involved is large in the end application.

2. Briefly explain the working principle of position sensors with neat sketch.

Position sensors are used to monitor the position of joints. Information about the position is fed
back to the control systems that are used to determine the accuracy of positioning.
In most cases in robots, a primary interest is to control the position of the arm. There is a large
variety of devices available for sensing position. However, the most popular angular-position sensors
are the following devices:
 Encoders
 Synchros
 Resolvers
 Potentiometers

Types of Position Sensor:

Position sensors use different sensing principles to sense the displacement of a body. Depending
upon the different sensing principles used for position sensors, they can be classified as follows:

1. Resistance-based or Potentiometric Position sensors

2. Capacitive position sensors
3. Linear Voltage Differential Transformers
4. Magnetostrictive Linear Position Sensor
5. Eddy Current based position Sensor
6. Hall Effect based Magnetic Position Sensors
7. Fiber-Optic Position Sensor
8. Optical Position Sensors
Potentiometric Position Sensors:

Potentiometric position sensor use resistive effect as the sensing principle. The sensing element
is simply a resistive (or conductive) track. A wiper is attached to the body or part of the body whose
displacement is to be measured. The wiper is in contact with the track. As the wiper (with the body or
its part) moves, the resistance between one end of the track and the wiper changes. Thus, the
resistance becomes a function of the wiper position. The change in resistance per unit change in
wiper position is linear.
Resistance, proportional to wiper position, is measured using voltage divider arrangement. A
constant voltage is applied across the ends of the track and the voltage across the resistance
between the wiper and one end of the track is measured. Thus, voltage output across the wiper and
one end of the track is proportional to the wiper position.
The conductive track can be made linear or angular depending upon the requirements. The
tracks are made from carbon , resistance wire or piezo resistive material.
3. Briefly explain the working principle of Range sensors with neat sketch.

The distance between the object and the robot hand is measured using the range sensors Within
it is range of operation. The calculation of the distance is by visual processing. Range sensors find
use in robot navigation and avoidance of the obstacles in the path. The - location and the general
shape characteristics of the part in the work envelope of the robot S done by special applications for
the range sensors. There are several approaches like, triangulation method, structured lighting
approach and time-of flight range finders etc. In these cases the source of illumination can be light-
source, laser beam or based on ultrasonic.

Triangulation Method:

This is the simplest of the techniques, which is easily demonstrated in the Figure. The object is swept
over by a narrow beam of sharp light. The sensor focussed on a small spot of the object surface detects
the reflected beam of light. If ‗8‘ is the angle made by the illuminating source and ‗b‘is the distance
between source and the sensor, the distance ‗c of the sensor on the robot is given as
Structured Lighting Approach:
This approach consists of projecting a light pattern the distortion of the pattern to calculate the
range. A pattern in use today is a sheet of light generated narrow slit.
As illustrated in. Figure, the intersection of the sheet with objects in the‘ work space yields a light
stripe which is viewed through a television camera displaced a distance B from the light source. The
stripe pattern is easily analyzed by a computer to obtain range information. For example, an inflection
indicates a change of surface, and a break corresponds to a gap between surfaces.

Specific range values are computed by first calibrating the system. One of the simplest
arrangements is shown in Figure, which represents a top view of Figure. In this, arrangement, the
light source and camera are placed at the same height, and the sheet of light is perpendicular to the
line joining the origin of the light sheet and the center of the camera lens. We call the vertical plane
containing this line the reference plane. Clearly, the reference plane is perpendicular to the sheet of
light, and any vertical flat surface that intersects the sheet Will produce a vertical stripe of light in
which every point will have the same perpendicular distance to the reference plane. - The objective
of. the arrangement shown in Figure. is to position the camera so that every such vertical stripe also
appears vertical in the image plane. In this way, every point, the same column in the ‗image will be
known to have the same distance to the ‗reference plane.
4. Briefly explain the working principle of Proximity sensors with neat sketch.

Proximity Sensors:
The output of the proximity sensors gives an indication of the presence of an object with in the
vicinity job operation. In robotics these sensors are used to generate information of object grasping
and obstacle avoidance. This section deals with some of the important proximity sensors used in
robotics.
Proximity sensor is a sensor, which senses the presence or absence of the object without having
physical contact between the objects.

Inductive Proximity Sensors:

The ferromagnetic material brought close to this type of sensor results in change in position of the
flux lines of the permanent magnet leading to change in inductance of the coil. The induced current
pulse in the coil with change in amplitude and shape is proportional to rate of change of flux line in
magnet.

Construction:
The proximity inductive sensor basically consists of a wound coil located in front of a permanent
magnet encased inside a rugged housing. The lead from the coil, embedded in resin is connected to
the display through a connector.
The effect of bringing the sensor in close proximity to a ferromagnetic material causes a change
in the position of the flux lines of the permanent magnet.
5. Explain the Machine vision systems of Robot. (AU-Nov/Dec-2009)
 Machine vision system consists of: Lighting, camera, A/D convertor, frame grabber,
computer processor, robot controller and robot manipulator.

 The hardware and software for perfomring the function of sensing and processing the
image and utilising the results obtained to command the robot.

 The sensing and digitizing functions involve the input of vision data by means of a
camera focused on the scene of interest. Special lighting techniques are frequently used to
obtain an image of sufficient contrast for later processing.

 The image viewed by the camera is typically digitized and stored in computer memory.
The digital image is called a frame of vision data, and is frequently captured by a hardware
device called a frame grabber.

 These devices are capable of digitizing images at the rate of 30 frames per second. The
frames consist of a matrix of data representing projections of the scene sensed by the
camera.

 The elements of the matrix are called picture elements, or pixels. The number of pixels
are determined by a sampling process per formed on each image frame.

 A single pixel is the projection of a small portion of the scene which reduces that portion
to a single value. The value is a measure of the light intensity for that element of the scene.

 Each pixel intensity is converted into a digital value. (We are ignoring the additional
complexities involved in the operation of a color video camera.)

 The digitized image matrix for each frame is stored and then subjected to image
processing and analysis functions for data reduction and interpretation of the image.

 These steps are required in order to permit the real-time application of vision analysis
required in robotic applications.

 Typically an image frame will be thresholded to produce a binary image, and then
various feature measurements will further reduce the data representation of the image.
 This data reduction can change the representation of a frame from several.
6. Explain the various techniques in Image Processing and Analysis.

In the industrial applications the algorithms and programs are developed to process the images
captured, digitized and stored in the computer memory.
The size of data to be processed is huge, of the order of 106 which is to be substantially executed
in seconds.
The difficult and time consuming task of processing is handled effectively by the following
techniques.
(1) Image data reduction
(2) Segmentation
(3) Feature extraction
(4) Object recognition.

Image Data Reduction:

The purpose of image data reduction is to reduce the volume of data either by ellimination of
some or part processing, leading to the following sub-techniques.
(a) Digital conversion
Digital conversion is characterized by reduction in number of gray levels. For a 8-bit register each
pixel would have 28=256 gray levels. When fewer bits are used to represent pixel intensity the digital
conversion is reduced, to suit the requirements.

Segmentation:
An image can be broken into regions that can then be used for later calculations. In effect this
method looks for different self contained regions, and uses region numbers instead of pixel
intensities.
 A simple segmentation algorithm might be,
1. Threshold image to have values of 1 and 0.
2. Create a segmented image and fill it with zeros (set segment number variable to
one).
3. Scanning the old image left to right, top to bottom.
4. If a pixel value of 1 is found, and the pixel is 0 in the segmented image, do a flood fill for the
pixel onto the new image using segment number variable.
5. Increment segment # and go back to step 3.
6. Scan the segmented image left to right, top to bottom.
7. If a pixel is found to be fully contained in any segment, flood fill it with a new segment as in
steps 4 and 5.

Object Recognition:
Form Fitting
It can sometimes help to relate a shape to some other geometric primitive using compactness,
perimeter, area, etc.
- ellipse
- square
- circle
- rectangle
7. With suitable applications brief explain the following: (AU-Nov/Dec-2010)

(i)Optical encoders (ii) Laser range meters (iii) Capacitive type touch sensors
(iv)Ultrasonic proximity sensors

(i) Optical encoders:

The absolute optical encoder employs the same basic construction as incremental optical encoders except
that there are more tracks of stripes and a corresponding number of receivers and transmitters. Usually, the
stripes are arranged to provide a binary number proportional to the shaft angle. The first track might have two
stripes, the second four, the third eight, and so on. In this way the angle can be read directly from the encoder
without any necessary counting. Figure illustrates an absolute optical encoder.

(ii) Laser range meters:

 A pulsed-laser system described by larvis [produces a two-dimensional array with values
proportional to distance. The two-dimensional scan is accom plished by deflecting the laser light via a
rotating mirror. The 66 working range of this device is on the order of I to 4 m, with an accuracy of ±
0.25 cm. Figure shows a collection of three-dimensional objects, and Figure is the corresponding
sensed array displayed as art image in which the intensity at each point is proportional to the distance
between the sensor and the reflecting surface at that point (darker is closer). The bright areas around
the object boundaries represent discontinuity in range determined by post processing in a computer
An alternative to pulsed light is to use a continuous-beam laser and measure the delay (i.e., phase
shift) between the outgoing and returning beams.

(iii) Capacitive type touch sensors:

Unlike inductive and Hall-effect sensors which detect only ferromagnetic materials, capacitive
sensors are potentially capable (with various degrees of sensitivity) of detecting all solid and liquid
materials. As their name implies, these sensors are based on detecting a change in capacitance
induced by a surface that is brought near the sensing element.
The basic components of a capacitive sensor are shown in Figure. The sensing element is a
capacitor composed of a sensitive electrode and a reference electrode. These can be, for example, a
metallic disk and ring separated by a dielectric material. A cavity of dry air is usually placed behind the
capacitive element to provide isolation. The rest of the sensor consists of electronic circuitry which
can be included as an integral part of the unit, in which case it is normally embedded in a resin to
provide sealing and mechanical support.
There are a number of electronic approaches for detecting proximity based on a change in
capacitance. One of the simplest includes the capacitor as part of anOscillator circuit designed so that
the oscillation starts only when the capacitance of the sensor exceeds a predefined threshold value.
The start of oscillation is then translated into an output voltage which indicates the presence of an
object. This method provides a binary output whose triggering sensitivity depends on the threshold
value.
A more complicated approach utilizes the capacitive element as part of a circuit which is
continuously driven by a reference sinusoidal waveform. A change in capacitance produces a phase
shift between the reference signal and a signal derived from the capacitive element. The phase shift
is proportional to the change in capacitance and can thus be used as a basic mechanism for
proximity detection.
(iv)Ultrasonic proximity sensors:

The previously discussed proximity sensors are useful for detection of ferro-magnetic matter only.
If the robot has to handle other type of materials ultrasonic sensors find the application.
Construction:
The main part in this type of sensor is the transducer which can act both as transmitter and
receiver. The sensor is covered by a resin block which protects from dust and humidity. For the
acoustic damping, absorber material is provide as shown in Figure. Finally a metallic housing gives
general protection.
 UNIT IV Robot kinematics and Robot Programming
Part-A Questions

1. What are the methods of robot programming?

 Lead through methods
 Textual robot languages
 Mechanical Programming

2. What are the ways of accomplishing lead through programming?

 Powered Lead through
 Manual Lead through

3. What is teach pendant?

The teach pendant is usually a small handheld control box with combinations of toggle switches,
dials and buttons to regulate the robot‘s physical movements and program capabilities.

4. What are the methods of teaching?

 Joint movements
 X-Y-Z coordinates motions
 Tool coordinate motions

5. What is robot kinematics?

Forward kinematics
It is a scheme to determine joint angles of a robot by knowing its position in the world coordinate
system.

Reverse kinematics
It is a scheme to determine the position of the robot in the world coordinate system by knowing
the joint angles and the link parameters of the robot.

6. What is trajectory planning?

It is defined as planning of the desired movements of the manipulator.

7. Define degrees of freedom.

The number of independent ways by which a dynamic system can move without violating any
constraint imposed on it, is called degree of freedom. In other words, the degree of freedom can be
defined as the minimum number of independent coordinates which can specify the position of the
system completely.

8. Explain joint mode of teaching robots.

The teach pendant has a set of toggle switches (or similar controlled devices) operate each joint
either of it to directions until the endeffector has been positioned to the desired point.

9. Explain the reasons for defining points in a program.

 To define a working position for the endeffector
 To avoid obstacles
10. What is position representation?
The position of the end of the arm may be represented by the two joint angles q1 and q2.this is
known as position representation.
Pj = (q1,q2)

11. Define servo controlled robots.

Servo controlled robots, which are programmed by lead through an textual language methods
tend to actuate all axes simultaneously.

12. What is circular Interpolation?

Circular Interpolation requires the programmer to define a circle in the robot‘s workspace which is
done by specifying three points that lie along the circle.

13. What are irregular smooth motions?

The segments in manual lead though programming are sometimes approximately straight
sometimes curved and sometimes back and forth motions. These motions are called irregular smooth
motions.

14. What is manual lead through programming?

In manual lead through programming the programmer moves the manipulated wrist to teach
spray-painting or arc welding. The movements consist of combination of smooth motion segments.
 Part-B Questions

1. Derive the forward and reverse transformation of 2-Degree of freedom and 3- degree of
freedom arm.