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Module - 3 Machine Tools and Automation

Machine Tools and Automation: Machine Tools Operatioru: Turning,
facing, knurling, Thread cutting, Taper
Turning by swivelling the compound rest, Drilling, Boring, Reaming, ropping,
Counter Sinking, Counter Boring, -
Plane milling, End milling, Slot milling. Q'lo sketches of Machine tools, sketches
to be used only foracplaining
operatiow' Students to be shown the available machine tools in the Machine Shop
of the college before explaining
the operations). Robotics and Automation: Robotics: Introduction, classiJication
based on robots configuration;
Polar' cylindrical, Cartesian Co-ordinate ond spherical. Application, Advantages, and
disadvantages
Automation: Definition, types -Fixed, Programmable & Flexible automation, NC/
CNC machines: Basic elements
with simple block diagrams, advantages and disadvantages.

INTRODUCTIoN: Several metal cutting operations are carried out to produce a mechanical part
of
required shape and size. The metal cutting operations may be carried out either
manually by using hand
tools such as chisels, files, saws etc... or using metal cutting machines. When machines perform
the
metal cutting operations by the cutting tools mounted on them, they are called machine
tools. A machine
tool may be defined as a power driven machine which accomplishes the cutting or machining
operations
on it. The fundamental machine tools that are used formost ofthe machining processes
are given below
1. Lathe Machine. 2. Drilling Machine. 3. Milling Machine. 4. Grinding Machine.
LATHE: A lathe is a machine tool which turns cylindrical material, touches a cutting tool to it, and
cuts
the material. It is said to be the mother of all the machine tools. The lathe is the oldest
of all machine
tools and the most basic tool used in industries. A lathe is defined as a machine tool is primarily
used to
produce circular objects and is used to remove excess material by forcing a cutting
tool against a rotating
work piece- Lathes are also called tuming machines, since the work piece is turned or
rotated between
two centres. since it is so versatile, that almost all the machining operations which are performed
on
other machine tools like, drilling grinding, shaping milling, etc., can be performed
on it.
WORKING PRINCIPLE OF LATHE:

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A lathe, basically a turning machine works on the principle that a cutting tool can remove
material in the
form of chips from the rotating work pieces to produce circular objects- This is accomplished
in a lathe
which holds the work pieces rigidly and rotates them at high speeds while a cutting
tool is moved against
it' rilork piece held rigidly by one of the work holding devices, known as chuck, and is rotated
at very
high speeds. A cutting tool held against the work piece opposite to its direction of rotation
when moved
parallel to the axis of the work piece produces circular surfaces as shown
in figure- The material of the
tool will be harder and stronger than the material of the work piece.

Suhas U, Assistant professor, DepL Of Mechinical Engg., Ciiu-hlEffi Page 1

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LATHE OPERATIONS:
All most all the basic machining operations can be performed on a lathe. They are

l. Turning 2- Taper tuming, 3.Thread cutting,4. Boring 5. Facing, 6. Drilling 7. Reaming 8. Knurling
9. Milling, 10- Grinding. A few of them are discussed briefly below-

Turning: Fig shows the principle of a metal cutting operation using a single-point tool on a lathe. The
work piece is supported in between the two centres which permit the rotation of the work piece. A single
point cutting tool is fed perpendicular to the axis of the work piece to a known pre-determined depth of
cut, and is then moved parallel to the axis of the work pibce. This operation will cut the material which
comes out as shown fig. This method of machining operation in which the work piece is reduced to the
cylindrical section of required diameter is called'Turning'.

Machiaed

Facing: Facitrg is defined as an operation performed on the lathe to generate either flat surfaced or
shoulders at the end of the work piece. In facing operation, the direction of feed given is perpendicular to
the axis of the lathe. The work piece is held in the chuck and the facing tool is fed either from outer edge
of the work piece progressing towards the centre or vice versa. The cutting tool is held by a tool holder in
a tool post.

For:rjaw chuck
Workpir:ce
Machined
flat strfface

Spindle Cutting tool"

Suhas U, AssistantProfessor, Dept OfMechanical Engga CiTech, Bengaluru Page 3

Knurling: Knurling is defined as an operation performed on the lathe to generate serrated surfaces on
work pieces by using a special tool called knurling tool which impresses its pattem on the work piece. A
typical knurling tool consists of one upper roller and one lower roller on which the desired impression
pattern can be seen. The serration or impression pattern can be straight lines or diamond pattem.

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Thread Cutting: A thread is a helical ridge formed on a cylindrical or conical rod. It is cut on a lathe
when a tool ground to the shape of the thread, is moved longitudinally with uniform linear motion while
gear ratio
the work piece is rotating with uniform speed as shown in Fig. By maintaining an appropriate
between the spindle on which the work piece is mounted, and the lead screw which enables the tool to
move longitudinally at ttre appropriate linear speed, the screw thread of the required pitch can be cut- The
pointed tool shown in Fig, is employed to cut V-threads. When square threads are to be cut, the tool is
ground to a squared end.

Taper turning: Taper is defined as a uniform increase or decrease in diameter of a piece of work
measured along its length. Taper turning is an operation on a lathe to produce conical surface on the
work pieces.

TaperTurning by the Swivelling the Compound Tool Rest:

This method of taper turning shown in Fig. It is more suitable for work pieces, which require steep taper

for short lengths. The compound tool rest is swivelled to the required taper angle and then locked in the
angular position. The carriage is also locked at that position. For taper turning, the compound tool rest is
moved linearly at an angle so that the cutting tool produces the tapered surface on the work piece. This
method is limited to short tapered lengths due to the limited movement of the compound tool rest-

Page 4
suhas u, Assistant Professor, DepL of Mechanical Engg.,'ciTech, Bengaluru
The angle at which the compound rest to be swivelled is calculated using the equation given below
,:
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zxL or c=tan-l -Zxt

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(b) Taper portioo of rcrkpiee

(a) ToO view of swivelled compound rest

DRILLING
INTRODUCTION: Drilling is a metal cutting process carried out by a rotating cutting tool to make
circular holes in solid materials. The tool which makes the hole is called a drill. It is generally called as
twist drill, Since it has a sharp twisted edges formed around a cylindrical tool provided with a helical
groove along its length to allow the cut material to escape through tithe sharp edges of the conical
surfaces ground at the lower end of the rotating twist drill cuts the material by peeling it circularly layer
by layer when forced against a work piece. The removed. material chips get curled and escapes through
the helical groove provided in the drill.

DRILLING MACHINE: Drilling machine is a power operated machine tool, which holds the drill bit in
its spindle rotating at high speeds and when manually actuated to move linearly simultaneously against
the work piece produces a hole, is called drilling machine.

lifl1d fsed lever

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Spindle
Ch(ck
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Suhas U, Assistant Professor, Dept Of Mechanical Engg., CiTech, Bengaluru Page 5

DRILL BIT NOMENCLATURE:
Ijlutes

A twist drill shown in Fig.it is ttre cutting tool that is employed in the drilling machines. Two long
diametrically opposite helical flutes are formed throughout its effective length. A twist drill is composed
of three major parts-point, body and shank.

DRILLING OPERATIONS: Apart from drilling a number of other operations that can be performed
on a drilling machine,using the various tools are:

1) Dritling 2) Boring 3) Reaming,3) Counter boring 4) Countersinking, 5) Spot facing & 6) Tapping.

Drilling is a cutting process that uses a drill bit to cut or.enlarge a hole of circular cross-section in solid
materials. The.drill bit is a rotary cutting tool, often multipoint. The bit is pressed against the work piece
and rotated at rates from hundreds to thousands ofrevolutions per minute- This forces the cutting edge
against the work piece, cutting offchips (swarfl from the hole as it is drilled.

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Boring: Boring is done on a drilling machine to increase the size of an already drilled hole. When a
suitable size drill is not available, initially a hole is drilled to the nearest size and using a single point
cutting tool, the size of the hole is increased as shown in Fig. By lowering the tool while it is
continuously rotating, the size of the hole is increased to its entire depth. Fig shows when the boring
operation is in progress. It will be continued till the lower surface of the work piece.

r-IWBoringtoor

Work piece

Suhas U, Assistant Professor, Dept. Of Mechanical Engg., CiTech, Bengaluru Page 6

Reaming: Reaming is the process of smoothing the surface of the drilled holes with a reatner. A reamer
is similar to the twist drill, but has straight flutes. After drilling the hole to a slightly smaller size, the
reamer is mounted in place of twist drill and with the speed reduced to half of that of the drilling,
reaming is done in the same way as drilling. It removes only a small amount of material and produces a
smooth finish on the drilled surfaces.

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Counter boring: Counter boring is to increase the size of a hole at one end only through a small depth as
shown in Fig. The counter boring forms a larger sized recess or a shoulder to the existing hole. The
cutting tool will have a small cylindrical projection known as pilot to guide the tool while counter boring.
The diameter . of the pilot will always be equal to the diameter of the previously drilled hole.
Interchangeable pilots of different diameters are also used for counter boring holes of different diameters.
The speeds for counter boring must be two-thirds of the drilling speed the corresponding size of the
drilled hole. Generally the counter boring is done on the holes to accommodate the socket head screws,
or grooved nuts, or round head bolts.

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Countersinking: Countersinking shown in Fig. it is the operation of making the end of a hole into a
conical shape, It is done using a countersinking tool shown in figure. The countersinking process may
also be employed for deburring the holes. The cutting speeds for countersinking must be about one-half
of that used for similar size drill. The countersunk holes are used when the countersunk screws are to be
screwed into the holes so that their top faces have to be in flush with the top surface of the work piece.

Suhas U, Assistant Professor, Depu OfMechanical Engg" CiTech, Bengaluru PageT

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Tapping: - The tapping shown in Fig. it is the process of cutting internal threads with a thread cutting
tool called tap. A tap is a fluted threaded tool used for cuffing internal threads. Before tapping, a hole
which is slightly smaller than the size of the tap is drilled. For cutting the threads, the tap is fitted in the
tapping attachment which in turn is mounted in the drilling machine spindle, and the threads are cut in
the same way as drilling. While tapping in a drilling machine the spindle has to rotate at very slow
speeds. The tap will be held in a collapsible type of tapping chuck, which is inserted in the spindle of the
drilling machine. Generally tapping is done on a drilling machine when identical threading is required on
large number of parts.

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MILLING
INTRODUCTION
Milling: -Milling is a manufacturing process in which the excess material from the work piece is
removed by a rotating multipoint cutting tool called millirg cutter.
The milling cutter is a multipoint cutting tool. The work piece is mounted on a movable work table
which will be fed against the revolving milling cutter to perform the cutting operation.

Milling machine: - A milling machine is a power operated machine tool in which the work piece is
mounted on movlng table is machined to various shapes when moved under a slow revolving serrated
cutter-

Suhas U, Assistant Professor, DepL Of Mechanical Engg., CiTech, Bengaluru Page B

PRINCIPLE OF MILLING
Cuttet

Chip
L
.'- -Feed

(a) Up milling (Conventional milling) .{b} Down milling (Climb millingl

The above figure shows the types of milling process that is upmilling and downmilling. upmilling is also
called as conventional milling and downmilling is called climb milling. The milling cutter is mounted on
a rotating shaft known as arbor. The workpiece which is mounted on the table can be fed either in the
direction opposite to that of the rotating cutter as shown in figure (a) or in the same direction of the cutter
as shown in figure (b).

MILLING OPERATIONS OR PROCESSES:

The milling operations are given below
l)Plain milling 2) End milling, 3) Slot milling 4)Form milling 5)Straddle milling 6)Gang milling
7)Angularmilling

Plain milling or SIab mitling: slab milling is the operation of producing flat, horizontal surface parallel
to the axis of rotation of a slab-milling cutter. Slab milling is done to remove the material from the upper
surface of the work piece. The slab milling cutters is held in the arbor and it may have straight or helical
teethes. Both cuffers can be used to generate flat surfaces. The require depth ofcut can be adjusted by
raising the table or the knee and the feed is given by moving &e saddle.

Slab rnill culter

Workpiece

End milling: -End milling is a process of milling that is used to mill slots, pockets and keyways in such
a way that the axis of the milling cutter is perpendicular to the surface of the work piece. The milling
operation when used for keyway cutting as shown in figure. The advantage of the end milling operation
is that we can achieve depth of cut of nearly of the diameter of the mill.

Suhas U, Assistant Professor, Dept OfMechanical Engg. CiTech, Bengaluru Page 9

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Slot milling: Slot milling is the operation of producing slots like T-slots, plain slots, dovetail slots etc., in
worktable fixtures and other work holding devices. The operation may be performed using eighter end
milling cutter, T-slot cutter, dovetail cutter or side milling cutter. The type of cutter selected depends on
the shape of the slot to be produced. Two separate milling cutters are required for milling T-slots.
Initially a side cutter or an end milling cutter is used to cut the throat (open slot) starting from one end of
the work piece to its other end. A T-slot milling cutter is then used to cut the headspace to the desired
dimensions. Similar procedure is followed for cutting a dovetail slot, but a dovetail slot cutter is used in
place of T-slot cutter.

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AUTOMATION

In today's fast-moving, highly competitive industrial world, a company must be flexible, cost
effective and efficient if it wishes to survive. In the process and manufacturing industries, this has
resulted in a great demand for industrial control systems/ automation in order to streamline operations in
terms of speed, reliability and product output. Automation plays an increasingly important role in the
world economy and in daily experience.

Automation is the use of control systems and information technologies to reduce the need for human work
in the production of goocls and services- ln the scope of industrialization, automation is a step beyond
mechanization. Whereas mechanization provided human operators with machinery to assist them with the
muscular requirements of worlg automation greatly decreases the need for human sensory and mental requirements
as well.

Suhas U, Assistant Professor, Dept Of Mechanical Engg., CiTech, Bengaluru Page 10

Types of Automation
Automated system can be classified into three basic types-
l. Permanent/FixedAutomation
2. Programmable Automation
3. FlexibleAutomation.

1. Fixed automation: Fixed automation is a system in which the sequence of processing (or assembly)
operations is fixed by the equipment configuration. The operations in the sequence are usually simple. It
is the integration and coordination of many such operations into one piece of equipment that makes the
system complex.
The typical features of fixed automation are:
D High initial investment for custom-engineered equipment
F High production rates
), Relatively inflexible in accommodating product changes.
The economic justification for fixed automation is found in products with very high demand rates and
volumes. The high initial cost of the equipment can be spread over a very large number of units, thus
making the unit cost attractive compared to alternative methods of production.

2. Programmable automation: In programmable automation, the production equipment is desigred

with the capability to change the sequence of operations to accommodate different product
configurations. The operation sequence is controlled by a program, which is a set of instructions coded so
that the system can read and interpret them. New programs can be prepared and entered into the
equipment to produce new products- Some of the features that characterize programmable automation
include:
F High investment in general-purpose equipment
) Low production rates relative to fixed automation
F Flexibility to deal with changes in product configuration
F Most suitable for batch production
D Automated production systems that are programmable are used in low and medium volume production.
3. Ilexible automation: Flexible automation is an extension of programmable automation. The concept
of flexible automation has developed only over the last 15 to 20 years, and the principles are still
evolving. A flexible automated system is one that is capable of producing a variety of products (or parts)
with virtually no time lost for changeovers from one product to the next. There is no production time lost
while reprogramming the system and altering the physical setup (tooling, fixtures and machine settings).

Consequently, the system can produce various combinations and schedules of products, instead of
requiring that they be made in separate batches.
The features of flexible automation can be summarized as follows:
D High investment for a custom-engineered system
) Continuous production ofvariable mixtures of products
F Medium production rates
) Flexibility to deal with product design variations

Suhas U, Assistant Professor, DepL Of Mechanical Engg., CiTech, Bengaluru Page 11

Advantages and disadvantages of Automation:
The main advantages of automation are:
F Replacing human operators in tasks that involve hard physical work.
) Replacing humans in tasks done in dangerous environments (i.e. fire, space, volcanoes, nuclear
facilities, underwater, etc.)
D Performing tasks that are beyond human capabilities of size, weighq speed, endurance,etc.
) Safer working conditions.
D Automation results in reduces total cost per unit output.
! Better product quality and consistent in accuracy. '

The main disadvantages of automation are:

> High initial cost for equipment's and technologies.
) High maintenance costs.
) Increase in un-employment.
F Not suitable for short product life cycle.
) Not economically justifiable for small scale production.

INTRODUCTION TO NC MACHINES:
Numerical control can be defined as a form of programmable automation in which process is controlled
by numbers, letters and symbols. ln NC, the numbers form a programme of instructions designed for a
particular work part or job. When job changes the program of instruction changes. T[is capability to
change a program for each new job gives NC its flexibility.

Basic components of NC system:

An operational numerical control system consists ofthe following three basic components:
I . Program of instructions.
2. Controller unit also called machine tool unit (MCU),
3. Machine tool or other controlled process.

The program of instructions seryes as input to the controller unit, which in turn commands the machine
tool or other process to be controlleG

Program of Controller
instructions unit Machine tool
Throe'baslc componsftts of a numericsl conlrol system.

1. Program of Instructions: The program of instructions is the detailed step by step set of instructions
which tell the machine what to do. It is coded in numerical or symbolic form on some type of input
medium that can be interpreted by the controller unit. The most common one is the I -inch-wide punched
,"p". O""r rh. V."t
Suhas U, Assistant Professor, DepL OfMechanical Engg, CiTech, Bengaluru PageL2

.s
and even 35mm motion picture film. There are two other methods of input to the NC system which
should be mentioned. The first is by manual entry of instructional data to the controller unit. This is time
consuming and is rarely used except as an auxiliary means of control or when one or a very limited no. of
parts to be made. The second method of input is by means of a direct link with the computer. This is
called direct numerical control, or DNC{

2. Controller Unit The second basic component of NC system is the controller unit. This consists of
elechonics and hardware that read and interpret the program of instructions and convert it toftn""frJ""i
actions of the machine tool. The typical elements of the controller unit include the tape reader, a data
buffer, signal output channels to t}e machine tool, and the sequence controls to coordinate the overall
operation of the foregoing elements.
The tape reader is an electrical-mechanical device for the winding and reading the punched tape
containing the program of instructions. The signal output channels are connected to the servomotors and
other controls in machine tools. Most N.C. tools today are provided with positive feedback controls for
this purpose and are referred as closed loop systems. However there has been growth in the open loop
systems which do not make use of feedback signals to the controller unit.

3- Machine Tool: The third basic component of an NC system is the machine tool or other controlled
process. It is part of the NC system which performs useful work In the most common example of an NC
system, one designed to perform machining operations, the machine tool consists of the worktable and
spindle as well as the motors and controls necessary to drive them. It also includes the cutting tools, work
fixtures and other auxiliary equipment needed in machining operationl

Advantages and disadvantages of NC MACHINES:

Advantages:
1. Higherproductivity.
2. Higher precision with better quality control of products.
3. Multi operational facilities (or tasks).
4. Does uot require a skilled operator-
Disadvantages:
l, High initial cost of equipment's,
2. Maintenance cost. i
3. Required skilled personal to execute a program.
4. Tapes tend to wear and become dirty on frequent use and thus may become unreadable.
5- Punched tape needs to be recycled for each product ofthat batch.

INTRODUCTION TO CNC MACHINES:

Computer Numerical Control (CI.fc) is defined as an NC system who,s MCU is based
on a
dedicated Microcomputer rather than on a hard-wired controller. The latest computer
controllers for CNC
feature high speed processors, large memories, solid-state flash memory, improved seryos,
and bus
architectures. Some controllers have the capability to control multiple machines.

suhas u, Assistant Professor, Dept of Mechanical Engg.,.cirech, Bengaluru

Page 13
THE MACHINE CONTROL I'NIT FOR CNC

The MCU is the hardware that distinguishes CNC from conventional NC. The general configuration of
the MCU in a CNC system is illustrated in Figure 8. The MCU consists of following components and sub
systems: (1) central procegsing unit, (2) memory (3) VO interface, (4) controls for machine tool axes and
spindle speed, and (5) sequence controls for other machine tool functions.

Central processing unit. The central processing unit (CPU) is the brain of the MCU. It manages the
other components in the MCU based on software contained in main memory. The CPU can be divided
into three sections: (1) control section, (2) arithmetic-logic unit, and (3) intermediate access memory.

Memory. The immediate access memory in the CPU is not intendta m, storing CNC software- A much
greater storage capacity is required for the various programs and data needed to operate the CNC system.

Input/output interface. The VO interface provides communication between the various components of
the CNC system, other computer systems, and the machine operator- As its name suggests, the VO
interface transmits and receives data and signals to and from external devices.

Controls for machine tool axes and spindle speed. These are hardware components that control the
position and velocity (feed rate) of each machine axis as well as the rotational speed of the machine tool
spindle.

Sequence controls for other machine tool functions. In addition to control of table position, feed rate,
and spindle speed, several additional functions are accomplished under part program control- These
auxiliary functions are generally on/off actuations, interlocks, and discrete numerical data. To avoid
overloading of CPU, a progrirmmable logic controller is sometimes used to manage the VO interface for
these auxiliary functions.

Advantages of CNC Machine:

. It eliminates human errors.
. Higher flexibility-
. High accuracy.
. Wastage is minimum.

Suhas U, Assistant Professor, DepL Of Mechanical Engg., CiTech, Bengaluru Page 14 ":.
1
1:-&--"
 Suitable for batch production less space is required.
Reduces inspection cost
More operational safety.
Quality of product is high.

Disadvantages of CNC Machine

. Initial cost is high.
. It requires skilled progrirmmers.
. It is not suitable for small scale production.
. Maintenance cost is more.

Major difference between NC and CNC machines fallows.

NC Machine CNC Machine
The punched tape is cycled
through the reader for every work piece in the The program is entered once and
batch then stored in computer memory

It has no additional flexibility and It has additional flexibility

computational capability and
computational capability

The hardware NC controller unit is present The conventional hardware NC control

unit is replaced microcomputer
!y
use of comput"ir."fin@
We cannot easily refine. change and improve part programming procedure through interactive
the part programming procedure graphic techniques

Total factory automation with the help of NC Total factory automation is easily
machines not easily possible possible and is more compatible

Adaptive control and in-process compensation Use of adaptive control and in-process
cannot be done with the help of NC machine compensation optimize the working conditions

Data are stored in the tape to the control unit Data may be stored or directly sent

Modifications are not easy Modifications can be done very easily

Suhas U, Assistant professor, DepL Of Mechanical Engg.,

CiTech, Bengaluru Page 15
 ROBOTICS
Introduction:
An industrial robot is a general - purpose, programmable machine processing certain anthropomorphic
characteristics. The most obvious anthropomorphic characteristic of an industrial robot is its mechanical
arm, which is used to perform various indushial tasks. Other human - like Characteristics are the robot's
capabilities to respond to sensory inputs, communicate with other machines, and make decisions. These
capabilities permit robot to perform a variety of useful tasks. The development of robot technology
followed the development of numerical control, and the two technologies are quite similar. They both
involve coordinate control of multiple axes (the ixes are called joints in robot), and they both use
dedicated digital computers as controllers. The robots are designed for a wider variety of tasks. Typical
production applications of industrial robots include spot welding, material transfer, machine loading,
spray painting,- and assembly.

Classification based on ROBOT configurations:

Cartes ian confi guration

Cylindrical configuration t.
Polar configuration
a Jointed - arm configuration
SCARA(selective compliance assembly robot arm)

1. CARTESIAN CONFIGT]RATION ROBOT

Cartesian configurations robot is so called because the Arm movement of robot is designed to move
parallel to x, y, z-axis of a Cartesian coordinate system as show in figure. A robot designed with this type
of configurations Capable of moving its arm to any point linearly within rectangular work space. Since
the arm movement in linear, the robot is also called as rectilinear or gantry robot

Suhas U, Assistant Professor, DepL Of Mechanical Engg., CiTech, Bengaluru Page 16

Advantages:

> High degree of mechanical rigidity, accuracy and repeatability.

F It able to carry heavy loads.
D Movement can start and stop simultaneously along all three axis, motion of wrist end is smoother.
Disadvantages:

F The arm movement is limited to a small rectangular work space.

) Occupy large space.
D Low ratio of robotsize to operate volume T
Applications: Assembly, welding machine loading and unloading surface finishing inspection, etc.

2. CYLINDRICAL CONFIGURATION ROBOT

The cylindrical configuration combines both vertical (z-axis) and horizontal (x-axis) linear
movements with rotary movement in the horizontal plane about vertical axis (y-axis). It is also called sr-r
because its motions sweep out a partially cylindrical working volume.

This robot configuration finds application in radial workplace layout where the work approached
primarily in the horizontal plane and where no obstructions are present.

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h Wcr{rerarelapa
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I

A typical cylindrical configuration is illustrated in fig. It consists of a base, a horizontal arm and a
prismatic joint built into the horizontal around the vertical column, describing a partial cylinder in space-
The prismatic joint can slide in and out remaining parallel to the base.

Suhas u, Assistant Professor, DepL ofMechanical Engg, cirech, Bengaluru Page17

Advantages:

F Larger work space than Cartesian configuration.

Applications: machine loading and unloading investrnent casting, forging operations, conveyor pellet
transfer, assembly, coating applications etc.

3. POLAR CONHGI.IRATION OR SPHERICAL CONTIGI]RATION:

The geometr5r of the spherical or polar configuration combines rotational movement in both
horizontal and vertical planes with a single linear movement of the arm. I
This configuration occupies and sweeps out a relatively large volume and access of the arm
within this total volume is restricted.

This robot rotates about the vertical axis (T joint) of its waist on the base. The second axis is a
horizontal rotary joint (R joint) allowing arm to rotate in a vertical plane. Making use of both axes, the
arm can sweep through a partial sphere of radii depending on the length of the prismatic joint (L joint)
shown in fig

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trst€rse tfirts-f*t

Advantages:
F Configuration is simple in design, and hence easy to program.
F Provides good weight lifting capabilities.
Applications: Die-casting, injection moulding, forging machine tool press, material transfer
applications.

Suhas U, Assistant Professor, Dept Of Mechanical Engg., CiTech, Bengaluru Page 18

4. JOINTED -ARM CONFIGURATION ROBOT:
This robot manipulator has the general configuration of human arm- Consisting two straight
component's corresponding to the human forearm and upper are mounted on a vertical pedestal that can
be rotated about the base. The jointed arm configuration shown in fig. consists of a vertical column that
swivels about ttre base using a Tjoinl

L
At the top of the colurnn is a shoulder joint (R joint), whose output link connects to an elbow joint
(Rjoint).

Advantages'of robots
) Robotics and automation can, in many situation, increase productivity, safety, efficiency, quality
and consistency of product.
F Robots can work in hazardous environments.
) Robots need no environmental comfort.
F Robots work continuously without any humanity needs and illness.
F Robots have repeatable precision at all times.
) Robots can be much more accurate than humans; they may have milli or micro inch accuracy.
! Robots and their sensors can have capabilities beyond that of humans.
) Robots can process multiple tasks simultaneously but humans can only one.

Disadvantages of robots
Robots lack capability to respond in emergencies, this can cause.
o In appropriate and wrong response
o A lack of decision making power
o A loss 6f power
o Damage to the robot and other devices
o Human injuries

Suhas U, Assistant Professor, DepL Of Mechanical Engg., CiTech, Bengaluru Page 19

Robots may have limited capabilities in
. Degrees of freedom
o Dexterity
. Sensors
. Vision system.
. Real -time response
Robots are costly due to
. Initial cost of equipment
. Installation cost
. Need for peripherals
o Need for training
' . Need for programming.

Robot applications
. Need t<i replace human labor by robot.
. Work environment hazardous for human beings.
. Repetitive task
. Boring and unpleasant task
. Multi shift operations
. Operating for long hours without rest
. Assemblyapplications
. Material handling applications
. Processingoperations
. Inspectionapplications

Suhas U, Assistant Professor, DepL Of Mechanical Engg., CiTech, Bengaluru Page 20