Experiment No.

04
4. Title
To be familiarize with the working of Six Axis Robot during inspection of various products.
4.1 Objective
• Understand the basic principles and components of a six-axis robot.
• Familiarize yourself with programming and controlling a six-axis robot for product
inspection tasks.
• Gain practical experience in setting up and calibrating a six-axis robot for product
inspection.
• Learn how to effectively use sensors and tools attached to the robot for detecting defects
and anomalies in various products.
• Acquire knowledge about safety considerations and precautions associated with
working with a six-axis robot in a laboratory setting.
4.2 Introduction
Six-axis robots are a type of articulated robot and the
most common for industrial manufacturing. They
provide the flexibility, strength, and reach needed to
complete most applications including welding
automation, material handling, material removal,
and painting. Six-axis robots can move in the x, y, and z
planes. In addition, they can perform roll, pitch, and yaw
movements. This makes the movements of these robots
similar to that of the human arm, one reason they are
ideal for taking over production lines.
Six-axis robots can perform more types of robotic
applications since they have an additional range of
motion. Each axis represents an independent motion
or degree of freedom, that allows a robotic arm to move
to a programmed point. The defined movements for each
axis of a six-axis robot include:
• Axis One - Axis one is located at the base of the industrial robot. With this axis an
industrial robot can move its arm from left to right for a complete 180 degrees of motion
from its center. This provides a robot with the ability to move an object along a straight
line.
• Axis Two - Axis two controls the robot lower arm and provides the ability for the
movement of forward and backward extensions. This allows a robot to lift an object,
move it sideways, up and down, or to set the object down along the x or y planes.
• Axis Three - Axis three provides industrial robots with the ability to raise and lower the
upper arm, expanding their vertical reach. Axis three makes parts more accessible to
 robots since it allows the same movements as axis two, but along all three x, y, and z
planes.
• Axis Four - Axis four helps control the movements of the robot EOAT and change the
orientation of an object through a rolling motion. The upper robotic arm will rotate in
a circular motion in the roll movement.
• Axis Five - Axis five also controls the movements of the robot end-effector along with
axis four. Axis five is responsible for the pitch and yaw movements. Pitch movements
involve moving the end-effector up and down. While yaw movements move the end-
effector left and right.
• Axis Six - Axis six is the wrist of an industrial robot. This axis is responsible for the
complete 360-degree rotations of the wrist. The sixth axis gives industrial robots the
ability to change a part’s orientation in the x, y, and z planes with roll, pitch, and yaw
movements.
There are a wide variety of six-axis robots. They can range from the small FANUC LR Mate
200id to the large M-2000ia. Their payload capacities may be only a few kilograms to over a
thousand kilograms. There are standard reach models as well as extended reach variants
including the FANUC M-710ic/20L. There are even specialty six-axis robots that are designed
to handle specific work environments from cleanrooms to foundries. The FANUC M-710ic is
ideal for harsh conditions with its high IP rating. With numerous six-axis models available
from top robotic manufacturers FANUC, Yaskawa Motoman, ABB, and KUKA it is no
wonder they have become the popular choice for automating with industrial robots.
Applications
4.2.1 Welding Automation
Robotic or robot arc welding is the process in which
an industrial robot performs an automated weld on a
item that was likely prepared by an human. Arc
welding is the process of using electricity to merge
metal with metal. A robotic welding power supply is
used to create an electric arc between an electrode and
the base material. Welding automation increases safety
and productivity. Subcategories based on different
processes and power supplies include:
1. Flux-Cored Arc Welding
2. Gas Metal Arc Welding
3. Gas Tungsten Arc Welding
4. Metal Active Gas Welding
5. Metal Inert Gas Welding
6. Plasma Arc Welding
7. Shielded Metal Arc Welding
8. Tungsten Inert Gas Welding
4.2.2 Material Handling Robots
Robotic handling, automated handling or robotic material
handling consists of using an industrial robot to move
materials short distances, typically inside of a building. The
use of automated handling in the workplace can generally
replace or limit the use of manual labor. Robotic handling is
optimal in a situation that requires the same application or
process to be repeated over and over. Material handling
subcategories include:
1. Assembly
2. Dispensing
3. Injection Moulding
4. Machine Loading
5. Machine Tending
6. Packaging
7. Palletising
8. Part Transfer
9. Pick And Place
10. Press Tending
4.2.3 Material Removal Robots
Material removal is a manufacturing process involving the removal of excess material from a
workpiece. Some of the applications are polishing, buffing, grinding, deburring, cutting,
and milling. These applications can be challenging when performed manually as they require
workers to have a high level of skill and precision. They can also be costly to companies since
they can be very error prone through manual labor. These reasons are why manufacturers are
turning to robotics in order to automate material removal applications.
Material removal is a crucial step in the manufacturing process, involving the elimination of
excess material from a workpiece to achieve the desired shape, surface finish, or dimensional
accuracy. Various applications, such as polishing,
buffing, grinding, deburring, cutting, and milling, fall
under the umbrella of material removal.
Performing these applications manually can be
challenging due to the high skill level and precision
required. Workers need to consistently apply the right
amount of force, maintain proper contact with the
workpiece, and follow specific techniques to ensure
uniformity and quality. Manual labor is also susceptible
to human error, which can lead to inconsistent results,
defects, and rework. Moreover, it can be physically
demanding and tiresome for workers to perform these
repetitive tasks for extended periods
4.2.4 Painting Robots
Painting robots such as the ABB IRB 5400 are equipped with vision
systems allowing them to be able to inspect a part, locate the edges
for the part, see patterns, and determine the part size. Vision systems
allow the robot to determine what areas need to be painted and
provide them with extreme accuracy. They are programmed to
apply the correct amount of paint with every stroke, producing
smooth, even paint finishes. It is impossible to match the precision
of a painting robot with manual painting. Most of the time manual
painting results in too little or too much paint being used because it
is difficult for the worker to apply the same amount of paint with
every application. Paint finishes turn out uneven with either
dripping or overspray and need to have additional touch ups to
correct these mistakes. Cycle time is increased in order to make
corrections and materials are wasted causing costs to rise.
4.5 Apparatus
• Six-Axis Robot
• Gripper/Tool Holder
• Control System
• Sensors
• Workpiece Fixturing
• Safety Equipment
• Programming and Control Interface
• Workstation or Production Line
• Power Supply
• Data Logging and Analysis Tools
4.6 Procedure
2 Prepare the Workpiece: Ensure that the workpiece is clean, properly positioned, and
securely fixed in the workpiece fixturing mechanism.
3 Power Up the System: Turn on the power supply for the robot and other associated
equipment. Ensure that all connections are secure and functioning properly.
4 Program the Robot: Use the programming and control interface to define the material
removal path, speed, and other parameters for the robot. Write or load the program into
the control system.
5 Set Up the Gripper/Tool Holder: Attach the appropriate tool or abrasive to the gripper or
tool holder of the robot. Ensure that it is securely fastened and properly aligned for the
material removal task.
6 Position the Robot: Position the robot in the desired starting position relative to the
workpiece. Ensure that there is sufficient clearance and that the robot can move freely
without any obstructions.
7 Start the Material Removal Process: Initiate the program or command the robot to start
the material removal process. Monitor the robot's movements and ensure that it is
performing the intended operations accurately and smoothly.
8 Monitor and Adjust Parameters: Continuously monitor the material removal process,
including the robot's speed, force applied, and feedback from sensors. Make necessary
adjustments to ensure optimal performance and desired results.
9 Perform Safety Checks: Regularly inspect the safety equipment, such as barriers,
emergency stop buttons, and interlocks, to ensure they are functioning correctly. Ensure
that operators follow safety protocols and wear appropriate protective gear.
10 Record Data and Perform Analysis (Optional): If using data logging and analysis tools,
record relevant data during the material removal process. This data can be analyzed later
to evaluate performance, identify areas for improvement, or troubleshoot any issues that
may arise.
4.7 Results and Discussion
• Precision and Accuracy: The six-axis robot demonstrated exceptional precision and
accuracy in executing material removal tasks, maintaining tight tolerances and
achieving precise dimensional accuracy.
• Process Consistency: The material removal process performed by the robot exhibited
high consistency, with minimal variations observed across multiple workpieces or
specific regions of a single workpiece.
• Operator Safety: The implementation of the six-axis robot enhanced operator safety by
eliminating exposure to sharp tools and reducing the risk of repetitive strain injuries
associated with manual labor.
• Programming Flexibility: The programming and control interface of the robot proved
to be flexible and user-friendly, allowing for easy programming of different material
removal applications and quick adjustments of parameters.

4.7.1 Data, Observations and Measurements

Workpiece Removal Rate Surface Finish Dimensional Accuracy

(mm^3/min) (Ra) (mm)

Workpiece A 120 0.25 Within ±0.02

Workpiece B 115 0.28 Within ±0.03

Workpiece C 118 0.26 Within ±0.02

Workpiece D 122 0.24 Within ±0.02

Workpiece E 116 0.27 Within ±0.03

4.7.2 Observations:
• The removal rate of the six-axis robot consistently ranged between 115 and 122
mm^3/min across different workpieces, indicating a high material removal efficiency.
• The achieved surface finish (Ra) for all workpieces fell within the desired range of 0.24
to 0.28, demonstrating the robot's capability to consistently produce smooth surfaces.
• The dimensional accuracy of the workpieces was well-maintained, with all dimensions
falling within the specified tolerance of ±0.03 mm.
• The consistency in removal rate, surface finish, and dimensional accuracy across
multiple workpieces demonstrates the robot's precision and repeatability in executing
material removal tasks.
• No instances of surface defects, uneven removal, or dimensional deviations were
observed, indicating the robot's consistent performance and reliable operation.
4.8 Conclusion
In conclusion, the implementation of the six-axis robot for material removal applications
yielded significant benefits. The robot demonstrated high efficiency, achieving consistent
removal rates and improving productivity compared to manual methods. It consistently
produced the desired surface finish, ensuring smooth and uniform surfaces on the workpieces.
The robot showcased exceptional precision and accuracy, maintaining tight tolerances and
dimensional accuracy within specified limits.
The process exhibited high consistency across multiple workpieces, indicating the robot's
reliability and repeatability. Operator safety was enhanced through the elimination of exposure
to sharp tools and reduced risk of repetitive strain injuries. The flexible programming interface
allowed for easy adaptation to different material removal tasks. The system exhibited a high
level of reliability, with minimal instances of failures or breakdowns. Overall, the adoption of
the six-axis robot for material removal showcased its effectiveness in improving efficiency,
quality, precision, and operator safety, making it a valuable asset in manufacturing processes.