INTRODUCTION TO

ROBOTICS
ROBOTICS
It is the science of designing and building robots suitable for real-life applications in
automated manufacturing and other non-manufacturing environments.

ELECTRICAL
COMPUTER
MECHANICAL AND
SCIENCE
ELECTRONICS

ROBOTICS
 FACTORS FOR INTRODUCTION OF ROBOTICS TO
INDUSTRIAL WORLD

• Improved Quality of Products

• Lesser Preparation time
• Lower rejects and less waste
• Skilled labour shortage
• Demand of improvement quality
• Rising costs
• Pressure to increase the production
INDUSTRIAL ROBOT
"An industrial robot is a reprogrammable multifunctional manipulator
designed to move material, parts, tools or specialized devices through
various programmed motions for the performance of a variety of tasks"
 FUNCTIONS OF ROBOT

The functions of a robot can be classified into three areas :

• Sensing the environment by external sensors.
Example : Vision, voice, touch, proximity and so on.
• Decision making" based on the information received from the sensors.
• "Performing" the task decided.
 OBJECTIVES OF USING INDUSTRIAL ROBOTS
• To reduce production time.
• To minimise the labour requirement.
• To raise the quality level of products.
• To increase productivity.
• To enhance the life of production machines.
• To minimise the loss of man-hours on account of accidents and diseases
 ADVANTAGES AND DISADVANTAGES WITH
APPLICATIONS
ADVANTAGES DISADVANTAGES
• Working during unfavorable hours. • Lack in capability of responding in emergencies
• Increasing productivity, quality of products • Cost of installation is very high
• Achieve more accuracy • Replace human workers and affects their life
• Providing repeatability and consistency style.
• Lifting and moving heavy objects

APPLICATIONS

Welding Material Handling Assembly Grinding

Painting Cleaning Cutting Packing
 ROBOT COMPONENTS :
The various components of a robot :

1. Base

2. Manipulator arm

3. End-effector

4. Actuators and transmissions

5. Controller

6. Sensors
Base:
The base may be fixed or mobile
Manipulator arm:
The most obvious mechanical configuration of the robot is the manipulator arm. A robotic manipulator arm
consists of several separate links making a chain. The arm is located relative to the ground on either a fixed base
or a movable
base. It has a free-end where an end-deflector or gripper or some times a specialised tool holder (for holding,
say, a welding gun) or any powered device (say, a drill) is attached.
End-effector:
Robot end-effector is the gripper or end of arm tooling mounted on the wrist of the robot manipulator arm.
The wide range of gripping methods include :
(i) Mechanical clamping.
(ii) Magnetic gripping
(iii) Vacuum (suction) gripping
Actuators and Transmissions:
Actuators :
The robot arm can be put to a desired motion with its payload if actuator modules are fitted in to provide power
drives to the systems i.e. Pnumatic drive, hydraulic drive, Electric drives.
Transmissions:
"Transmissions" are elements between the actuators and the joints of the mechanical linkage
Controller:
The "controller" provides the intelligence that is necessary to control the manipulator system.
Sensor:
The sensors perform the following functions :
• To act as feedback devices to direct further actions of the manipulator arm and the end effector (gripper),
and
• To interact with the robot's working environment.
 BASIC MOTIONS:
• The six basic motions or degrees of freedom (DOFs) are as
follows:
• Vertical motion: The entire manipulator arm can be moved up
and down vertically either by means of the shoulder swivel, i.e.,
turning it about a horizontal axis, or by sliding it in a vertical slide.
• Radial motion: Radial movement, i.e., in and out movements, to
the manipulator arm is provided by Elbow extension by extending
it and drawing back
• Rotational motion: Clock wise or anti-clock wise rotation about
vertical axis of manipulator arm.
• Pitch motion: Up and down movement of wrist
• Roll motion: Enables of rotation of wrist
• Yaw: Enables rightward and leftward swivelling movement of the
wrist
ROBOT CLASSIFICATION:

The majority of commercially available

robots can be grouped into four basic
configurations :
(i) Cartesian coordinate configuration.
(ii) Cylindrical configuration.
(ii) Spherical configuration.
(iv) Jointed-arm configuration (Revolute)
(v) SCARA
Cartesian coordinate configuration
• In this there are three orthogonal directions X,Y and Z.
• X-coordinate axis may represent left and right motion.
• Y-coordinate axis may represent forward and backward motion.
• Z-coordinate axis may represent up and down motions.
• Example of Cartesian System is Overhead Crane Movement
Cylindrical Configuration Robot
• It uses a vertical column and a slide that can be moved up or down along the column.
• The robot arm is attached to the slide so that it can be moved radially with respect to the column.
• By rotating the column, the robot is capable of achieving a work space that approximates a
cylinder.
• It contains two linear motions and one rotational motion. Angular Motion, θ along vertical axis;
Translation Motion, z along z-direction that corresponds to up and down motion; Radial, r in or out
translation.
Spherical Configuration Robot
• It uses an arm that can be raised or lowered about a horizontal pivot.
• The pivot is mounted on a rotating base.
• The various joints provide the robot with capability to move its arm within a spherical space, and hence it is also
called as “ Spherical Coordinate Robot.”
• It has one linear and two rotary motions.
SCARA Robot
• SCARA is a special type of jointed arm configuration.
• It stands for Selective Compliance Automated Robot Arm (or) Selective Compliance Articulated Robot Arm.
• It is similar to jointed-arm except that the vertical axes are used for shoulder and elbow joints to be compliant in
horizontal direction vertical insertion tasks.

Revolute or Articulated Configuration

• The Revolute configuration comprises a number of rigid arms connected by rotary joints, rotary movement at the
base is also provided.
• Since all movements are by angular rotation of the joints complex calculations are often needed to move the arm
in straight lines.
INTRODUCTION TO CNC
Numerical Control Machine(NC)

 Form of programmable automation.

 Mechanical actions of machine tool are
controlled by program.
 The program is in form of alphanumeric
data.
 After a job is finished the program of
instructions can be changed to process a
new job.
Numerical Control Machine(NC)

Advantages Disadvantages
 High investment cost.
 Reduces non productive time
 High maintenance effort.
 Reduces manufacturing lead time
 Part programming.
 Greater manufacturing flexibility
 Higher utilization of NC Equipment's.
 Improves quality control
 Reduced inventory
CNC Machine

 To overcome the shortcomings of the NC machines CNC machines evolved.

 CNC machines are the NC machines whose MCU is based on the micro
computer rather than the hardwired controller.

Elements of
Machine Machine
CNC Part program Control Unit
machines are tool

Features of Improved
Storage of more In-process Adaptive control
programming
CNC than one part compensation and operating adjustments
program features
machines are:
Block diagram of CNC Machine
Elements of CNC machines

Elements of CNC machine tool essentially consists of the following

parts:
 Part Program
 Program Input Device
 Machine Control Unit (MCU)
 Drive System
 Machine Tool
 Feedback System.
Part Program
A part program is a series of coded instructions required to
produce a part.
It controls the movement of the machine tool and on/off control
of auxilary functions such as spindle rotation and coolant
The coded instructions are composed of letters, numbers and
symbols.
E.g:
N10 G01 X5.0 Y2.5 F15.0
| | | | |
| | | | Feed rate (15 in/min)
| | | Y-coordinate (2.5")
| | X-coordinate (5.0")
| Linear interpolation mode
Sequence number
G Codes
G00 Rapid traverse G40 Cutter compensation – cancel
G01 Linear interpolation G41 Cutter compensation – left
G02 Circular interpolation,CW G42 Cutter compensation- right
G03 Circular interpolation, CCW G70 Inch format
G04 Dwell G71 Metric format
G08 Acceleration G74 Full-circle programming off
G09 Deceleration G75 Full-circle programming on
G17 X-Y Plane G80 Fixed-cycle cancel
G18 Z-X Plane G81-G89 Fixed cycles
G19 Y-Z Plane G90 Absolute dimensions
G20 Inch Units (G70) G91 Incremental dimensions
G21 Metric Units (G71)
M Codes
M00 Program stop
M01 Optional program stop
M02 Program end
M03 Spindle on clockwise
M04 Spindle on counterclockwise
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
M10 Clamps on
M11 Clamps off
M30 Program stop, reset to start
Program Input Device

The program input device is the means

for part program to be entered into
the CNC control.
Three commonly used program input
devices are punch tape reader, magnetic
tape reader, and computer or USB
communication.
Machine Control Unit (MCU)
The machine control unit (MCU) is the heart of a CNC system. It is used to perform the
following functions

a) To read the coded instructions.

b) To decode the coded instructions.
c) To implement interpolations (linear, circular, and
helical) to generate axis motion commands.
d) To feed the axis motion commands to the amplifier
circuits for driving the axis mechanisms.
e) To receive the feedback signals of position and
speed for each drive axis.
f) To implement auxiliary control functions such as
coolant or spindle on/off and tool change.
Drive System

 A drive system consists of amplifier circuits,

drive motors, and ball lead-screws.
 The MCU feeds the control signals (position and
speed) of each axis to the amplifier circuits.
 The control signals are augmented to actuate
drive motors which in turn rotate the ball lead-
screws to position the machine table.
Feedback System

The feedback system is also referred to as the

measuring system.
 It uses position and speed transducers to
continuously monitor the position at which
the cutting tool is located at any particular
instant.
 The MCU uses the difference between
reference signals and feedback signals to
generate the control signals for correcting
position and speed errors.
Common types of CNC machines

CNC Lathe machine

CNC Milling machine
CNC Drilling machine
CNC Grinding machine
CNC Laser cutting machine
Water jet cutting machine
Electro discharge machine
Applications
 Parts needed in a hurry
 Parts with complicated contours
 Parts requiring expensive jigs and fixtures
 Parts those have several engineering changes
 Cases where human errors can be extremely costly
 Parts requiring close tolerance or good repeatability
 ADVANTAGES OF CNC MACHINE

 Productivity
Machine utilization is increased because more time is spent cutting and less time is
taken by positioning. Reduced setup time increases utilization too.
PROFIT increases as COST decreases and as PRODUCTIVITY increases.

PRODUCTIVITY through AUTOMATION

helping the workers to

perform their tasks more
efficiently

AUTOMATION

Transfer of the skill of the

operator to the machine
 Quality
1. Parts are more accurate.  Higher accuracy
2. Parts are more repeatable.  Reduce lead time
3. Less waste due to scrap.
 Higher flexibility
 Machining Complex shapes  Reduce scrap rate
1. Slide movements under computer control.
 Reliable operation
2. Computer controller can calculate steps.
 Consistent quality
 Management Control
 Reduced manpower
1. CNC leads to CAD
2. Process planning  Increased productivity
3. Production planning  Reduced non productive time
 Increased dimension precision of the work part through high basic precision of the
machine tool (1/1000mm).
 DISADVANTAGES OF CNC MACHINE

1. Machine Cost is Higher than Conventional Machine.

2. Higher Maintenance Costs .

3. Higher Labor Costs .

4. Higher Machine Attachment Costs.

5. Higher Tooling Costs.

6. High maintenance requirements

 FLEXIBLE MANUFACTURING SYSTEMS (FMS)
• An FMS is a “reprogrammable” manufacturing system capable of producing a
variety of products automatically.
• Conventional manufacturing systems have been marked by one of two distinct
features:
• The capability of producing a variety of different product types, but at a high
cost (e.g., job shops).
• The capability of producing large volumes of a product at a lower cost, but very
inflexible in terms of the product types which can be produced (e.g., transfer
lines).
• An FMS is designed to provide both of these features.
FMS Components

• Numerical Control (NC) machine tools

• Automated material handling system (AMHS)
• Automated guided vehicles (AGV)
• Conveyors
• Automated storage and retrieval systems (AS/RS)
• Industrial Robots
• Control Software
Flexible Manufacturing System
Computer
control
room
Tools

Conveyor

Machine Machine

Pallet

Load Unload

Terminal Finished
Parts
goods
A flexible manufacturing system (FMS) is a production method that is designed to
easily adapt to changes in the type and quantity of the product being manufactured.
A flexible manufacturing system may include a configuration of interconnected
processing workstations with computer terminals that process the end-to-end creation of
a product, from loading/unloading functions to machining and assembly to storing to
quality testing and data processing. The system can be programmed to run a batch of
one set of products in a particular quantity and then automatically switch over to another
set of products in another quantity.