Experiment No - 1: DEMONSTRATION OF ROBOT CONFIGURATION

Objective
1) To know about the specifications of robots
2) To study basic robot co-ordinate configurations

Theory
Introduction
“An industrial robot is an automatically controlled, reprogrammable, multipurpose manipulator
designed to move material, parts, tools, or special devices through variable programmed motions
for the performance of a variety of tasks”. The field of industrial robotics may be more practically
defined as the study, design and use of robot systems for manufacturing. Typical applications of
industrial robots include welding, painting, ironing, assembly, pick and place, palletizing, product
inspection, and testing, all accomplished with high endurance, speed, and precision. The most
commonly used robot configurations for industrial automation include articulated robots, SCARA
robots and gantry robots.

Robotics and Automation

Robotics is the science of designing and building robots suitable for real-life applications in
automated manufacturing and other non-manufacturing environments. Robot are the means of
performing multifarious activities for man’s welfare in the most planned and integrated manner,
maintaining their own flexibility to do any work, effecting enhanced productivity, guaranteeing
quality, assuring reliability and ensuring safety to the workers. To produce more goods in a
reasonably shorter period of time, the speed of production emerged as a factor of paramount
importance. For the given five-M inputs (Man, machines, materials, money and motivation), more
outputs at faster speed became imperative to raise the level of productivity.
Programmable automation uses information technology and numerical engineering to provide
coordination, machine control and communication through computers in the most effective way.
An example of the Programmable automation technology is the robot. The robot is an essential
component of CAM and CIM technologies. So, robots with their sensory capabilities and artificial
intelligence (AI) are more advanced than the conventional and automated machines in all respects.
Components of Robots
The industrial robots shown in figure resemble an inverted human arm mounted on a base. The
most complex robotics system can be broken down into a few basic components.

Figure: Basic components of a robot

1) Manipulator
2) Sensors
3) Power Supply
4) Teach pendant
5) End-effectors
6) Actuator

Manipulator
Manipulator is the main body of the robot is comprised of a structural frame with provisions for
supporting mechanical linkage and joints, guides, actuators (linear or rotary), control valves,
sensors, and communications within the manipulator.

Sensors
Sensors provide industrial robots with feedback about their workspace. The most common types
of sensors include vision systems and microphones as these act as the eyes and ears of a robot.
Sensors allow robots to dynamically adapt to their work environment by sending signals to the
robot’s CPU. The types of sensors used are temperature sensor, light sensor, sound sensor,
accelerator sensor, etc.

Power Supply
Energy is provided to various robot sensors, actuators, and their controllers as electrical,
pneumatic, or hydraulic power. These power sources can be hazardous to workers depending on
the energy infeed(s) and/or the resulting energy produced (e.g. motion, stored energy). The robot's
drives are usually electrically powered. Pneumatic power (typically 80-90 psi air) is often used for
end-effectors, and hydraulic power can be used for associated processes. Electrically-powered
robots are by far the most prevalent in industry. Either AC or DC electrical power can be used to
supply energy to electromechanical drives, sensors, and the robot's respective control systems.

Teach pendant
It is also called teach box or hand-held programmer shown in figure which teaches a robot the
movements required to perform a useful task manually. During the manual mode of operation, the
programmer performing the teaching must have control of the robot and associated equipment and
should be familiar with the operations to be programmed, system interfacing, and control functions
of the robot system, application, and other equipment. When systems and/or applications are large
and complex, it could be possible to improperly activate functions. Since the programmer doing
the teaching can be within the restricted space, such mistakes can result in injuries.

Figure: Teach pendant

End-effectors
End-effectors are sometimes referred to as End-of-Arm Tooling (EOAT). Many industrial robot
systems use robots that can be equipped with different end-effectors as required for the application.
Common end-effectors include grippers, pickers, welding torches, cutting and trimming tools,
material removal tools, drilling tools, collision sensors, force-torque sensors, inspection
equipment, cameras, and adhesive dispensers.

Actuator
An actuator is the energy conversion device used inside a robot. It produces a motion that converts
power into robot movements. The motion can be either rotary or linear. Linear actuator provide
motion along a straight line. Rotary Actuator provide rotation, moving loads in arcs and circles.

Basic configurations of Industrial Robots with their applications

Industrial robots come in a variety of shapes and sizes. They are capable of various arm
manipulations and they possess different motion systems. This section discusses the various basic
physical configurations of robots. The following four basic Configurations can be combined in
various ways to produce a variety of robotic combinations.
1) Cartesian Configuration
Robots with Cartesian configurations consists of links connected by linear joints (L).
Cartesian robot is form by 3 prismatic joints, whose axes are coincident with the x, y and
z planes. In the Cartesian coordinate configuration shown in given figure, the three
orthogonal directions are x, y and z. The x-axis is lateral motion, the y-axis is longitudinal
motion, and the z-axis is vertical motion. Thus, the arm can move up and down on the z-
axis; the arm can slide along its base on the x axis; and then it can telescope to move to and
from the work area on the y-axis. Motions in any coordinate axis can be imparted
independently of the other two. The manipulator can reach any point in a cubic volume of
space. It allows three DOFs (x, y, z) in translation only.

Figure: Cartesian robot with its rectangular workspace

Advantages:
1) 3 linear axes.
2) Easy to visualize, ability to do straight line insertions into furnaces.
3) Easy computation and programming.
Disadvantages:
1) Can only reach front of it.
2) Requires large floor space.
3) Axes hard to seal.
Applications:
Pick and Place operations, Assembly and Sub-Assembly (Mostly Straight), Nuclear Material
handling, Welding etc.

2) Spherical Configuration
Polar/Spherical robots are robot configurations with combined linear joint and two rotary
joints, with an arm connected to a robotic base and a twisting joint. The linear motion, r
corresponds to a radial in or out translation, the first angular motion corresponds to a base
rotation, and second angular motion, is one that rotates about an axis perpendicular to the
vertical through the base and is sometimes termed as elbow rotation. The two rotations
along with the in or out motion enable the robot to reach a specified point in the space
bounded by an outer and inner hemisphere.

Figure: Spherical Configuration

Advantages:

1) 1 linear + 2 rotating axes.

2) Large working envelops.
Disadvantages:

1) Can’t reach around obstacles.

2) Low accuracy.
3) Complex coordinates more difficult to visualize, control, and program.

Applications:

Die Casting, Forging, Glass Handling, Heat Treating, Injection Molding, Machine Tool Handling,
Material Transfer, Parts Cleaning, Press Loading etc.

3) Cylindrical Configuration
The cylindrical robot configuration allows the robot to reach the work space in a rotary
movement like a cylinder. The cylindrical arm and body configuration is shown in given
figure . They have the following movements

• Rotational movement of the column about its axis because of one twisting joint.
• Linear movement of the assembly along the column because of one linear joint.
• Linear movement in and out, relative to the column axis because of one orthogonal
joint.

Figure: Cylindrical Configuration

Advantages:

1) 2 linear axes +1 rotating.

2) Can reach all around itself.
3) Rigid enough to handle heavy loads through large working space.
4) Relatively easy programming.

Disadvantages:
1) Can’t reach above itself.
2) Base rotation axis as less rigid.
3) Won’t reach around obstacles.

Applications:
Commonly used for handling at die-casting machines, assembly operations, handling machine
tools, spot welding.

4) Revolute (Articulated) Configuration

The revolute configuration, or jointed-arm, is the most common. These robots are often
referred to as anthropomorphic because their movements closely resemble those of the
human body. It also offers a more flexible reach than the other configurations, making it
ideally suited to welding and spray painting operations. Typical applications of revolute
configurations include the following: automatic assembly, parts and material handling,
multiple-point light machining operations, in-process inspection, palletizing, machine
loading and unloading, material cutting, material removal, thermal coating, paint and
adhesive application, welding and, die casting.

Figure: Revolute (Articulated) Configuration

Advantages:
1) All rotary joints allow for maximum capacity.
2) Any point in total volume can be reached.
 3) All joints can be sealed from the environment.

Disadvantages:
1) Extremely difficult to visualize, control, and program.
2) Low accuracy.

5) SCARA
SCARA is an acronym for Selective Compliance Assembly Robot Arm. In SCARA, the
robot arm has following movements:
• Linear movement that allows the arm to extend and retract because of one
orthogonal joint.
• Rotary movement at the top of the column about the shoulder joint (along vertical
axis) because of one revolving joint.
• Rotary movement at the output arm about the elbow joint (along vertical axis)
because of one rotational joint.

Figure: SCARA

Advantages:
1) 1 linear + 2 rotating axes.
2) Height axis is rigid.
3) High Speed.
4) Large work area for floor space.
5) Moderately easy to program.
Disadvantages:
1) Difficult to program off-line.
2) Highly complex arm.
 3) 2 ways to reach point.
4) Limited Applications.
Applications:
Assembly operations, Pick and Place work etc.