Industrial Robotics

Introduction
Robot configuration
Programming
End effectors
Sensors
Industrial applications
 Introduction

Briefhistory of development
Definition of the ‘Robot Institute of America’:
A robot is a programmable, multi-function
manipulator designed to move material, tools or
special devices through variable programmed
motions for the performance of a variety of tasks
4
 Robot Physical Configuration

1. Polar coordinate configuration

2. Cylindrical coordinate configuration
3. Jointed arm configuration
4. Cartesian coordinate configuration
 Polar coordinate configuration

• Alsocalled Spherical Coordinate configuration

• Ex: Unimate 2000 series
Cylindrical coordinate configuration

Ex: Unimate 3000 series

 Jointed arm configuration

• Cincinatti
Milacron T model
• Unimate PUMA model
Cartesian coordinate configuration

• Rexroth robotic system

Robot motions: six degrees of freedom
 Cartesian Robot

Cartesian robot is formed by 3 prismatic joints, whose axes

are coincident with the X, Y and Z planes.
  Gantry Robot

Cartesian coordinate robots with the horizontal member supported

at both ends are sometimes called Gantry robots.
  Parallel Robot

Parallel robot is a complex mechanism which is constituted by

two or more kinematics chains between, the base and the platform
where the end-effectors are located. Good examples are the flying
simulator
  Spherical Robot

It is still in the research laboratory, the Spherical robot is

actually a spherical shape robot, which has an internal driving
source.
Configuration Advantages Disadvantages

Cartesian 3 linear axes, easy to visualize, rigid structure, Can only reach front of itself, requires large
coordinates easy to program floor space, axes hard to seal

Cylindrical 2 linear axes +1 rotating, can reach all around Can’t reach above itself, base rotation axis as
coordinates itself, reach and height axes rigid, rotational axis less rigid, linear axes is hard to seal, won’t
easy to seal reach around obstacles

SCARA coordinates 1 linear + 2 rotating axes, height axis is rigid, 2 ways to reach point, difficult to program
large work area for floor space off-line, highly complex arm

Spherical 1 linear + 2 rotating axes, long horizontal reach Can’t reach around obstacles, short vertical
coordinates reach

Revolute 3 rotating axes can reach above or below Difficult to program off-line, 2 or 4 ways to
coordinates obstacles, largest work area for least floor space reach a point, most complex manipulator
 Other Technical Features

Work volume
Precision of movement
Speed of movement
Payload capacity
Type of drive system
Accuracy and Repeatability
 Robot Programming

1. Manual method

2. Walkthrough method

3. Leadthrough method

4. Off-line programming
 Manual method

• It is more like setting up the machine rather than

programming

• Used for simple robots

• Involves setting stops, cams, switches and relays

• Uses low technology for short work cycles

 Walkthrough method

• The programmer manually moves the robot’s arm and hand

through the motion sequence of the work cycle

• Each movement is recorded into memory for subsequent

playback during production

• Once the motion sequence is recorded, the speed of

movement can be controlled independently

• Appropriate for spray painting, arc welding, etc

 Leadthrough method

• Uses a teach pendent to power drive the robot through its

motion sequence

• Each motion is recorded into memory for future playback

during the work cycle

• Popular because it is easy and convenient

 Off-line programming

• Uses off-line programming language

• Since programming is done off-line, it means higher

utilisation of the robot and the equipment with which it
operates

• Ensures integration of the robot with FMS and CIM systems

 Robot Programming Languages

VAL
• Developed by Victor Scheinman for the PUMA robot

• Stands for Victor’s Assembly Language

• Two types of statements: Monitor commands and

Programming instructions

• Program instructions are written in VAL, while various point

locations are defined using a teach pendent
 Monitor Commands

• Preparing the system for the user to write programs

• Defining points in space

• Commanding the robot to execute a program

• Listing programs on the CRT

• Examples: EDIT, EXECUTE, SPEED, HERE, etc

 Program Instructions

• MOVE: Moves the robot to the location and orientation specified by the
symbol
• MOVES: Moves the robot along a st.-line trajectory, to the specified location
• APPRO: Moves the end effector to the position defined, but offset along the Z-
axis by the specified distance in mm
• APPROS: Similar as above, but along a st.-line trajectory
• DEPART: Moves the tool the distance given along the current Z-axis of the
tool
• OPENI: Opens the gripper immediately
• CLOSEI: Closes the gripper immediately
• EXIT: Exits from the program and transfers control to monitor mode
 VAL Programming Example

TASK:

• Pick and place operation

• Robot should pick up a part from one conveyor (Point A)

• Place the part on another conveyor (Point B)

 VAL Programming Example

• PROGRAM PICK

1.APPRO A, 50
2.MOVES A
3.CLOSEI
4.DEPART 50
5.APPRO B, 50
6.MOVES B
7.OPENI
8.DEPART 50
LISTL A
X/JT1 Y/JT2 Z/JT3 P/JT4 Q/JT5
-105.5 87.8 119.0 -25.6 100.9

LISTL B
X/JT1 Y/JT2 Z/JT3 P/JT4 Q/JT5
-50.0 115.8 55.5 -10.7 100.2
 End Effectors

• It is a device which is attached to the robot’s wrist to perform

a specific task

• It is a special purpose tooling which enables the robot to

perform a particular job

• It is usually custom engineered for the job

• Most robot manufacturers have engineering groups which

design and fabricate end effctors or provide advice to their
customers on end effector design

• There are two types of end effectors: Grippers and tools

 Grippers

• Mechanical Grippers: Friction or the physical

configuration of the gripper retains the object

• Suction cups: also called vacuum cups, used for flat

fragile objects

• Magnetic Grippers: for ferrous objects

• Hooks: to lift parts off conveyors

• Scoops/Ladles: for handling fluids, powder, pellets, or

granular substance
 Grippers

Pivot action Gripper

 Grippers

Slide action Gripper

 Grippers

Double Gripper Pivot action mechanism

 Grippers

Vacuum Gripper
 Tools as End Effectors

• Spot welding gun

• Arc welding tools (and wire-feed mechanism)

• Spray painting gun

• Drilling head

• Routers, grinders, wire brushes

• Heating torches
 SENSORS IN ROBOTICS

Internal: for controlling position and veleocity of various

joints. Ex: optical encoders, potentiometers, etc

External: for workcell control.

 Types of Sensors in Robotics

 Tactile and Proximity sensors

 Voice sensors

 Machine vision
 Tactile and Proximity sensors

• Provides the robot with capability to respond to contact forces with other
objects within the work volume
• Two types: Touch sensors and stress sensors (tactile sensors)
• touch sensors will simply indicate that a contact has been made with an
object. A simple micro switch can serve the purpose
• Stress sensors measure the magnitude of the contact force. Starin gauges
are the most popular choice
• Tactile sensors are useful in assembly and inspection operations.
• In assembly, the robot can perform delicate part alignment and joining
operations
• In inspection, touch sensing would be useful in gauging operations and
dimensional measuring activities
• Proximity sensors are used to sense when one object is close to another
 Voice sensors

• Used for voice programming

• A speech recognition system analyses the voice inputs and

compares it with a set of stored word patterns

• when a match is found between the input and the stored

vocabulary word, the robot performs some action which
corresponds to that word

• It can speed up robot programming

 Machine Vision

Machine vision can be defined as the acquisition of image

data, followed by processing and interpretation of this data
by computer for some useful application

Classification: 2D and 3D vision systems

 Basic Functions of Vision system

• Image acquisition and digitisation

• Image processing and analysis

• Interpretation
 Image Acquisition and Digitization

A camera captures the image

 Image is obtained by dividing the viewing area into a matrix of
discrete picture elements(pixels)
 Each pixel has a value that is proportional to the light intensity
of that portion of the scene
 The intensity value for each pixel is converted into equivalent
digital value by an ADC
 Selection of appropriate lighting system is important to
establish contrast between the object and the background
 Image Acquisition and Digitization

 Binaryvision: light intensity of each pixel is ultimately

reduced to either of two values, white or black, depending
on whether light intensity exceeds some threshold level

 Gray scale system: capable of distinguishing and storing

different shades of gray in the image. It can highlight the
object’s texture and colour.
 Image Acquisition and Digitization

 Each
set of pixel values is referred to as a frame and stored in
computer memory as frame buffer

 Theprocess of reading all the pixel values in a frame is

performed with a frequency of 25-30 times per second

 Cameras used: Vidicon and Solid-state

 Types of illumination: front lighting, back lighting and side

lighting
 Image Acquisition and Digitization

 The data for each frame must be analysed within the time
required to complete one scan (1/30 sec)

 Segmentation: define and separate regions of Interest within

the image

 segmentation techniques: thresholding and edge preparation

 Feature extraction: length, width, perimeter, c.g., aspect ratio,

etc
 Image Acquisition and Digitization

Interpretation

 Object/pattern recognition

 Template matching

 Feature weighting
 Machine Vision Applications

1. Inspection

2. Part identification

3. Visual guidance and control

4. Safety monitoring
 Robotic Applications

 Material handling: material transfer and machine

loading/unloading

 Processing operations: spot welding, continuous welding,

spray painting, drilling, grinding, laser cutting, riveting, etc

 Assembly and inspection