Prash Robotics Updated
Prash Robotics Updated
Prash Robotics Updated
Assistant Professor
Department of Mechanical Engineering
Amrita School of Engineering
Introduction
Term “Robot” derived from Czech word robota, meaning
“forced labor” by Karel Capek, around 1921.
Robots are highly automated mechanical manipulators
controlled by computers.
Robotics Industries Association (RIA) defines a Robot as:
"A programmable multi-function manipulator designed to
move material, parts, or specialized devices through
variable programmed motion for the performance of a
variety of tasks”.
International Standards Organization (ISO) describes
Industrial Robot as: “An automatically controlled,
reprogrammable, multipurpose, programmable manipulator
in three or more axes, which may be either fixed in place or
mobile for use in industrial automation applications.”
Introduction
In 1950s Isaac Asimov Came up with laws of robotics in
Robot:
First law (Human Safety): A robot may not injure a
human being, or, through inaction, allow a human
being to come to harm.
Second law (Robots are Slaves): A robot must obey
orders given it by human beings, except where such
orders would conflict with the First Law.
Third law (Robot Survival): A robot must protect
its own existence as long as such protection does not
conflict with the First or Second Law.
Robots were originally used in hazardous operations such
as Handling toxic and radioactive materials, loading &
unloading hot workpieces from furnaces and handling
them in foundries.
Automation and Robots
Automation is a technology concerned with the use of
Mechanical, Electrical/Electronics and computer based systems
to control and operate production processes. For example,
Mechanized assembly machines, NC machine tools, Feedback
control systems and robots.
Robots are Mechanical devices that assist Industrial
automation.
Automation is generally regarded as being able to be divided
into 3 types:
Fixed Automation (Hard Automation)
Programmable Automation (Soft Automation)
Flexible Automation
Types of Automation
Fixed automation
Used when the volume of production is very high and it is,
therefore, appropriate to design specialized equipment to
process products at high rates and low cost.
Eg: automobile industry, where highly integrated transfer line
are used to perform machine operation on engine and
transmission components.
Programmable Automation
Used when volume production is relatively low.
Production equipment is designed to make suitable changes
in a product configuration.
Program is read into the equipment & equipment performs
particular sequence or assembly of operations to make the
product.
Types of Automation
Flexible automation
Most suitable for the mid-volume production range.
Typically consists of a series of workstation that are
interconnected by material-handling and storage equipment
to process different product configuration at the same time to
control manufacturing system.
There is no lost production time while reprogramming the
system and altering the physical set up.
Eg: Flexible Manufacturing System (FMS), Computer
Integrated Manufacturing (CIM)
Types of Automation
History and Evolution of Robots
1921: R.U.R. (Rossum‘s Universal Robots), a play by Czech
writer Karel Capek features the first mention of the word
‘robot’, from the Czech word ‘robota’, meaning ‘forced
labour’.
1956 - The world's first robot company, Unimate.
1961 – Unimate, the first industrial robot goes online in a GM
automobile factory in New Jersey, USA.
1963 – The first artificial robotic arm to be controlled by a
computer is designed.
1974 – Asia’s first robot, IRB 6, is developed.
History and Evolution of Robots
Late 1970s: The robot industry starts its rapid growth, with a
new robot or company entering the market every month.
The development of robotics technology followed the
development of numerical control, and the two technologies
are quite similar.
NC machines are designed to perform specific processes
whereas, robots are designed for a wider variety of tasks.”
Technology of Robots
Robot technology is an applied science that is referred to as a
combination of Machine tools and Computer applications.
Includes such diverse fields as Machine design, Control theory,
Microelectronics, Computer programming, Artificial
intelligence, Human factors, and Production theory.
In general, there are Industrial, Laboratory, Mobile, Military,
Security, Service, Hobby, Home and Personal Robots.
General Characteristics
A specialized machine tools with a degree of flexibility that
distinguishes them from fixed-purpose automation.
Is essentially a mechanical arm that is bolted to the floor, a
machine, the ceiling, or, in some cases the wall fitted with its
mechanical hand, and taught to do repetitive task in a
controlled, ordered environment.
Ability to move mechanical arm to perform work.
Robot interface with their work environment once a
mechanical hand has been attached to the robot’s tool
mounting plate.
Definitions
Work Envelope: The set of points representing the maximum
extent or reach of the robot hand or working tool in all
directions.
Payload: The ability to carry, continuously and satisfactorily,
a given maximum weight at a given speed.
Velocity: The maximum speed at which the tip of a robot is
capable of moving at full extension, expressed in inches or
millimeters per second.
Cycle: Time it takes for the robot to complete one cycle of
picking up a given object at a given height, moving it to a
given distance, lowering it, releasing it, and returning to the
starting point.
Definitions
Accuracy: A robot’s ability to position the end effector at a
specified point in space upon receiving a control command
without previously having attained that position.
Repeatability: The ability of a robot to return consistently to a
previously defined and achieved location.
Resolution: The smallest incremental change in position that it
make or its control system can measure.
Size: The physical size of a robot, which influences its
capacity and its capabilities.
Working Envelope
Basic Components
The Basic Components of an Industrial Robot are the
Manipulator
End Effector (which is the part of the Manipulator)
Power supply
Controller
Cam-operated hand
End-effectors: Grippers and Tools
This special hand, with pair of pneumatic actuators, is one of
the many special hand designs for industrial robots. It is
suitable for parts of light weight.
Magnetic pick up
End-effectors: Grippers and Tools
Ladling hot materials such as molten metal is a hot and
hazardous job for which industrial robots are wellsuited.
In piston casting permanent mold die casting and related
applications, the robot can be programmed to scoop up and
transfer the molten metal from the pot to the mold, and then do
the pouring.
Ladle
End-effectors: Grippers and Tools
Ability of the industrial robot to do multi pass
spraying with controlled velocity fits it for
automated application of primers, paints, and
ceramic or glass frits, as well as application of
masking agents used before plating. For short
or medium‑length production runs, the
industrial robot would often be a better choice
than a special purpose setup requiring a
lengthy change‑over procedure for each
different part. Also the robot can spray parts
with compound curvatures and multiple
surfaces.
Spray gun
End-effectors: Grippers and Tools
A single industrial robot can also handle several tools
sequentially, with an automatic tool‑changing operation
programmed into the robot's memory. The tools can be of
different types or sizes, permitting multiple operations an
the same work piece.
Tool changing
Power Supply
The function of the power supply is to provide and regulate
energy that is required for a robot to be operated.
There are three basic types of power supplies:
Electric
Hydraulic
Pneumatic
Electricity is the most common source of power and is used
extensively with industrial robots.
The second most common is pneumatic, and the least common
is hydraulic power.
The power supply has a direct relation to the payload rating.
Controller
The controller is a communication and information processing
device that initiates, terminates and coordinates the motions
and sequences of a robot.
It accepts necessary inputs to the robot and provides the output
drive signals to a controlling motor or actuator to correspond
with the robot movements and outside world.
The heart of the controller is the computer and its solid-state
memory.
The computer controls the motion of the robot arm by means
of drive signals that pass through the drive interface to the
actuators on the arm.
Robot Anatomy
Robot anatomy is concerned with the physical construction and
characteristics of the body, arm, and wrist, which are
components of robot manipulator.
Movements between the various components of the body, arm,
and wrist are provided by a series of joints.
Attached to the robot wrist is the end effector (or end-of-arm
tooling) that performs the work.
The end effector is not considered a part of the robot’s
anatomy.
Robot anatomy deals with:
Types and sizes of these joints and links
Other aspects of the manipulator’s physical construction
Robot Anatomy
What is a Joint?
A joint of robot is similar to a joint in
the human body.
Each joint gives the robot with a Joint
degree-of-freedom (d.o.f) of motion.
In the nearly all cases, only 1 d.o.f is
allowed to a joint.
Link
What is a Robot link?
Links are rigid components that form a
chain connected together by joints
Each joint has two links, known as an
input link and an output link
Robot Anatomy
Manipulator consists of joints and links
Joints provide relative motion
Links are rigid members between joints
Various joint types: linear and rotary
Robot manipulator consists of two sections:
Body-and-arm – for positioning of objects in the robot's work
volume
Wrist assembly – for orientation of objects
Types of Robot joints
Linear joint or Prismatic (Parallel) joint (L)
Orthogonal joint (O)
Rotational joint (R)
Twisting joint (T)
Revolving joint (V)
Types of Robot Joints
Linear or Prismatic or Parallel Joint (L)
The relative movement between the input link and the output
link is a linear sliding motion, with the axes of the two links
being parallel.
Types of Robot Joints
Orthogonal Joint (O)
This is also linear sliding motion, but the input and output links
are perpendicular to each other during the move.
Types of Robot Joints
Rotational Joint (R)
This type provides a rotational relative motion of the joints,
with the axis of rotation perpendicular to the axes of the
input and output links.
Types of Robot Joints
Twisting Joint (T)
This joint also involves a rotary motion, but the axis of
rotation is parallel to the axes of the two links.
Types of Robot Joints
Revolving Joint (V)
In this types, the axis of the input link is parallel to the axis
of rotation of the joint, and the axis of the output link is
perpendicular to the axis of rotation.
Joint Notation Scheme
This joint‑link numbering, scheme is shown below.
Joint Notation Scheme
Uses the joint symbols (L, O, R, T, V) to designate joint types
used to construct robot manipulator
Separates body-and-arm assembly from wrist assembly using a
colon (:)
Example: TLR : TR
Solution:
R
R
T T R
R T
R
R V
T T
Advantages:
They can obtain large work envelope because raveling
along the x-axis, the volume region can be increased
easily.
Their linear movement allows for simpler controls.
They have high degree of mechanical rigidity, accuracy,
and repeatability due to their structure.
They can carry heavy loads because the weight-lifting
capacity does not vary at different locations with in the
work envelope.
Cartesian Coordinate Configuration
Disadvantages:
They makes maintenance more difficult for some models
with overhead drive mechanisms and control equipment.
Access to the volume region by overhead crane or other
material-handling equipment may be impaired by the
robot-supporting structure.
Their movement is limited to one direction at a time.
Applications:
Pick-and-place operations.
Adhesive applications (mostly long and straight).
Assembly and subassembly (mostly straight).
Automated loading CNC lathe and milling operations.
Nuclear material handling and Welding.
Cylindrical Coordinate Configuration
Notation TLO:
Consists of a vertical column, relative to which an arm
assembly is moved up or down.
The arm can be moved in or out relative to the column.
Has two linear motions and one rotary motion.
Robots can achieve variable motion.
The first coordinate describe the angle theta of base rotation -
about the up-down axis.
The second coordinate correspond to a radical or y - in out
motion at whatever angle the robot is positioned.
The final coordinate again corresponds to the up-down z
position.
Cylindrical-coordinated robot: (a) A cylindrical-coordinated arm rotates about its base, moves in &
out, and up & down. (b) The space between the two cylinders shown is the work envelope occupied by a
cylindrical-coordinated manipulator. (c) The movements of a construction crane on top of a tall
building are similar to those of a cylindrical-coordinated manipulator.
Cylindrical Coordinate Configuration
Rotational ability gives the advantage of moving rapidly to
the point in z plane of rotation.
Results in a larger work envelope than a rectangular robot
manipulator.
Suited for pick-and-place operations.
Applications:
Assembly
Coating applications.
Conveyor pallet transfer
Die casting.
Foundry and forging applications, Inspection moulding.
Investment casting, Machine loading and unloading.
Cylindrical Coordinate Configuration
Advantages:
Their vertical structure conserves floor space.
Deep horizontal reach is useful for far-reaching operations.
Their capacity is capable of carrying large payloads.
Disadvantages:
Their overall mechanical rigidity is lower than that of the
rectilinear robots because their rotary axis must overcome
inertia.
Their repeatability and accuracy are also lower in the
direction of rotary motion.
Their configuration requires a more sophisticated control
system than the rectangular robots.
Spherical Coordinate Configuration
Notation TRL:
Consists of a sliding arm (L joint) actuated relative to the
body, which can rotate about both a vertical axis (T joint)
and horizontal axis (R joint).
Has one linear motion and two rotary motions.
The work volume is like a section of sphere.
First motion corresponds to a base rotation about a vertical
axis, second motion corresponds to an elbow rotation and
third motion corresponds to a radial or in-out, translation.
A spherical-coordinated robots provides a larger work
envelope than the rectilinear or cylindrical robot.
Design gives weight lifting capabilities.
Advantages and disadvantages same as cylindrical-
coordinated design.
Spherical-or polar-coordinated robot: (a) A polar- or spherical-coordinated manipulator rotates about
its base and shoulder and moves linearly in and out. (b) The work envelope of a polar-coordinated
manipulator is the space between the two hemispheres. (c) A ladder on a hook-and-ladder truck has
movements similar to those of a polar-coordinated manipulator.
Spherical Coordinate Configuration
Applications:
Die casting
Dip coating
Forging
Glass handling
Heat treating
Injection molding
Machine tool handling
Material transfer
Parts cleaning
Press loading
Stacking and unstacking
Jointed-Arm Robot Configuration
Notation TRR:
Best simulates a human arm.
Also called as an Anthropomorphic manipulator.
Consists of two straight links, corresponding to the
human “forearm” and “upper arm” with two rotary joins
corresponding to the “elbow” and “shoulder joints”.
Also called as Revolute Arm Robot Configuration.
Work volume of the configuration is spherical shaped.
Jointed-Arm Robot Configuration
Disadvantages
Generally not as speedy and powerful as hydraulic
robots
Expensive for large and powerful robots, can become
fire hazard
Hydraulic Drive System
Larger robots make use of hydraulic drives.
Advantages:
More strength‑to‑weight ratio
Can also actuate at a higher speed
Disadvantages:
Requires more floor space
Tendency to oil leakage.
Applications:
Used on very big machines
Pneumatic Drive System
For smaller robots that possess fewer degrees of freedom
(two‑ to four joint motions).
They are limited to pick‑and‑place tasks with fast cycles.
Applications
Small robots
Often pick and place with simple control
Use often by peripheral equipment
Direct Drive Robots
In 1981 a "direct‑ drive robot" was developed at
Carnegle‑Mellon University, USA. Is used electric motors
located at the manipulator joints without the usual
mechanical transmission linkages used on most robots.
The drive motor is located contiguous to the joint.
A direct drive robot which includes a pedestal having two
motors which rotate around a common axis to directly drive
rotation of first and of second linking arms which are
rotating in a plane perpendicular to this pedestal.
Direct Drive Robots
The first, inner link is preferably driven through a column
directly driven by a first motor rotor, the column supporting
the inner end of the link.
The second, outer link is driven by the second coaxial direct
drive motor through a simple, highly-tensioned belt and
pulley arrangement.
Benefits
Eliminate backlash and mechanical deficiencies
Eliminate the need of a power transmission (thus more
efficient)
Joint back drivable (allowing for joint‑space force
sensing)
Advantages of Robots
Robots can work in hazardous environments
Robots need no environmental comfort
Robots work continuously without any humanity needs &
illnesses
Robots have repeatable precision at all times
Robots can be much more accurate than humans, they may
have mili or micro inch accuracy
Robots & their sensors can have capabilities beyond that of
humans
Robots can process multiple stimuli or tasks
simultaneously, humans can only one.
Disadvantages of Robots
Robots lack capability to respond in emergencies, this can
cause:
Inappropriate and wrong responses
A lack of decision-making power
A loss of power
Damage to the robot and other devices
Human injuries
Disadvantages of Robots
Robots may have limited capabilities in
Degrees of Freedom
Skillful performance in using the hand
Sensors
Vision systems
Real-time Response
Robots are costly, due to
Initial cost of equipment
Installation Costs
Need for peripherals
Need for training
Need for Programming
Sensors
• Sensors are any device that provide input of data to the
robot controller.
• Sensors collect all the information a robot needs to
operate and interact with its environment.
• The control of a manipulator or industrial robot is based
on the correct interpretation of sensory information.
• This information can be obtained either internally to the
robot (for example, joint positions and motor torque) or
externally using a wide range of sensors.
• A variety of sensors is available for inclusion in end
effectors.
• The most common sensors employed in end effectors
measure proximity, collision, and force.
Classification of Sensors
Since the “action” capability is physically interacting
with the environment, two types of sensors have to be
used in any robotic system:
“Proprioceptors” for the measurement of the robot’s
(internal) parameters;
“Exteroceptors” for the measurement of its
environmental (external, from the robot point of view)
parameters.
Proprioceptors
From a mechanical point of view a robot appears as an
articulated structure consisting of a series of links
interconnected by joints.
Each joint is driven by an actuator which can change the
relative position of the two links connected by that joint.
Proprioceptors are sensors measuring both kinematic
and dynamic parameters of the robot.
Based on these measurements the control system
activates the actuators to exert torques so that the
articulated mechanical structure performs the desired
motion.
Exteroceptors
Exteroceptors are sensors that measure the positional or
force-type interaction of the robot with its environment.
Exteroceptors can be classified according to their range
as follows:
Contact sensors
Proximity (“near to”) sensors
“far away” sensors
Exteroceptors
Contact Sensors
Contact sensors are used to detect the positive contact
between two mating parts and/or to measure the
interaction forces and torques which appear while the
robot manipulator conducts part mating operations.
Another type of contact sensors are the tactile sensors
which measure a multitude of parameters of the
touched object surface.
Force/Torque Sensors
The interaction forces and torques which appear,
during mechanical assembly operations, at the robot
hand level can be measured by sensors mounted on
the joints or on the manipulator wrist.
Exteroceptors
Tactile Sensing
Tactile sensing is defined as the continuous sensing
of variable contact forces over an area within which
there is a spatial resolution.
Tactile sensing is more complex than touch sensing
which usually is a simple vectorial force/torque
measurement at a single point.
Tactile sensors mounted on the fingers of the hand
allow the robot to measure contact force profile and
slippage, or to grope and identify object shape.
Exteroceptors
Proximity Sensors
Proximity sensors detect objects which are near but
without touching them.
These sensors are used for near-field (object
approaching or avoidance) robotic operations.
Proximity sensors are classified according to their
operating principle:
Inductive
Hall effect
Capacitive
Ultrasonic and Optical
Exteroceptors
Inductive sensors are based on the change of
inductance due to the presence of metallic objects.
Hall effect sensors are based on the relation which
exists between the voltage in a semiconductor
material and the magnetic field across that material.
Inductive and Hall effect sensors detect only the
proximity of ferromagnetic objects.
Capacitive sensors are potentially capable of
detecting the proximity of any type of solid or liquid
materials.
Ultrasonic and optical sensors are based on the
modification of an emitted signal by objects that are
in their proximity.
Exteroceptors
“Far Away” Sensors
Two types of “far away” sensors are used in robotics:
Range sensors and Vision.
Range Sensing
Range sensors measure the distance to objects in their
operation area. They are used for robot navigation,
obstacle avoidance or to recover the third dimension
for monocular vision.
Vision
Robot vision is a complex sensing process. It involves
extracting, characterizing and interpreting information
from images in order to identify or describe objects in
environment.
General Classification
General Classification
Sensors Used in Robot
Resistive sensors
Bend sensors, potentiometer, resistive photocells, ...
Tactile sensors
Contact switch, bumpers…
Infrared sensors
Reflective, proximity, distance sensors…
Ultrasonic Distance Sensor
Inertial Sensors (measure the second derivatives of position)
Accelerometer, Gyroscopes,
Orientation Sensors
Compass, Inclinometer
Laser range sensors
Vision, GPS, …
Gas Sensor
Accelerometer Gyro
Metal Detector
Pendulum Resistive
Tilt Sensors Piezo Bend Sensor
Gieger-Muller
Radiation Sensor
Pyroelectric Detector
UV Detector
Resistive Bend Sensors
CDS Cell
Resistive Light Sensor
Digital Infrared Ranging
Pressure Switch
Miniature Polaroid Sensor
Limit Switch Touch Switch
Mechanical Tilt Sensors
IR Modulator
Lite-On IR Radio Shack Solar Cell
Receiver
Remote Receiver Remote Receiver
Compass Compass
101 Piezo Ultrasonic Transducers
Industrial Applications
Objectives
Be familiar with automation in manufacturing.
Understand Robot applications.
Recognize material-handling applications
Be familiar with processing operations
Be informed of assembly and inspection operations
Know how to evaluate the potential of a robot application
Be aware of future applications
Be aware of the challenge for the future
Be informed of innovations
Be familiar with case studies.
Automation in Manufacturing
Goal: To integrate various operations to :
Improve Productivity
Increase product quality and Uniformity
Minimize cycle times and effort
Reduce labor cost
Computers allows us to integrate virtually all phases of
manufacturing operations.
Spray painting
Automotive - Painting
Non-Industry Applications
Biological Applications
The primary purpose for use of robotics in biology is to
achieve high throughput in experiments related to
research and development of life science.
Experiments involve the delivery and dispensation of
biological samples/solutions in large numbers each with
very small volumes.
Typical applications include high-throughput systems
for large-scale DNA sequencing, single nucleotide
polymorphism (SNP) analysis, haplotype mapping,
compound screening for drug development, and bio-
solution mixing and dispensing for membrane protein
crystallization.
Non-Industry Applications
Without robots and automation, biosamples/solutions
must be handled manually by human hands, which is not
only tedious but also slow.
Various robotic systems have been developed in
laboratories that are either specially developed for a
particular application or integration of commercially
available robots, general purpose tools and sensors.
The second purpose of robotics for biological
applications is for effective handling and exploration of
molecular and cell biology.
This type of application includes immobilization of
individual cells, cell manipulation, and cell injection for
pronuclei DNA insertion.
Non-Industry Applications
Special tools fabricated using different technologies
have to be developed such as lasers for microsensing and
manipulating, electroactive polymer for cell
manipulation, and microneedles for cell penetration.
Another interesting area of application is robotics-
inspired algorithms for molecular and cellular biology.
This includes the work for predicting protein folding,
and for structural biology (Zheng and Chen, 2004).
Non-Industry Applications
Medical Applications
Research on robotics for medical applications started fifteen
years ago and is very active today.
The purpose is three-fold.
First it is for robotic surgery.
Robotic surgery can accomplish what doctors cannot because
of precision and repeatability of robotic systems.
Besides, robots are able to operate in a contained space inside
the human body.
All these make robots especially suitable for non-invasive or
minimally invasive surgery and for better outcomes of surgery.
Non-Industry Applications
Today, robots have been demonstrated or routinely used for
heart, brain, spinal cord, throat, and knee surgeries at many
hospitals in the United States (International Journal of
Emerging Medical Technologies, 2005).
Since robotic surgery improves consistency and quality, it is
becoming more and more popular.
The second use of robotics in medicine is diagnosis.
Robotic diagnosis reduces invasiveness to the human body and
improves the accuracy and scope of the diagnosis.
One example is the robotic capsular endoscope that has been
developed for non-invasive diagnosis of gastrointestinal tract
by Polo Sant’Anna Valdera of the Sant’Anna School of
Advanced Studies in Italy.
Non-Industry Applications
The third use of robotics is for providing artificial components
to recover physical functions of human beings such as robotic
prosthetic legs, arms and hands.
For example, at the Technical University of Berlin there is
work on powered leg orthoses using electromyographic signals
for control and on prosthetic hands.
The latter is basically an exo-skeleton for a non-functional
hand.
Prosthetic hands are also being developed at University of
Tsukuba in Japan.
In addition, rehabilitation robotics can help patients recover
physical functions more effectively after injury by replacing or
supplementing the work of physical therapists.
Non-Industry Applications
Robotic devices and systems can also help elderly people
move around; this includes intelligent wheeled chairs, walking-
assistance machines, and limb-empowering robotic devices.
For example, a new type of powered walker was developed at
Waseda University. It is capable of sensing pressure from both
the left and right arms.
In addition, rehabilitation robotics can help patients recover
physical functions more effectively after injury.
Robotic devices and systems can also help elderly people
move around; this includes intelligent wheeled chairs, walking-
assistance machines, and limb-empowering robotic devices.
Military Applications
Bomb disposal robots
Make a dangerous job a little less hazardous.
Designed to search for, locate and neutralise explosive devices.
Military Applications
One of the main advantages
of robots is their ability to
operate in environments that
are hazardous or deadly to
humans.
American scientists
developed Pioneer in
response to the disaster at the
Chernobyl Nuclear Power
Station.
This robot was designed to
withstand large doses of
radiation and is capable of
clearing debris.
Research Applications - Biology
Biologically inspired
("biomimetic“)
autonomous Underwater
robots based on the
lobster and the lamprey
(an eel-like jawless
vertebrate).
Research Applications - Exploring
the Outer Space
• Canadarm - Canada's
most famous robot and
technological
achievement - made its
space debut on
November 13, 1981.
Research Applications - Exploring
the Outer Space