ME 3300 – Mechanical Engineering Lab - III

Class: B. Tech., (VI Semester)

Experiment: Industrial Robot – Task Programming

Faculty: Prof. N. Ramesh Babu

 Experiment: Industrial Robot – Task Programming
Aim:
1. To understand the basic hardware & software structure of an industrial robot
2. To learn the control of an industrial robot and to program for a task execution

Objective: At the end of this session, the students should be able to

• Explain the structure and control of an Industrial Robot
• Develop and implement program for Pick and place operation, Movement of
contour profile viz. Seam Welding, Deburring etc

Content Learning Aid TA Approach Student Activity Time

Introduction Motivate Involve 10

Robot
Manual Explain Understand 20
Description
Controller KR C2 Explain Understand 10

Interface KCP Explain Understand 10

Programming KCP Explain Understand 20

Robot Operation Program Demonstrate Observe 45

Report Clarify Prepare 25

Viva voce Examine Recollect 10

Introduction to Industrial Robots

The industrial robot is a programmable mechanical manipulator, capable of moving

along several directions, equipped at its end with a device called the end-effector. The
technology of robot is related to, but differs somewhat from, NC technology in that robots
operate at higher velocities and movement in more axes of motions. While with NC, only a
point, namely the endpoint of the cutter is controlled in the space, in robots; both end point
and orientation are manipulated

KUKA – KR 16: Technical Specifications:

Loads Other data and variants

Payload : 16 kg Number of axes : 6
Supplementary payload : 10 kg Repeatability : <±0.05 mm
Working envelope Weight : 235 kg
Max. reach : 1610 mm Mounting positions : Floor, ceiling
Controller : KR C2
Basic components of an Industrial Robot:

1. KR 16 – A Six axes degree of freedom robot manipulator

2. KR C2 – Controller for the manipulator
3. KCP – KUKA Control Pendant

KUKA KR 16 KUKA KR C2 KUKA Control Pendant

Structure of an Industrial Robot manipulator:

A Robot manipulator is a mimic of a human arm from waist to wrist. A one to one
comparison with the human arm structure with the 6 axes of the manipulator is as follows:
1. Axis A1 – Base (waist) joint with immobile base
2. Axis A2 – Shoulder joint
3. Axis A3 – Arm joint
4. Axis A4 – A6 -Wrist assembly

Controller KR C2:

Each axes of the robot is separately driven by means of an actuator, a servomotor which is in
turn controlled by a centralized controller.
The controller KR C2 is using standard PC components and drive technology that has proved
its worth in the field of automation.
It is possible to integrate up to two external axes in the basic cabinet. In conjunction with a
top-mounted cabinet, as many as six external axes can be controlled.

KUKA Control Pendant:

The KUKA Control Pendant (KCP) is the Human-Machine Interface (H.M.I) used for
programming and controlling the Robot operations. The KCP has a sophisticated keyboard
and a display window. The features available with the KCP and the necessary details are as
shown

Be Aware of these messages:

Axes control coordinate systems:

The control of all six axes can be done by specific coordinate control systems viz.,

1. World Coordinate system:

In this system the position and orientation control is based on the right hand
coordiante sytem, with origin located to the immobile base of the robot as shown in the
figure.

(0, 0, 0)

2. Axes Specific coordinate system:

In this mode all the six axes can be controlled individually. This mode comes in to use
while teaching postions prone to singularities or while mastering a robot.

3. Tool Coordinate system:

In TCS mode, based on the tool centre point (TCP), taught to the robot, the world
coordinate sytem is transformed to the TCP. This helps in controlling the axes specific to
angular positions. A total of 16 Tools can be controlled by the robot, thus enabling 16
different coordinate sytem control.
4. Base Coordiante system:
In BCS mode, the robot can be controlled in respect to a coordinate system
transformed in reference to WCS, but on the workbench or the machine table where the
workpiece or job to be handled is placed. A total of 32 Base coordinate system can be taught
to the robot.

Payload distribution in an Industrial Robot:

The payload of an Industrial robot is the maximum load that it can operate with its
end-effector. This includes both the supplementary load, if any on the arm and link arm.
Based on the payload Robots are classified as
1. Low payloads (5-16Kg)
2. Medium payloads (30-60Kg)
3. Heavy payloads (60-300)
4. Heavy Duty (>300Kg)

Modes of robot operation:

The robot can be operated in four modes viz.

1. Teaching mode T1 A A.E
2. Teaching mode T2
3. Automatic
T2 T1
4. Automatic External

Each mode has its own specific features in manipulator operation. The key features are listed
down as shown in the table below.
Robot Programming:

The Robot programming for KUKA 16 manipulator is supported by a high level

programming software developed by KUKA called KUKA Programming Language (KPL).
The motion and logic program both has the inline programming commands. Human Machine
Interface (HMI) is used for programming the robot manipulator.

HMI Programming structure Profile Traced

Applications
Handling, loading Packaging and Other handling
and unloading order picking operations
Metal casting machines,
Arc welding Soldering
foundry plants
Plastics processing
Machining operations Inserting, mounting
machines
Assembly/disassembly Forming machine
Cutting machine tools
operations tools
Handling for other Measuring, testing
Palletizing
machines and inspection

Braking characteristics of the Manipulator

Term Drives Brakes Software

Path- Switched off after In this time the controller brakes
Applied after
maintaining 1s the robot on the path using a
1s
braking hardware delay steeper stop ramp.
The controller attempts to brake
Path- the robot on the path with the
Switched off Applied
oriented remaining energy. If the voltage is
immediately immediately
braking no longer sufficient, the robot
leaves the programmed path.
Ramp-
Remain Normal ramp which is also used
down Remain on
disengaged for acceleration and deceleration.
braking