ME3015 - Industrial Robot - Nguyen, Quoc Chi - C2

Industrial Robot, Lecture 3-Robot Anatomy
Robot Anatomy
© 2016 Quoc Chi Nguyen, Head of Control & Automation Laboratory, nqchi@hcmut.edu.vn 3-1
Outline
Robot anatomy is concerned with the physical
construction and characteristics of the body, arm,
and wrist, which are components of the robot
manipulator:
- Degrees of freedom
- Drive systems
Structures of Robot
• Manipulator consists of joints and links
– Joints provide relative motion
– Links are rigid members between joints
– Various joint types: linear and rotary
– Each joint provides a “degree-of-
freedom”
– Most robots possess five or six
degrees-of-freedom
• 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
Degrees of freedom
Degree Of Freedom (DOF): are the set of independent displacements
and/or rotations that specify completely the displaced or deformed
position and orientation of the body or system.
In Robot:
- Point location in space specified by three coordinates.
- Object location in space specified by location of a selected point on it
and orientation of the object.
Robotic kinematics
depends on the use of
right handed
Cartesian frames of
reference
Links
A link is a solid mechanical structure which connects two joints. The main purpose
of a link is to maintain a fixed relationship between the joints at its ends. The last
link of a manipulator has only one joint, located at the proximal end (the end closest
to the base) of the link. At the distal end of this link (the end furthest away from the
base) instead of a joint, there is usually a place to attach a gripper: a tool plate.
Type 1 link Type 2 link Type 3 link
Two parallel revolute If one of the joints in a type 1

joints with no twist link is twisted about the Centre joint n in the type 1 link is rotated
between the axes; the line of the link by an angle, an 90o degrees about the Y axis so that the Z
axes of the joints are extra degree of rotation is axis is collinear with the centre line of the
parallel added. link,
Revolute Joint: Five constraints
Prismatic Joint: Five constraints
Cylindrical Joint: Four constraints
Helical Joint: ??? constraints
Spherical Joint: ??? constraints
Closed and Open Chain
Simple Kinematic Chain: When each and every link is

coupled to at most two other links
– Closed: If each and every link coupled to two other links ->
Mechanism
– Open: If it contains only two links (end ones) that are
connected to only one link-> Manipulator
Open-chain
Degrees of freedom
The number of degrees of freedom for mechanism:
ci: number of constraints imposed by joint i,

fi: number of DOF permitted by joint i,
j: number of joints in the mechanism,
n: number of links in the mechanism (mechanism has one link fixed),
λ: number of DOF of the space in which the mechanism lives
We have:
(Grubler (1917) / Kutzbach (1929))
Degree of freedom
4
F = 3(4 − 4 − 1) + ∑1 = 1
1
2
F = 3(3 − 2 − 1) + ∑1 = 2
1
9
F = 3(8 − 9 − 1) + ∑1 = 3
1
0-15
Quiz: 20 mins
Calculate the degree of freedom of five bar and
parallelogram mechanism
Quiz: 20 mins
Calculate the degree of freedom of five bar and
parallelogram mechanism
Determine the DOF of the two mechanisms
Degree of freedom
Drive systems
- The drive system determines the speed of the arm movement,
the strength of the robot, dynamic performance, and, to some
extent, the kinds of application.
- Robot actuators quality: have enough power to acc/dec the
links, carry the loads, light, economical, accurate, responsive,
reliable and easy to maintain.
• Electric drive • Hydraulic drive • Pneumatic drive
World of drive systems

World of Motors
Pneumatic Motors Electric Motors Hydraulic Motors
Servo Motors DC Motors AC Motors Stepper
Brush DC Universal Single Phase
Poly-Phase
Brushless DC
(3 phase)
Linear
Hydraulic system vs. Pneumatic system
Hydraulic system
Pneumatic system
Electric actuators
DC motor Brushless DC motor
Stepper motor AC motor
DC motor
DC motor
F: force on the conductor (in Newton)
The magnitude of the I: current through the conductor (in amperes)
force on the wire: B: magnetic flux density (in gauss)
L: length of the wire (in meters)
θ: angle between the magnetic field and current
Brushless DC motor
Brushless DC motors (BLDC) operate without brushes by taking
advantage of modern electronic switching techniques.
Brushless DC motor
A schematic of a generalized three-phase BLDC
Advantages: extremely reliable, very efficient, and easily controlled.

AC motor
AC motors work by rotating the stator field. It makes use of the natural
alternating nature of the AC wave to turn the field coils on and off
sequentially.
AC motor
As the stator field rotates past an
individual bar, the field strength in
the bar rises and falls. This changing Diagram of
“squirrel cage”
magnetic field induces a voltage in
the bar, and the voltage causes a
current to flow. The current flows
through the bar, through the end
rings, and back through other bars.
This current causes the bar to have a
magnetic field, and it is this field,
interacting with the rotating stator
field, that produces the mechanical
Assembled
torque. rotor
AC motor
The rotor is always going slower than the rotating field, and this difference is
referred to as slip. Slip is frequently given as a percentage (usually less than
10%) of the stator speed.
Synchronous equation:
Ss: synchronous (stator) speed (in rpm)
Sr: rotor speed (rpm)
f: frequency of the AC line
P: number of field poles per phase
Stepper motor
A stepper motor is a unique type of DC motor
that rotates in fixed steps of a certain number
of degrees. Step size can range from 0.9 to 90°.
Stepper motor
Excitation modes for PM stepper motors
The top electromagnet (1) is

The top electromagnet (1) is turned off, and the right
turned on, attracting the nearest electromagnet (2) is energized,
teeth of a gear-shaped iron rotor. pulling the nearest teeth
With the teeth aligned to slightly to the right. This results
electromagnet 1, they will be in a rotation of 3.6° in this
slightly offset from electromagnet example.
2
The left electromagnet (4) is

enabled, rotating again by 3.6°.
When the top electromagnet (1) is
The bottom electromagnet
again enabled, the teeth in the
(3) is energized; another 3.6°
sprocket will have rotated by one
rotation occurs.
tooth position; since there are 25
teeth, it will take 100 steps to make
a full rotation in this example.
Servo system
What is a servo motor? - A command signal which is issued from the user's
interface panel comes into the servo's "positioning controller". The positioning
controller is the device which stores information about various jobs or tasks. It
has been programmed to activate the motor/load, i.e. change speed/position.
Concept of a servo system

Servo system for motion control

electr. energy
PC, set value motion

controller command amplifier
PLC
energy
servo amplifier current
losses
position speed
signal signal motor
position,
sensor speed
load
position,
speed
mech. energy
What to control?
 Current control = torque control
- Maintaining current (torque) constant
- Mostly included in controller (but not always accessible)
- For fast motor reaction
- No special feedback device needed
 Speed control
- Maintaining speed constant
- "speed = 0" does not mean "position is held"
 Position control
- Moving from position to position, stop at and maintain a
position
set value system

Σ controller Σ motor
+ deviation +
- -
current-
feedback
actual value sensor
incremental
IxR DC tacho encoder Hall sensor resolver
Analog encoder speed control loop
• Speed control loop with encoder feedback
- Amplification (gain) depends on parameters PID
- Applies also to Hall Sensor feedback with EC motors (6 IMP)
• Current control loop
- Subordinate control loop, enhances system dynamics
- Power amplifier (MOSFET)
speed power
amplifier (PID) amplifier
set value R current current
Σ E Σ motor
speed + command +
- -
current-
C
feedback
speed
feedback encoder
Digital control loop

• Digital parameters (profile, position, amplification)
• DSP: digital signal processor
• Firmware: software of the controller
power
amplifier
set value
current
speed
command motor
DSP
current feedback
set value
position
path position position feedback

generator decoder
speed feedback encoder
Gain, amplification: PID

Amplifier (PID)
set value E current
How the deviation signal E is it Σ command
amplified to produce a purposeful +
reaction (current command)? actual value
• P: Proportional (a multiplication = "amplification") system reaction
– Problem: very small deviation lead to small corrections
only. The set value cannot be reached. PI
– Remedy: Combination of P and I
• I: Integration P only
– A persisting deviation is summed up (integrated) and
eventually corrected.
PID
• D: Differentiation
– a sudden increasing deviation (e.g. a set value jump),
produces a strong reaction
– for dynamic reaction set value
– overshoot, instability
t
How to measure the feedback value?

• Open loop
– no feedback system
• Current control
– no special feedback
• Speed control
– feedback devices for DC motors: Encoder, DCTacho,
Hall-sensor
• Position control
– feedback devices: Encoder, Hall-Sensor
Absolute optical encoder

Absolute optical encoders use a glass disk marked off with a
pattern of concentric tracks. A separate light beam is sent
through each track to individual photo sensors. Each photo
sensor contributes 1 bit to the output digital word.
Resolution = 1 / 2N
Incremental optical encoder

Incremental optical encoders have only one track of equally
spaced slots. Position is determined by counting the number of
slots that pass by a photo sensor, where each slot represents a
known angle.
Incremental optical encoder
Characteristics of actuating systems
 Weight, Power-to-weight Ratio.

 Operating Pressure.
 Stiffness vs. Compliance.
 Use of reduction gears.
Applications: electric motors are the most commonly

used actuators. Hydraulic systems were very popular
for large robots. Pneumatic cylinders are used in on/off
type joints, as well as for insertion purposes.
Stiffness vs. Compliance
Stiffness is the resistance of a material against deformation. Hydraulic
systems are very stiff and noncompliant. Pneumatic systems are
compliant.
* The stiffer the system, the larger load that is needed to deform it.
* The more compliant the system, the easier it deforms under the
load.
* Stiffness is directly related to the modulus of elasticity of the
material.
* Stiff systems have a more rapid response to changing loads and
pressures and are more accurate.
* A working balance is needed between these two competing
characteristics.
Reduction gears
Gears used to increase the torque and reduce the speed.
Hydraulic actuators can be directly attached to the links.
This Simplifies the design, Reduces the weight, Reduces the

cost, Reduces rotating inertia of joints, Reduces backslash,
Reduces noise and Increases the reliability of the system.
Electric motors normally used in conjunction with reduction gears to

increase their torques and to decrease their speed.
This increases the cost, increases the number of parts,

increases backslash, increases inertia of rotating body,
increases the resolution of the system.
Reduction gears
Planetary gears
Harmonic drive
A Harmonic Drive (also known as
"Strain Wave Gearing") is a special
type of mechanical gear system that
has no backlash, compactness and
light weight, high gear ratios (a ratio of
100:1 is possible in the same space in
which planetary gears typically only
produce a 10:1 ratio).
Harmonic drive
• Wave Generator
The wave generator is a
component having small ball
bearings built into the outer
circumference of the elliptical
cam. The wave generator is
usually attached to the input
shaft.
• Flexspline
The flexspline is a thin cup-shaped metal rim component with external
teeth. The bottom of the flexspline (cup bottom) is called the
diaphragm. The diaphragm is usually attached to the output shaft.
• Circular Spline
The circular spline is a rigid steel ring with internal teeth.
Harmonic drive
The circular spline (ncs) has two teeth more than the flexspline
(nfs) and is usually fixed to a casing.
nfs − ncs
Ratio =
nfs
Characteristics of harmonic drives
1. High-speed reduction ratio

2. Free of backlash (lost motion)
3. High precision
4. Small numbers of components and ease of
assembly
5. Small-sized and lightweight
6. High torque capacity
7. High efficiency
8. Quiet, vibration-free operation
Ball-screw drive
A ball screw is a mechanical linear actuator that translates rotational
motion to linear motion with little friction. The ball assembly acts as
the nut while the threaded shaft is the screw. Ball screws tend to be
rather bulky, due to the need to have a mechanism to re-circulate the
balls.
Timing-belt drive
Synchronous / timing
belts having grooves
which mate with teeth
on the pulleys.
Any slip of the belt

relative to the pulleys is
minor in degree and is
due to belt stretch, or
erosion of the grooves.
These belts are used for power transfer and for synchronized
drives to ensure that the driven pulley is always rotating at a
fixed speed ratio to the driving pulley.
Comparison between drive systems
Hydraulic Electric Pneumatic

+ Good for large robots + Good for all sizes of + many components are
and heavy payload robots usually off-the-shelf
+ Highest power / weight + Better control, good for + Reliable components
ratio high precision robots + No leaks and sparks
+ Stiff system, high + Higher compliance than + Inexpensive and simple
accuracy, better response hydraulics
+ Low pressure compared
+ No reduction gear + Reduction gears used to hydraulics
needed reduce inertia on the
+ Good for on-off
+ Can work in wide range motor
applications and for pick
of speeds without difficulty + Does not leak, good for and place
+ Can be left in position clean room.
+ Compliant systems
without any damage + Reliable, low
maintenance
+ Can be spark-free. Good
for explosive environments
Comparison between drive systems
Hydraulic Electric Pneumatic
- May leak. Not fit for clean - Low stiffness - Noisy systems
room applications - Need reduction gears, - Require air pressure,
- Require pump, reservoir, increased backlash, cost, filter, etc.
motor, hoses, etc. weight, etc. - Difficult to control their
- Can be expensive and - Motor needs braking linear position.
noisy. Requires device when not powered. - Deform under load
maintenance Otherwise, the arm will fall constantly
- Viscosity of oil changes - Very low stiffness.
with temperature Inaccurate response
- Very susceptible to dirt - Lowest power to weight
and other foreign material ratio
in oil
- Low compliance
- High torque, high
pressure, large inertia on
the actuator

ME3015 - Industrial Robot - Nguyen, Quoc Chi - C2

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Industrial Robot, Lecture 3-Robot Anatomy

Type 1 link Type 2 link Type 3 link

Two parallel revolute If one of the joints in a type 1

Revolute Joint: Five constraints

Prismatic Joint: Five constraints

Cylindrical Joint: Four constraints

Helical Joint: ??? constraints

Closed and Open Chain

Simple Kinematic Chain: When each and every link is

ci: number of constraints imposed by joint i,

(Grubler (1917) / Kutzbach (1929))

World of drive systems

Pneumatic Motors Electric Motors Hydraulic Motors

Servo Motors DC Motors AC Motors Stepper

Brush DC Universal Single Phase

Stepper motor AC motor

Advantages: extremely reliable, very efficient, and easily controlled.

The top electromagnet (1) is

The left electromagnet (4) is

Concept of a servo system

Servo system for motion control

PC, set value motion

set value system

Digital control loop

path position position feedback

Gain, amplification: PID

How to measure the feedback value?

Absolute optical encoder

Incremental optical encoder

Characteristics of actuating systems

 Weight, Power-to-weight Ratio.

Applications: electric motors are the most commonly

Hydraulic actuators can be directly attached to the links.

This Simplifies the design, Reduces the weight, Reduces the

Electric motors normally used in conjunction with reduction gears to

This increases the cost, increases the number of parts,

Characteristics of harmonic drives

1. High-speed reduction ratio

Any slip of the belt

Comparison between drive systems

Hydraulic Electric Pneumatic

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