Chapter-3

ROBOTICS
 Why Industrial Robots are required
 Robots can be substituted for humans in hazardous
or uncomfortable work environments.
 A robot performs its work cycle with a consistency
and repeatability that cannot be attained by
humans.
 Robots can be reprogrammed. When the
production run of the current task is completed, a
robot can be reprogrammed and equipped with the
necessary tooling to perform an altogether different
task.
 Robots are controlled by computers and can
therefore be connected to other computer systems
to achieve computer integrated manufacturing.
Definition of Robot:
An industrial robot is defined as “an
automatically controlled,
reprogrammable, multipurpose
manipulator programmable in
three or more axes, which may be
either fixed in place or mobile for
use in industrial automation
applications.”
 Robot anatomy:

The arm or manipulator of an industrial robot consists of a

series of joints and links. Robot anatomy is concerned with the
types and sizes of these joints and links and other aspects of the
manipulator’s physical construction.

Elements
• Manipulator- moving
mechanical structure
• Drives – actuates the
joints of manipulator
• Computer – Controller
and storer of task
programs
• End effectors – Gripper,
Tool, Camera, etc
 Joints and Links

 A robot’s joint, or axis as it is also called in

robotics, is similar to a joint in the human body.
 It provides relative motion between two parts of
the body. Robots are often classified according
to the total number of axes they possess.
 Connected to each joint are two links, an input
link and an output link. Links are the rigid
components of the robot manipulator.
 The purpose of the joint is to provide controlled
relative movement between the input link and
the output link.
 Most robots are mounted on a
stationary base on the floor.
 Let this base and its connection
to the first joint be referred to as
link 0.
 It is the input link to joint 1, the
first in the series of joints used in
the construction of the robot.
 The output link of joint 1 is link
1. Link 1 is the input link to joint 2,
whose output link is link 2, and so
forth.
Fig 1: robot joints & links [2]
 Different Types of joints

1.Linear joint (type L joint):

The relative movement between the
input link and the output link is a
translational telescoping motion,
with the axes of the two links being
parallel.
2. Orthogonal joint (type O joint):
This is also a translational sliding
motion, but the input and output
links are perpendicular to each other.
3. Rotational joint (type R joint):
This type provides rotational relative
motion, with the axis of rotation
perpendicular to the axes of the Fig 2: robot joints & links [2]
input and output links.
4. Twisting joint (type T joint):
This joint also involves rotary
motion, but the axis of rotation is
parallel to the axes of the two
links.
5. Revolving joint (type V joint, V
from the “v” in revolving):
In this joint type, 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.
Fig 3: robot joints & links [2]
1.Linear joint (type L joint): 2. Orthogonal joint (type O joint):

3. Rotational joint (type R joint): 4. Twisting joint (type T joint):

5. Revolving joint
 Work Volume/space:
 The work volume (also known as work envelope) of the
manipulator is defined as the three-dimensional space within
which the robot can manipulate the end of its wrist.
 Work volume is determined by the number and types of joints in
the manipulator (body-and-arm and wrist), the ranges of the
various joints, and the physical sizes of the links.
 The shape of the work volume depends largely on the robot’s
configuration.
 Different Configuration of robots
1. Articulated robot:
• It is also known as a jointed-arm
robot (Figure 4), it has the general
configuration of a human shoulder
and arm.
• It consists of an upright body that
swivels about the base using a
T joint.
• At the top of the body is a shoulder
joint (shown as an R joint in the
figure), whose output link connects
to an elbow joint (another R joint).
Typical applications for Articulated
Robots are assembly, arc welding,
material handling, machine Fig 4: articulated robot [2]
tending, and packaging.
2.Polar configuration:
 This configuration (Figure 5)
consists of a sliding arm (L joint)
actuated relative to the body,
which can rotate about both a
vertical axis (T joint) and a
horizontal axis (R joint).
 The axes of the robot work
together to form a polar
coordinate, which allows the
robot to have a spherical work
envelope.
 Polar robots are commonly
used for die casting, injection Fig 5: Polar configuration [2]
molding, welding, and material
handling.
3. SCARA:
SCARA is an acronym for Selectively
Compliant Arm for Robotic Assembly.
 This configuration (Figure 6) is similar
to the jointed-arm robot except that
the shoulder and elbow rotational axes
are vertical, which means that the arm
is very rigid in the vertical direction,
but compliant in the horizontal
direction.
 This permits the robot to perform
insertion tasks (for assembly) in a
vertical direction, where some side-to-
side alignment may be needed to mate
the two parts properly. Fig 6: SCARA configuration [2]
SCARA robots are used for assembly and
palletizing, as well as bio-med
application.
4.Cartesian coordinate robot:

 Other names for this configuration

include gantry robot, rectilinear
robot, and x–y–z robot.
 As shown in Figure 7, it consists of
three orthogonal joints (type O) to
achieve linear motions in a three-
dimensional rectangular work
space.
 It is commonly used for overhead
access to load and unload
production machines.

Fig 7: Cartesian configuration [3]

5.Delta robot:
 This unusual design, depicted in
Figure 8, consists of three arms
attached to an overhead base.
 Each arm is articulated and
consists of two rotational joints
(type R), the first of which is
powered and the second is
unpowered.
 All three arms are connected to a
small platform below, to which the
end effectors is attached. The
platform and end effectors can be
manipulated in three dimensions.
Fig 8: Delta configuration [2]
 The delta robot is used for high-
speed movement of small objects,
as in product packaging.
 Common application of robots

1. Material Handling Applications:

Material transfer, Die casting, plastic molding,
forging, Press working, Heat treating.

2. Processing Operation:
Spot welding, arc welding, spray coating, water
jet cutting, LASER cutting.

3. Assembly and Inspection:

 Introduction
What is Additive Manufacturing?
• The term Rapid Prototyping (or RP) is used to describe a process for
rapidly creating a system or part representation before final release
or commercialization.

• A recently formed Technical Committee within ASTM International

agreed that new terminology should be adopted. Recently adopted
ASTM consensus standards now use the term Additive
Manufacturing.

• The basic principle of this technology is that a model, initially

generated using a 3D Computer Aided Design (3D CAD) system, can
be fabricated directly without the need for process planning.
 Definition of Additive Manufacturing

Additive manufacturing (AM) is defined by the ASTM society as “a

process of joining materials to make objects from 3D model
data, usually layer upon layer, as opposed to subtractive
manufacturing methodologies”

Additive manufacturing also refers to technologies that create

objects, layer by layer or sequential layering, 3D Printing
 Examples of AM

1 2

Pic Courtesy: 1. PCMag, Tony Hoffman, 2. techcrunch,Andreas Bastion

Subtractive Manufacturing
Additive Manufacturing
 Advantages of AM

• Elimination of design constraints

• Allow parts to be produced with complex geometry with no additional costs related to
complexity
• Build speed; reduction of lead time
• Flexibility in design
• No expensive tooling requirements
• Dimensional accuracy
• Wide range of materials (polymers, metals, ceramics)
• Well suited to the manufacture of high value replacement and repair parts

Limitations of AM
• Part size
• Production series: Generally suitable for unitary or small series and is not relevant for mass
production. For small sized parts, series up to 25000 parts/year are already possible
General Additive Manufacturing Process

Fig 1: General Additive Manufacturing Process

 Step 1: Conceptualization and CAD

•The generic AM process start with 3D CAD information.

•There may be a many of ways as to how the 3D source data can be created.
•The model description could be generated by a computer.
•Most 3D CAD systems are solid modeling systems with some surface modeling
components.

Step 2: Conversion to STL

• The term STL was derived from STereoLithograhy.

• STL is a simple way of describing a CAD model in terms of its geometry alone.
• It works by removing any construction data, modeling history, etc., and approximating
the surfaces of the model with a series of triangular facets.
• The minimum size of these triangles can be set within most CAD software and the
objective is to ensure the models created do not show any obvious triangles on the
surface.
Step 3: Transfer to AM Machine and STL File Manipulation
• Once the STL file has been created, it can be sent directly to the
target AM machine.
• Ideally, it should be possible to press a “print” button and the
machine should build
• the part straight away.
• However, there may be several actions required prior to building
the part.
• The first task would be to verify that the part is correct.
• AM system software normally has a visualization tool that allows
the user to view and manipulate the part. The user may wish to
reposition the part or even change the orientation to allow it to
be built at a specific location within the machine.
Step 4: Machine Setup
• All AM machines will have at least some setup parameters that
are specific to that machine or process.
• Some machines are only designed to run perhaps one or two
different materials and with no variation in layer thickness or
other build parameters.
• In the more complex cases to have default settings or save files
from previously defined setups to help speed up the machine
setup process and to prevent mistakes.
• Normally, an incorrect setup procedure will still result in a part
being built.
 Step 5: Build Setup
•The first few stages of the AM process are semi-automated tasks that may
require considerable manual control, interaction, and decision making.
•Once these steps are completed, the process switches to the computer-
controlled building phase.
•All AM machines will have a similar sequence of layer control, using a height
adjustable platform, material deposition, and layer cross-section formation.
•All machines will repeat the process until either the build is complete or there
is no source material remaining.

Step 6: Removal and Cleanup

•The output from the AM machine should be ready for use.
•More often the parts still require a significant amount of manual finishing before
they are ready for use.
•The part must be either separated from a build platform on which the part was
produced or removed from excess build material surrounding the part.
•Some AM processes use additional material other than that used to make the
part itself (secondary support materials).
Step 7: Post Process
Post-processing refers to the (usually manual) stages of finishing the parts for
application purposes.
This may involve abrasive finishing, like polishing and sandpapering, or application
of coatings.

Step 8: Application
•post-processing, parts are ready for use.
•Although parts may be made from similar materials to those available from other
manufacturing processes (like molding and casting), parts may not behave
according to standard material specifications.
•Some AM processes create parts with small voids or bubbles trapped inside
them, which could be the source for part failure under mechanical stress.
•Some processes may cause the material to degrade during build or for materials
not to bond, link, or crystallize in an optimum way.
Applications

• Models for conceptualization, packaging and presentation.

• Prototypes for design, analysis, verification and functional testing.

• Parts for prototype tooling and low volume production tooling.

• Patterns for investment casting, sand casting and molding.

• Tools for fixture and tooling design, and production tooling

 General AM Applications

• Functional models
• Pattern for investment and vacuum casting
• Medical models
• Art models
• Engineering analysis models
• Rapid tooling
• New materials development
• Bi-metallic parts
• Re-manufacturing.

• Application examples for Aerospace, defence, automobile, Bio-medical and

general engineering industries