IRMH

Industrial Robotics and Material Handling System
Prabandh CHAKRABORTY
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➢Unit-3:
❑ Types of Industrial Robots
❑ Load handling capacity of Robots
❑ Robotic Material Handling
❑ General considerations in Robotic Material Handling
❑ CNC machine tool loading
❑ Robot Centred Cell
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Types of Industrial Robots
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➢ Types of Robot:
❑ Based on configuration the robots can be classified as:
1. Articulated Robots
2. Cartesian Robots
3. Selective Compliance Assembly Robot Arm(SCARA)
4. Delta Robots/Parallel Robots
5. Polar Robots
6. Cylindrical Robots
7. Cobots /Collaborated Robots
❑ Based on classes of control, the robots can be classified as:
1. Pick and Place
2. Point to Point
3. Continuous Path
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➢ Types of Robot:
❖ Articulated robot is one of the most comment types of
industrial robots.
❖ It resembles a human arm in its mechanical configuration.
❖ The arm is connected to the base with a twisting joint.
❖ The joints can be parallel or orthogonal to each other.
❖ Articulated robots having six degrees of freedom are the most
commonly used industrial robots as the design offers maximum
flexibility.
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➢ Types of Robot:
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➢ Types of Robot:
❖ Advantages:
• High speed
• Large work envelope for least floor space
• Easier to align to multiple planes
❖ Disadvantages:
• Requires dedicated robot controller
• Complicated programming
• Complicated kinematics
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➢ Types of Robot:
❖ Applications:
• Food packaging
• Arc welding
• Spot welding
• Material handling
• Machine tending
• Automotive assembly
• Steel bridge manufacturing
• Steel cutting
• Glass handling
• Foundry and forging application
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➢ Types of Robot:
2. Cartesian Robots
❖ Cartesian robots are also called rectilinear or gantry robots and
have a rectangular configuration.
❖ These types of industrial robots have three prismatic joints to
deliver linear motion by sliding on its three perpendicular axes
(X, Y and Z).
❖ They might also have an attached wrist to allow rotational
movement. Cartesian robots are used in majority of industrial
applications as they offer flexibility in their configuration which
make them suitable for specific application needs.
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➢ Types of Robot:
2. Cartesian Robots
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➢ Types of Robot:
2. Cartesian Robots
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➢ Types of Robot:
2. Cartesian Robots
❖ Advantages:
• Provides high positional accuracy
• Simple operation
• Easy to program offline
• Highly customizable
• Can handle heavy loads
• Less cost
❖ Disadvantages:
• Requires large operational and installation area
• Complex assembly
• Movement limited to only one direction at a time
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➢ Types of Robot:
2. Cartesian Robots
❖ Applications:
• Pick and place operations
• Loading and unloading
• Assembly and sub-assembly
• Nuclear material handling
• Adhesive applications
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➢ Types of Robot:
❖ SCARA (Selective Compliance Assembly Robot Arm) robots have a
donut shaped work envelope and consists of two parallel joints that
provide compliance in one selected plane.
❖ SCARA Robots function on 3-axis (X, Y, and Z), and have a rotary
motion as well.
❖ The rotary shafts are positioned vertically, and the end effector
attached to the arm moves horizontally. SCARA robots specialize in
lateral movements and are mostly used for assembly applications.
❖ The SCARA robots can move faster and have easier integration than
cylindrical and cartesian robots.
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➢ Types of Robot:
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➢ Types of Robot:
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➢ Types of Robot:
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➢ Types of Robot:
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➢ Types of Robot:
❖ Advantages:
• High speed
• Excellent repeatability
• Large workspace
❖ Disadvantages:
• Limited to planar surfaces
• Hard to program offline
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➢ Types of Robot:
❖ Applications:
• Assembly applications
• Semiconductor wafers handling
• Biomed applications
• Packaging
• Palletizing
• Machine loading
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➢ Types of Robot:
4. Delta Robots/ Parallel Robot
❖ Delta robots are also called parallel link robots as it consists of
parallel joint linkages connected with a common base.
❖ Owing to direct control of each joint over the end effector, the
positioning of the end effector can be controlled easily with its
arms resulting in high-speed operation.
❖ Delta robots have a dome shaped work envelope.
❖ It can move both delicately and precisely at high speeds due to
each joint of the end effector being directly controlled by all
three arms. .
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➢ Types of Robot:
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➢ Types of Robot:
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➢ Types of Robot:
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➢ Types of Robot:
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➢ Types of Robot:
❖ Advantages:
• Very High speed
• Excellent repeatability
• High operational accuracy
❖ Disadvantages:
• Complicated operation
• Complicated kinematics design
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➢ Types of Robot:
❖ Applications:
• Food industry
• Pharmaceutical industry
• Electronic industry
• Flight simulators
• Automobile simulators
• Optical fiber alignment
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➢ Types of Robot:
5. Polar Robots/ Spherical Robot
❖ Polar robots have a twisting joint connecting the arm with the base
and a combination of two rotary joints and one linear joint
connecting the links.
❖ These are also called as spherical robots, since it has a spherical
work-envelope and the axes form a polar co-ordinate system.
❖ These robots have a centrally pivoting shaft and an extendable
rotating arm.
❖ The gun turret configuration of polar robots sweeps a large volume
of space, but the access of the arm is restricted within its workspace.
❖ Polar Robots are credited as one of the first types of industrial robots
to ever be developed.
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➢ Types of Robot:
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➢ Types of Robot:
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➢ Types of Robot:
❖ Advantages:
• Can reach all around
• Can reach above or below obstacles
• Large work volume
• Requires less floor space
❖ Disadvantages:
• Cannot reach above itself
• Short vertical reach
• Low accuracy and repeatability in direction of rotary motion
• Requires sophisticated control system
• Fallen out of favor and not common in new designs
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➢ Types of Robot:
❖ Applications:
• Die casting
• Glass handling
• Stacking and unstacking
• Injection molding
• Forging
• Welding
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➢ Types of Robot:
❖ Cylindrical robots have at least one rotary joint at the base and at least
one prismatic joint connecting the links.
❖ These robots have a cylindrical workspace with a pivoting shaft and an
extendable arm which moves vertically and by sliding. Thus, robots with
cylindrical configuration offers vertical and horizontal linear movement
along with rotary movement about the vertical axis.
❖ The compact design of the end of the arm allows the robot to reach
tight work envelopes without any loss of speed and repeatability.
❖ It is mostly used in simple applications where materials are picked up,
rotated and placed.
❖ It is also as one of the first types of industrial robots to ever be
developed.
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➢ Types of Robot:
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➢ Types of Robot:
VERSATRAN developed in 1954

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➢ Types of Robot:
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➢ Types of Robot:
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➢ Types of Robot:
❖ Advantages:
• Simple operation and installation.
• Minimal assembly.
• Can reach all around itself.
• Requires less floor space.
• Can carry large payloads.
❖ Disadvantages:
• Cannot reach around obstacles.
• Low accuracy in direction of rotary motion.
• Fallen out of favor and not common in new designs.
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➢ Types of Robot:
❖ Applications:
•Transport of LCD panels
•Assembly applications
•Coating applications
•Die casting
•Foundry and forging application
•Machine loading and unloading
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➢ Types of Robot:
7. Collaborative Robots or Cobots
❖ Collaborative Robots or Cobots are robots that can directly and safely
interact with humans in a shared workspace
❖ Cobot applications contrast with traditional industrial robot
applications in which robots are isolated from human contact.
❖ Cobot safety may rely on lightweight construction materials, rounded
edges, and inherent limitation of speed and force, or on sensors and
software that ensure safe behavior.
❖ Operators can program cobots by simply guiding the robotic arm
through the desired waypoints of an application.
❖ The collaborative robot is able to store the application path to then
recall the waypoints, replicating each step on its own over and over.
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➢ Types of Robot:
❖ The IFR defines four levels of collaboration between industrial robots
and human workers:
• Coexistence: Human and robot work alongside each other without
a fence, but with no shared workspace.
• Sequential Collaboration: Human and robot are active in shared
workspace but their motions are sequential; they do not work on a
part at the same time.
• Cooperation: Robot and human work on the same part at the
same time, with both in motion.
• Responsive Collaboration: The robot responds in real-time to
movement of the human worker.
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➢ Types of Robot:
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➢ Types of Robot:
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➢ Types of Robot:
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➢ Types of Robot:
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➢ Types of Robot:
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➢ Types of Robot:
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➢ Types of Robot:
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➢ Types of Robot:
❖ Advantages:
• Simple operation and installation.
• Lowly technical skilled person can operate.
• No skill of programming required to define the path and control.
• Less complicated control system.
• Cost very less than many robots.
• Creates job rather than taking the job from market.
• Creative jobs can be done with ease.
❖ Disadvantages:
• Worker may have psychological impact as he/she may be alone with it.
• Cannot be used to highly weighed payloads and complex operations.
• Cobots are not reflective.
• Quality and the productivity of cobots depends upon the ability of the worker
programming and working with the robot.
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➢ Types of Robot:
❖ Applications:
• Glass manufacturing
• Automobile industry
• Packaging
• Loading and unloading CNC machine.
• Assembly
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➢ Types of Robot:
❑ Work envelopes:
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➢ Types of Robot:
1. Pick and Place
❖ Pick and place or limited sequence manipulators, use mechanical
stops to set two stopping positions on each axis.
❖ The joint must travel backwards and forwards between these two
end stops, whose positions can be adjusted when the machine is set
up
❖ It is not possible to select any intermediate stopping point, although
sometimes extra stops can be inserted for particular parts of the
program.
❖ They are fast and relatively cheap; as the name suggests they are
limited to the transfer of parts from one place to another.
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➢ Types of Robot:
1. Pick and Place
❖ The parts are always well orientated at the pick-up site, and
often only three or four degrees of freedom are needed.
❖ Some designs are modular, allowing the user to select how
many degrees of freedom to provide.
❖ Pick and place robots are usually pneumatic since there is no
need for servo control of position, the speed of each axis is
limited by an orifice on the actuator.
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➢ Types of Robot:
1. Pick and Place
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➢ Types of Robot:
2. Point to Point Robots
❖ Point to point robots have servo position control of each axis and can
go through a sequence of specified points. The path between these
points is unspecified.
❖ There can be any number of stopping positions in each axis.
❖ The program for such a robot consists of a series of points, for each
point all the joint angles (or distances in the case of prismatic joints)
must be specified.
❖ This method of operation implies that the actuator for each joint is
controlled by a position servo (see the section 'Servo control of
actuators’ in this chapter).
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➢ Types of Robot:
❖ Speed(linear and angular velocity of a prismatic joint) and acceleration
are not controlled explicitly, although in practice they are limited in
some way, if only because the actuators have a finite top speed.
❖ The result is that each axis of the arm moves at a nearly constant speed
between programmed points. Such an arm is clearly unsuitable for tasks
requiring speed control.
❖ A further limitation is that it is not in general possible to guarantee that
a segment of the programmed path will take a desirable form. For
example, the payload cannot be made to move in a straight line unless
this coincides with the axis of a prismatic joint.
❖ This is why assembly robots so often have a prismatic joint parallel to
the main axis of the assembly (usually vertical).
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➢ Types of Robot:
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➢ Types of Robot:
3. Continuous Robots
❖ Continuous path robots do not go through a finite list of target
points but can, ideally, execute a smooth path of any shape,
with continuous variation of speed as the arm moves along the
path.
❖ This requires not only servo control of the velocity of each joint
but that several joints move at once in a coordinated way,
whereas for a point-to-point robot it is possible, although not
compulsory, to move only one joint at a time.
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➢ Types of Robot:
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➢ Types of Robot:
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Robotic Material Handling
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➢ Robotic Material Handling:

❑ As previously stated, material handling systems can always be
improved, but rarely eliminated. In most operations, material
handling can account for 30-75% of an item’s total production
cost(Kulak, 2005).
❑ In theory and in practice, robotic material handling and tending
solutions deliver major productivity gains. Recently, an
agricultural manufacturer was experiencing production
bottlenecks for pinion gear drive train components. They
needed an automation solution to replace manual
loading/unloading for lathe and part washing processes.
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❑ Material handling robots can automate some of the most
tedious, dull, and unsafe tasks in a production line and is one of
the easiest ways to add automation.
❑ Material handling robots enhance the efficiency of your
production line and increase customer satisfaction by providing
quality products in a timely manner.
❑ When picking material handling equipment for your facility, you
should consider payload and speed requirements, end-of-arm
tooling(end effector) or grippers needed, facility layout and
floor-space, the type of material being handled and any
additional possible production problems.
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➢ General Considerations in Robotic Material Handling:
❑ Part positioning and orientation:
❖ In most parts-handling applications the parts must be presented to the
robot in a known position and orientation.
❖ Robots used in these applications do not generally possess highly
sophisticated sensors (e.g., machine vision) that would enable them to seek
out a part and identify its orientation before picking it up.
❑ Gripper design:
❖ Special end effectors must be designed for the robot to grasp and hold the
work part during the handling operation.
❑ Minimum distances moved:
❖ The material-handling application should be planned so as to minimize the
distances that the parts must be moved.
❖ This can be accomplished by proper design of the workcell layout (e.g.,
keeping the equipment in the cell close together), by proper gripper design
(e.g., using a double gripper in a machine loading/unloading operation),
and by careful study of the robot motion cycle.
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❑ Machine Loading and Unloading:
❖ Robotic machine loading/unloading or automated machine
loading/unloading automates the strenuous, repetitive task of supplying
and placing or installing part(s) onto a machine in a safe environment.
❖ The machine feed application can be both a static, repeatable motion or
the collaborative robotic arm can be mounted on an Automated Guided
Cart AGC and load or unload parts or products safely from workcell to
workcell, workcell to production, or any other combination.
❖ Programming the robotic machine for loading or unloading is easy to
alter if customer demands increase/decrease or the product changes.
❖ Our robotic loading and unloading machine can be configured or
reconfigured within hours by non-technical employees.
❖ Final setup is fast and easy with a series of screens that simulates the
operator’s range of motion.
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➢ General Considerations in Robotic Material

Handling:
❑ Robot work envelop:
❖ The cell layout must be designed with proper consideration given to
the robot’s capability to reach the required extreme locations in the
cell and still allow room to maneuver the gripper.
❑ Robot weight capacity:
❖ There is an obvious limitation on the material handling operation that
the load capacity of the robot must not be exceeded.
❖ A robot with sufficient weight-carrying capacity must be specified for
the application.
❑ Accuracy and repeatability:
❖ Some applications require the materials to be handled with very high
precision. Other applications are less demanding in this respect. The
robot must be specified accordingly.
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❑ Robot configuration, degrees of freedom, and control:
❖ Many parts transfer operations are simple enough that
they can be accomplished by a robot with two to four
joints of motion.
❖ Machine-loading applications often require more
degrees of freedom. Robot control requirements are
unsophisticated for most material-handling operations.
❖ Palletizing operations, and picking parts from a moving
conveyor are examples where the control requirements
are more demanding.
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❑ Machine utilization problems:
❖ It is important for the application to effectively utilize all pieces of
equipment in the cell.
❖ In a machine loading/unloading operation, it is common for the robot
to be idle while the machine is working, and the machine to be idle
while the robot is working.
❖ In cases where a long machine cycle is involved, the robot is idle a
high proportion of the time. To increase the utilization of the robot,
consideration should be given to the possibility for the robot to
service more than a single machine.
❖ One of the problems arising in the multi machine cell is machine
interference.
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❑ CNC machine tool loading Robots / Machine Tending Robots :
❖ The machining industry – including capital equipment like lathes,
mills, machining centers, forges, presses, and injection molding
machines – has been the backbone of manufacturing. It is
unlikely that any job shops or manufacturing plants have not
invested in this technology.
❖ Automating these machines gives manufacturers clear
advantages in terms of utilization, secondary processes, labor
resources, and productivity. Anytime a machine sits idle or an
operator isn’t available to support it, that equates to lost
productivity and profits.
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❖ CNC machine tool loading make it easy to connect your equipment
and improve throughput and overall equipment effectiveness.
❖ CNC tool loading includes:
1. Loading and unloading raw materials
2. Transferring finished parts to post-processing
3. Upstream and downstream assembly tasks
4. Material handling
❖ From collaborative robots to robotic arms, the solutions are designed
to get the most out of CNC machines by automating them with little
to no down time.
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❑ CNC machine tool loading Robots / Machine Tending Robots : Advantages
❖ Faster Tool Changes: With a wide range of tool changing station mounting
options, including top mounting, some industrial robot types serve as
highly efficient tool changers. Capable of working with a huge range of
tools, these models can handle any number of tools regardless of their
weight.
❖ Increase Task Throughput: Robots offer maximized speed, reliability, and
performance, which leads to increased throughput. Automating these tasks
also increases the quality of your output thanks to precise, consistent
movements that result in reduced variation in finished products.
❖ Dramatically Boost Your Uptime:When labor is difficult to obtain, train,
and retain, unmanned machine tending solutions are an ideal option. With
industrial robots, these systems can operate around the clock, providing
you with the productivity you need to stay competitive.
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❑ CNC machine tool loading Robots / Machine Tending Robots : Advantages
❖ Flexibility: Compared to fixed automation solutions, using robotic CNC machining
and manufacturing allows for increased flexibility. Rather than being dedicated to
a single process or machine, the robots can be quickly and easily repurposed for
other tasks as needed. This helps to future-proof your investment and keep your
operation agile.
❖ System Performance: Machine tending robots are able to take on many of the
tasks that would normally require operator intervention, such as loading and
unloading parts, transferring finished parts to post-processing, and material
handling.
❖ Employee safety and satisfaction:By automating the strenuous and repetitive
tasks of loading and unloading with CNC machining automation operations, you
can reduce the risk of employee injury, making their jobs much safer. When
employees don't have to manually handle these arduous duties and can instead
focus on higher value tasks, they will be more satisfied with their workplace,
thereby decreasing turnover and limiting your need to specifically hire manual
laborers in those positions.
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❑ Robot Centered Cell:
❖ In the robot-centered cell, illustrated in fig, the robot is located at the approximate center of the cell
and the equipment is arranged in a partial circle around it.
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❖ With these robot-centered cell arrangements, a method for
delivering the workparts into and/or out of the cell must be
provided.
❖ Conveyors, parts feeders with delivery chutes, and pallets
are the means for accomplishing this function.
❖ Machining, die casting, plastic molding, and other similar
production operations for discrete part production are
examples of this case.
❖ These devices are used to present the parts to the robot in a
known location and orientation for proper pick up.
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Industrial Robotics and Material Handling System

Types of Industrial Robots

VERSATRAN developed in 1954

Robotic Material Handling

➢ Robotic Material Handling:

➢ Robotic Material Handling:

➢ General Considerations in Robotic Material

➢ General Considerations in Robotic Material Handling:

➢ General Considerations in Robotic Material Handling:

➢ Robotic Material Handling:

➢ Robotic Material Handling:

➢ Robotic Material Handling:

➢ Robotic Material Handling:

➢ Robotic Material Handling:

➢ Robotic Material Handling:

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